A R M A TU R E WI N D I N G

A ND

M OT OR R E P A I R

ct i ca
P ra l I n form at i on a n d Da t aC ove ri n g Wi n di ng a n d R e con n e ct i n g

P roce du re for Di re ct a n d A l t e rn a t i n g C u rre n t M a chi n e s C om pil e d ,

for E l ect ri ca
l M e n R e s pons ibl e for t h e Ope r a t i on a n d R e pair
of M ot ors a n d Ge n e r a t ors i n I n du s t ri a l Pla nt s a n d for

Re pa i rm e n a n d A rm a t u re Wi n ders i n
E l e ct r ica l R e pa i r Sh ops

BY

DA N I E L H B R A Y M E R A B E E
.
, . .
, . .

M EM B ER A M E R I C A N I N S TI T U T E O F E L E C T R I C A L E N GI N E ER S — M A N A GI N G E DI TO R
O F EL E CT R I C A L W O R L D —
F O R M E R L Y E DI T O R O F E L E C TR I C A L
E N GI N E E RI N G A N D OF E L E C TR I C A L R EC OR D

Fm s r E
'
DI TI ON

M cG R A W -
H I L L B OOK C OM P A N Y ,
INC .

NE W Y OR K : 239 WE S T 3 9 T H S T R E E T
L ON D ON : s as B OU V E R I E ST .
, E . C . 4

1 92O
 C O PY RIGHT ,
1 920, B Y THE

M C G RA W -
H I LL BO O K C OMP ANY ,
I NC .

T H E M A P L E P R E S S Y O R K P A
 C
i T / w
P R E FA C E

In thi s book n o a tte mpt h a s b e e n ma de to di s cuss t h e s u b

j cet of a rm a ture wi n di n g from theoreti ca l or de s i gn s t a nd

poi n ts On t h e co n tra
. ry
,
i t i s acompi l a ti on of pr a cti ca l
me thods tha t a r e u se d by r e pa i r me n a nd a rm a ture wi n ders .

I n s e l e cti n g t h e m a te ri a l as pe ci a l e ff ort h a s be e n m a de to
i ncl ud e a s fa r a s po ssi bl e d e t a i l s of thos e m e thod s whi ch h a ve
bee n foun d by a ctu a l ex pe ri e n ce to re pre sen t be s t pra cti ce i n

are pa i r s hop of a ve r a ge s i ze I n thi s work t h e wri ter h a

. s

dr a wn from h i s own ex pe ri e n ce i n re p a i r work f r om t h e e x

,

pe ri e n ce s of re p a i rme n a nd a rm a ture wi n ders i n l a r ge a n d s ma ll

re p a i r s ho ps a n d ma n uf a ctur i n g pl a n t s whi ch h a ve be e n
vi s i te d f r om de s cri pti on s of pr a
, ct i ca l me thod s a n d t h e pr o

ce dur e followe d i n t h e s oluti o n of s pe ci a l problem s a s pres en te d

by pra ct i ca l m e n i n te chni ca l journ a . ls

Th e ti tle of r e p a irm a n a s u se d thr oughout thi s book i s on e

tha t agood en gi n ee r ca n be a r wi th pri d e wh e n h e m e a s ur es

up t o a l l i t s qu a li fi ca ti ons S u ch a
. n e n gi n ee r i s on e who i n
i n t h e ma j o ri ty of ca s es n ot o n ly kn ows w h a t to do i n t h e ca se

of a n e le ctr i ca l trouble but j u s t how to procee d to do tha t

‘

pa r ti cul a r thi n g a n d who s e ldom gu e s s es wi thout a good per

ce n t a ge of t h e proba bi li ti es of bei n g ri ght in h i s fa vor Th e
.

ma i n di ffe re n ce be twe e n t h e de s i gn er a n d t h e re pa i rm a n is

th a t t h e for m e r mus t kn ow wha t t o do wh i l e t h e l a tter mus t

kn ow h ow to do i t A ca . pa ble re p a i rm a n combi n e s both

qu a lifi ca ti on s through ye a r s of e x pe ri e n ce .

Whe n Ca lle d upon to lo ca t e tr ouble s i n motors a n d ge n e r a

tors e le ctri ci a ns a n d re p a i rm e n who se e x pe ri e n ce i n th i s ki n d

'

of wor k h a s be e n li mi t e d Oft e n fin d th e m s e lve s won d e r i n g jus t

wha t to do fir s t I t i s fr om just thi s vi e wp oi n t th a

. t t h e i nf or
ma t i on on wi n di n g pr o ce dure a n d t h e hu n ti n g a n d co rre cti n g

Of tr oubl e s h a s be e n pre s e n t e d . Th a ,
t i s i ns te a d of di s cussi n g
t h e fun d a me n t a ls i n volve d i n a n y m e thod of wor ki n g out a

re p a i r probl e m t h e a
, ctu a l p roble m or job a s t h e ca se m a y eb
i s di s cuss e d fr om t h e how to do i t s t a
“
- - -
”
n dpo i n t
. T he n f or
ea ch i n di vi du a l Oper a ti on or pr oce dure t h e a ppli ca ti ons of
v
vi PR E FA C E

fun d a me n t a l la ws a n d rul e s a r e wo r ke d out C o n si d e r a

. ble
re p e ti ti on of s om e d e t a i l s of si mi l a r m e thod s wi ll th e r e for e be

di s cove re d i n conn e cti on wi th i n form a ti on cove ri n g su ch pro

ce dur e a s t h e r e wi n d i n g of m a chi ne s of t h e s a m e cl a s s but

of di ff ere nt type s Thi s h a . s b ee n co n si d e re d a dvi s a ble si n ce

are pa i rm a n s hould n ot be re qui re d to s tudy acompl e t e

volum e when de t a i ls a n d i n for m a ti o n a r e d es i r e d a t a n y on e

ti me on t h e proce dure for ap a r ti cul a r typ e of wi n di n g for a

pa r ti cul a r d e si gn Of m a chi n e .

L i be ra l u se h a s b ee n m a de of pr a cti ca l da taa n d pr a cti ce s

i n re p a i r s hop s s o a s to combi n e t h e good f e a ture s of abook of

me thods wi th ha n dbook i n fo r m a ti on coveri n g these m e thod s .

I f thi s book s h a l l he lp y ou n g r e p a i r me n to a bs orb i n form a ti o n

th a t ca n be s e cure d oth er wi s e o n l y thr ough ye a r s of e x p e r i en ce

i n ha n dli n g one job a fter a n oth e r a n d if t h e old e r a

, n d mo re

e x pe ri e n ce d re p a i rme n fin d i t ah a n dy s our ce of re f e r en ce a s

as upple men t to thei r own s tock of i nfo rm a ti o n the n t h e a , im

of t h e a uthor wi ll be a ccompli s h e d .

Wh e n m a t eri a l ha s be e n t a ke n fr om t h e ex pe ri e n ce s of
e n gi n e e r s a n d th e i r re comm en d a ti on s on re p a i r m e thod s a s

publi s he d i n t h e te chni ca l jour n a ls it h a s b e en t h e a

,
i m to
g i v e cr e d i t to both t h e a utho r a n d t h e jou r n a l i n t h e p ar a
g r a ph ,o r s e c t i o n wh e re t h e m at e r i a l i s u se d S p e c.i a l a c k n o w l
e dg m e n t i s m a d e to A H M cI n t i re e di tor of t h e E l ectri c
. .
,

J ou r na l for pe rmi s si on t o m a
,
ke li be r a l u s e of i n for ma ti on con
ta i n e d i n s e ve r a l a r ti cl e s compi le d a t hi s s ugge s ti o n a n d pub

li sh e d i n t h e J ou rn a l Thi s m a
. te r i a l ha s b e e n i n cor por a te d
i n C ha pters 3 8 9 a , ,
nd 1 1 T o A M D udle y e n gi n ee r of t h e
. . .
,

i n dus tri a l d i vi si on Wes ti nghous e E lectri c

, Ma n uf a ctu r i n g

C omp a ny t he a
, uthor i s a lso e s pe ci a lly g r a teful for s u g g e s
t i on s a n d f or p e r mi s si o n to u se d e t a il s of m e thod s whi ch h e
ha s d e ve lope d for re co n n e cti n g a n d te s t i n g i n d u cti o n moto r

wi n di n gs Thi s i nform a
. ti o n a pp e a rs i n C h a pte rs 9 a nd 1 1 .

T h e di a gra ms a t t h e e n d of C h a pter 1 1 h a ve be e n s e le cte d

fr om ase ri es of e i ghty on e de vi se d by M r Dudle y a
- . nd

s ho rtly to be pub li s h e d i n a va lu a ble t re a ti s e on C on n e cti n g

I n du cti o n M oto rs
”
.

Th e a uthor a l s o de si res to a ckn owl ed ge t h e a s si s ta n ce ren

d e re d by H S R i ch a . . n d A l e x R Kn a . pp i n t h e form of d a ta
 P RE FA C E

a n d i nf or m a ti o n compi le d from thei r ow n e xpe ri e n ces i n s olvi n g

ava r i e ty of motor tr oubl e s m e t wi th i n i n du s tri a l pl an ts a nd

i n ma ki n g re p a i rs T o H e n ry S ch e ri l for me r ly ame mbe r of

.
,

t h e e n gi n ee ri n g de pa r tm e nt of t h e C r o cke r Wh e e le r C omp a
-
ny ,

a ck n owl e dgm e n t i s m a d e for he lpful sugges ti on s i n a rr an gi n g

t h e ma teri a l a n d f or a s si s t an ce i n ch e cki n g an d re a di n g t h e
proof C re di t i s a
. ls o du e a n d i s h e re by accor d e d to t h e e le c

t ri ca l ma n uf acture rs who fur ni s he d t h e photogr a phs from

whi ch m a n y Of t h e h a lfto n e i llus tra ti ons were ma de .

DA N I E L H . B R A YM E R .

NE W Y ORK C IT Y ,

Decem ber, 1 9 1 9 .
 I N TR ODU C TI ON

Through t h e ourtes y of t h e a
c uthor of thi s book t h e wri te r
ha s ha d t h e pri vi le ge of re a di n g t h e pr oofs I h a . ve foun d ,

wi th g re a t d eli ght th a , t t h e t re a tmen t of t h e s ubj ects di s cuss e d

i s n ot on ly cl e a
. r a n d ea s i l y un d e rs tood but a lwa ys fr om t h e
pr a ct i ca l ma n s
’
s ta n dpoi n t . Whi le t h e book wi ll a ppe a l
s tr o n gly to pr a cti ca l m en en ga g e d i n re p a i r s hop wor k po wer
,

s ta ti on w or k a n d t h e ma i n ten a n ce of motors i n in dus t ri a l

pla n ts ,
i t wi ll a ls o a ppe a l i n t h e opi n i on Of t h e wri te r t o
, ,

s tud e n t s of e l e ct ri ci ty S i n ce t h e ma
. te ri a l pre se n te d i n thi s
book w hi ch I d a
, re s a y i s u n i qu e i n i t s fi e ld , h a s b e e n O b
ta i n e d fr om a ctu a l pr a cti ca l e x peri e n ce s a n d outli n e s t h e

pr a ct i cal r e me di e s th a t ha ve bee n a pp li e d by re p a i rm e n i n t he
s olvi n g of puzzli n g p robl e m s i t w i ll be of d e ci d e d a
, s si s t a
n ce

to m e n who a r e i n n ee d of s u ch p r a cti ca l he lp .

I t is a n e l e ct ri ca
“
l book of kn owle dge for i n i t s p a,
”
g e s

re a d e rs wi ll fin d a n s w e r s to p r a cti ca lly a ll a rm a tur e wi n di n g

que s ti on s a n d s oluti on s Of m a n y of t h e re p a i r p r oble ms tha t
the y wi ll me e t i n pr a cti ca l work Th e di a . gr a ms a re cl e a r and

ea s i ly followe d by t h e s hop m a n a n d ru n i n s yn chr o ni s m wi th

t h e te xt . Th e ory wi th m a the m a ti ca l cons i dera ti ons h a ve be en

r e s o r t e d to o n l y i n ave r y fe w ca s es s o th a t t h e re a d er of t h e
book ca n ma ke u se of t h e i n fo rm a ti o n a n d un d ers t a n d t he

di s cus si on s of a ll ph a s es of a rma tur e wi n di n g e ve n though h e

m a y h a v e on ly a li m i t e d k n o wl e dg e of m a th e m a t i.c s

A book Of thi s ki n d i n s pi te of t h e e rr ors th a

, ta r e boun d to

cr e e p i n i s a
, ve r y va lua ble a s s e t to a n y pr a cti ca lma n who de

s i r e s to e n l a r ge h i s ow n s to ck of kn owl e dge by l e a rni n g how

othe r m e n i n si mi l a r po s i ti on s h a ve s olve d t h e ma n y e le ctri ca l

pr oblem s th a t come to t h e re p a i r ma n
.

HE NRY SC HE RIL .

NE W Y ORK C ITY ,

Decem ber , 1 9 1 9 .
 C ON TE N T S
PAC E

PRE F ACE
I NTRODUCT ION

C HA PTE R I

DIREC T CURRENT WINDINGS

-

A ct i on aC om m u t a
Of t or
Typ es of D C A rm a t u re Wi n di n g s .

Wi n di n g P art s a
n d Te rm s

A rm at u re C on du ct or or I n du ct or .

Wi n di n g E l em e n t or S ect i on
A rm a
t u re C oi l s
Wi n di n g Pi t ch or C oi l P i t ch
Fr on t a
nd Ba
ck Pi t ch

Fu l l Pi t ch a
nd Fr a
ct i on a
l Pi t ch C oi l s

S y m bol s U s ed i n Wi n di n g Form u l a s

N um be ri n g C oi l S i de s i n A r m a t u re S l ot s
La p
—
M u l t i p l e or P a r a
l l e l W i n d i n gs
Form u l a s for L a p W i n d i n g s —
M u l t i pl e ; S i n g l e ,
Do u bl e a
n d
Tri pl e Wi n di n g s —
M ea n i n g of t h e T e rm R e e n t ra nt —
M ul t i
pl e x L a p W i n d i n g s .

Wa
ve —
S e ri es or Tw o-ci rc u i t Wi n di n g s
Form ulas for Wa v e Wi n di n g s M ul t i pl e x Wa
—
v e or S e ri e s

Pa ra l l el Wi n di n g s Form u l a
—
s for S e ri es P a ra l l e l Wi n din g s
-

S ym m e t ri ca l Wi n di n g s .

P os s i bl e S y m m e t r i ca l Wi n di n g s for D C M a ch i n e s Of Di ff er e n t
-

N u m bers of P ol es
E qui pot en t i al C o n n ect ors

B es t D— C Win di n g s for aR epa

ir S h op t o U s e
N um be r of A rm a t u re S l ot s
V ol t a
g e be t w e e n C om m u t a t or S e g m en t s .

N u m ber Of C om m u t a t or B a rs

Usu al S pe e ds a n d P ol es of Di ff e r e n t S i z es of Ge n e ra
t ors .

Safe A rm a t u re S pe e ds .

HA PTE C R II

A L TE R N A TrN c - C URRENT WI N D ING S

Ty pes Of A -C Wi n di n g s
Di st ri bu t ed Win di n g s
 C ON TE N TS

C a
on cen t rt ed Wi n di ng s
S pi ra l or C h ai n Wi n di n g s
La p
. a n d W av e W i n di n gs
Wh ol e coil ed a
- n d Ha lf-coi l ed Wi n di n g s
se a
Si ng l e -ph a n d P ol yph a s e Wi n di n g s .

C oil P i t ch .

P ha s e S prea d of Wi n din g
Two p - h as e f rom F ou r -
ph a se W i n di n g s

Th ree -ph a s e from Si x-ph a s e Wi n di n g s .

Wi re , S t ra p a n d B ar W o u n d C o il s

M et h ods Of L a i
y ng ou t a n d C on n e c t i n g A - C Wi n di n g s
Group Wi n di n g s Full a — n d Fr a ct i ona l P i t ch Wi n di n g s
S i m pl e Wi n di ng Di a g ra m —
R ec o nn e c t i n g a W i n d i n g
—
S i rn pel
M et h od for I n di ca t in g P ol a ri t y of C oil Gr ou ps —
C ha n g i ng St a r

t o De l t aC onn ect i on —
A C Wa
- v e Wi n di n g s —
P rog r es s i v e a nd

R et rog ressi v e A -C Wa v e W i n di n g s —
C o n n ec t i ons
'
f or C o i l s

of P ol y ph a s e Wm din g s —
Doubl e l a -
y er Wi n di n g , L a p C on -

m et e d — C onnect in g a C h a
o

i n Wi n di n g Ot h e r C om m on
—

Wi n di n g s .

E a s il y R e m em bered R ul es for A rra n g e m e n t of C oi l s i n a n I n d uc

t i on M ot or
S i m pl e R ul es for C h e cki n g P rope r P h a s e R el a t i on s h i p i n Two
Or Th ree -ph a s e Wi n di n g s

C H A PTE R 11 1
R EPAI R S H OP ME TR OD s P OR R E W INDING D-C A RM ATU RE S
Dis m a n t li n g aD C A rm a t u re
Wi n di n g Da t aN eeded for aDi s m a
n t l e d A rm a
t u re

Wi n di n g D-C A rm a
t ures Ha vin g rt i a
Pa ll y C l os e d S l ot s
Wi n din g aTh rea d ed-i n C oi l I ns u l a
—
t i n g L i n i n g f or S l ot s
I ns e t i ng C oil s i n t h e S l ot s I ns u l a
r
‘
—
t i n g Overl a pp g i n E n d C o n

n ect i ons of C oil s — C onn e ct i n g Fi ni s h E n ds of C oi l s t o C om

a
m u t t or— L oop Wi n di n g s for S m a
l l M ot ors .

Win di n g a
nd I ns ul at i n g C oil s I n sul a
—
t in g Open S l ot s In —

s e rt i n g C oi l s i n Op en S l ot s — Sh a i
p g n E n d C o n n ec t i ons

Tm in g up t h e H ea ds of t h e Wi n di n g —
I ns ul a t i on B e t w ee n
C om m ut a t or E n d C on n ect i ons .

Wi n di ng L a rg e D-C A rm a t u res
C oi l s for L a rg e D-C A rm a t u res —
La p a n d W av e W i n di n g s f or

La rg e A rm a t ur es —
I n sul a t in g t h e C ore —
I n s e rt i n g t h e C oil s
Ba n di n g Wi re B a
—
la n ci n g L a rg e A rm a t u res —
R ot a ry C on

v e rt e rs —
Th r ee-wi re Gen e ra t ors .
 C ON TE N TS

Wi n di n g Rail wa y, M i l l a n d C ra n e Types Of A rm a t ures

Ra il w ay Type A rm a t ure C o si l C oil I ns ul a t i on I ns u l a
t i ng
— —

t h e C ore Of R a il wa y A rm at u r e s —
I n s e rt i n g t h e C oil s — C
on

n ect i ons wi t h Dea d C oil s Hoodi n g a

—
nd B a n di n g.

CHA PTE R I V
M AKING C oN N E C TI ON s TO TH E C OMMUTATOR
L oca t i n g Fi rst C on n e ct i on t o C om m u t at or .

Tes t i n g Out C oil Term i n a ls

C om m u t a t or C onn ect i on s for aL a p Wi n di n g .

R e q ui rem e n t s of aL a p W i n di n g
C om m u t a t or C onn ect i ons for aWa y e Wi n d i n g

L oca t i n g Fi rs t C onn ect i on t o C om m u t a t or for aWa ve Wi ndi n g

Re q ui re m e n t s for aWa v e Wi n di n g .

R e g ress i v e a
nd R et rog r essi v e Wa
v e Wi n d i n g s .

Wa
v e Wi n d i n g a
w it h De d C oil s
C u t t i n g out C oil s of a R et rog ress i ve a n d P r og ress i ve Wave

Wi n di n g
Ta bl es for P l a ci n g C oil s a n d C onn e c t i n g Th e m i n a D C Wi n di n g
Wa v e vs L a
.
p W m d i n gs
La p W i n d i n g s f or D - C A r m at u r es

La p W i n d i n g s f or A -C M a ch i n e s

Wa v e Wi n d i n g s for D C A rm a t u re s
.

Wa v e Win di n g s for A -C M a ch i n es

S in g l e vs aN u m be r of I n de pe n den t Win di n g s
.

La p W i n d i n g s v
. s M u l t i p l e W a v e W i n d i n g s

U s e of E q u a li z e r R in g s

C HA PT E R V

T ES T ING DIREC T -C URRENT A R MAT URE WI N DI N G s

Caus es Of S h ort C i rcu i t s i n a n A rm a t u re .

Test for S h ort C i rcui t s i n a n A rm at u re

Tes t i n g for S h ort C i rcu i t s a
n d Ope n C i rcui t s w i t h aS m a
ll Tra
ns

form er

C a
u ses Of Ope n C i rcu it s i n a n A rm a t ure
Tes t s for a n Op e n C i rcui t in a n A rm a t u re
C u t t i n g Ou t I n j u red C oil s
Ca uses Of G rou n ds i n a n A rm a t ure
Tes t s for Grou n ds I n a n A rm a t u re
U se Of aB a r Ma g n e t a n d M i ll i v ol t m e t e r L
t o o ca te a Re v e rs ed
A rm a t u re C oi l
Us e of aC om pa ss t o L o ca t e aR ev e rs e d A rm a t u re C oi l
L oca t i n g L ow R esi s t a n ce or Dea d Grou n ds
 C ON TE N TS

PA GE
U se of aTel e ph on e R ecei ve r i n Tes t i n g for S h ort C i rcu i t s , Ope n
C i rcu i t s an d Groun ds

Tes t i n g for R e v ers ed a n d De a d Fi el d C oi l s .

Th e C om m ut a t or
T es t i n g E q ui pm en t for aR e pa i r S h op

C HA PTE R VI

OP ERATIO N S B E FO R E A N D A FTER WIND ING D-C A RMATURES

S t r i ppi n g Off a n Ol d Win di n g

C l ea nin g a n d Fi l i n g S l ot s

Tes t i n g C om m u t a t or
Ma ki n g N e w C oil s
Form s for Wi n di ng C oils
I nsul a t i on of C ore a n d S l ot s

Tes t i n g Ou t t h e Wi n di n g
S ol de ri n g C oil L e a ds t o t h e C om m u t at or
'

H oods for A rm a t u res

Ba n d i n g Ar m a t u r es
S ea s on i n g a n d G rin di n g aC om m u t a t or
U n de r cut t i n g M i caof aC om m u t a t or
Ba la n ci n g a n A rm a t u re
Pa i n t i n g t h e Win di n g
R e l in i n g S pl i t B ea ri n g s

C HA PTE R VII

INSU LA ING T C OI L s AND SL O TS D C

F OR - AN D A C -
WI N DI N G s
t i on f or A rm a
In s ul a t u re C oi l s a
n d S l ot s

For
.

For M ech a n i ca
l P rot e ct i on a n d E l ect ri ca l I n su l a
t i on —

H i g h Te m pera t ures a nd E l ect ri ca

l I n s ul at i on For E l ect ri ca
—
l
I ns u l a t i on On l y .

Des cri pt i on s a n d U s es of I n s u l a
t in g M a t e ri a
ls
Tre a t e d C l ot h s —
P ress boa rds , Fi bres a nd P a pers —
C oi l a nd

S l ot I n s u l a t i on U se d i n On e L a rg e R e p a i r Sh op M i ca
—
rt a

fol i u m .

Th i ckn ess of I n s ul a
t i on R e qui red in S l ot s
I n su l a
t i on of Form ed C oi l s
I ns ul a
t i on for C oil s U s ed i n 24 0-V ol t a l D-C M a
ch i n es
n d 500- v o t
C oil I ns u l a
t i on for I n duct i on M ot or Wi n di n g s
C oi l a n d S l ot I ns u l at i on E m pl oy e d by aL a rg e M a nuf a ct u r e r .

I n sul a t i on of E n d C onn ect i on s of C oi ls

Pha s e I nsu l a t i on Wh en R e conn e ct i n g f rom 2 ph a - s e t o 3 ph a
- se

M i caI ns u l a t i on for A rm a t u re C oi l s .

R epa i ri n g C oi l s D a ma g e d i n W i n d i n g P r oce s s

V ol t a g e t o U s e W h e n T es t i n g C o i l a n d C o m m u t a
t o r I n s u l a
t i o n .
 C ON TE N TS

Fi e l d C oil I ns u l a t i on
Va r ni s h es a n d I m preg na t i n g C om pou n ds for C oi l s
C ha ra ct eri s t i cs of I ns u l a
t in g V a rni s h es

S ol v e n t C h a r t for I ns u l a
t in g V a rn is h es

M e t h od for M a k in g Ta pe f rom C ot t on C l ot h
Dry i n g Ou t I ns ul a t i on of D C Ge n e ra t ors
Dryi n g Ou t I ns u l a t i on Of S yn ch r on ou s M ot ors
Dry in g Ou t I n du ct i on M ot ors
M ea suri n g I nsul at i on R es is t a
n ce

C HA PTE R VI I I

R E P AIR S HO P M ETH O D S F OR E INDING

R W A -C M AC HI NES
Wi n di n g Sm a l l S i n g l e-ph a s e M ot ors

I ns u l a t i n g L i n i n g for S l ot s —
Wi n din g t h e S ke i n C oi l I ns e rt
—

i n g S k e i n C oil i n S l ot s Wi n di n g for aR e pu l s ion —s t a

—
rt M ot or
—
n n m a a
Wi di g S ll M ot ors by H d Wi n di n g s for Odd Frs
n —

q u e n ci es —
C o n n ec t i ons f or M ai n a n d S t art i n g W i n di n g s
Tes t i n g S m a l l I n du ct i on M ot or Wi n di n g s Wi n di n g s for —

Sm a l l P ol y ph a s e I n du ct i on M ot ors .

Wi n di n g S m a l l I n duct i on M ot ors wi t h Form e d C oil s i n P a

rt i a
l ly
C l os ed S l ots
I ns u l a
t i on for S l ots Ba s ke t
—
C oil s Wi n di n g a 3 —ph a
—
se

Sta t o r wi t h B a s k e t C oil s —
Th rea d ed Di a m on d C oil —
Wi n di n g
a3 —ph a se Sta t or w i t h Di a m on d C oi l s .

Wi n di n g I n du ct i on M oto rs H a v i n g Op e n S l ot s

Wi n di n g a2 ph a - se St a t or H a v i n g Op e n S l ot s Tes t i n g t h e
—

Win di n g s I n s e rt i n g aN e w C oi l i n aWi n di n g C on n ect i n g

— —

the C oi l s —
P oi n t s to C ons i de r w h en C onn ect i n g C oil s —
C l ea
ts
a
n d Te rm i n a
ls —
Pa
i n t in g Wi n di n g .

I n du ct i on M ot or S e con da ri es

S q ui rr e l ca
-
g e S econ d a
r i es —
P h a
s e w
- ou n d S eco n da
ri es .

Wi n di n g rg e Al t e rn a
La ti ng C u rre n t St a
t ors
rt i a
C oil s for P a l l y C l os ed S l ot s —
C oi l s f or Op en S l ot s —
La
p
a
nd Wa
ve C onn ect i ons —
I ns u l a
t i on of C oi l s —
I n s e rt i n g
S h ov ed Th rou g h C on ce n t ri c C oi l s —
ra
Ba nd C o n n e ct o r Wi n d
i ng —
Di a m on d C oi l Dou bl e Wi n di n g s Tes t i n g Wi n di n g s
s—
—

o f L ag M a
r e chi n es —
C onn e ct i n g t h e C oi l s B r a ci n g N e e de d —

for H e a v y Wi n di n g s .

Wi n di n g t h e S t ato O A
r f l te rn at i n g C u rr e n t T u rbo-
g en e rat ors .

C oi l s f or A - C Tu rbo-g e n e ra t ors Form i n g t h e C o i l s

—
I nsu l a —

t i on for Th rbo—g e n e r a t or C oi l s Te s t i n g Tu rbo-g e n e r a

—
t or
W di n g s I ns e rt i n g t h e C oi l s i n aTu rbo-g e n e r a
i n —
t or B ra ci n g —

for Wi n di n g s — C on n e ct i n g t h e Wi n di n g B rea k- dow n Tes t —

.
XV I C ON TE N TS

C HA PTE R IX
PA GE
TE s TI N G I ND U CTI O N M OTO R WI N D I N G s FOR M I s TA KE s A N D FA ULTS
Tes t i n g for Grou n ds a n d S h ort -ci r cui t s

R ev e rs a l of On e or M ore C oi ls or Grou ps
Ope n C i rcu i t s
P la
ci n g Wron g N u m ber of C oi l s

Using a n I m prope r Grou p C onn ect i on

Orde r i n Wh i ch Tes t s S h ou l d be M a de
C on n ect i n g for t h e Wron g N u m be r of P ol es
A ppl yi n g Di rect C u rren t a n d E xpl ori n g wi t h aC om pa ss .

C HA PTE R X

A DAPT ING D IRECT C

- URRENT M oT OR s TO C HA NGED OPERATING C ON
DI TI ON s

C ha n g es i n S pe e d .

C ha n g es i n Ope ra t i n g V ol t a ge
Ope ra ti g a
n M ot o r o n O n e ha
- lf or Dou bl e V Ol t a g e

S i z e of Wi re for D C A rm a t u r e C oi l s
Ope r a t i n g aGe n er a t or a s aM ot or a n d V i ce V ers a

M ot o r S p ee d w h e n R e co n n ec t i n g a D -C M ot or W i n d i n g Wa ve

to L a p
A dj u s t i n g t h e Ai r Ga -C u rr e n t M a
'

p o n D i r ec t ch i n es

C ha n g e i n B ru sh es w h en R e co nn ect i n g D - C M ot or from aHi g h e r

to aL ow er V ol t a
t u re W
ge
R e wi n di n g a n d R econn e ct i n g D C A rm a - i n di n g s f or a
C ha n g e I n V ol t age
R econ n ect i n g a La p Wi n di n g R e con—
n ect i n g aW av e W i n di n g
—
R econn ect i ng Du pl ex Wi n di n g s .

C HA PTE R X I
PRACTI CAL WA Ys FOR R E C O NNECTI N G I N D U CTION M OTO RS
P oi n t s t o C ons ide r before M a
ki n g R e con n ect i ons
Di ag ra m s for Di ff e re n t C h an g es Of C on n ect i ons

Di ag r am s f or Th r e e - ha
p s e M o t ors

U se Of T a bl e of C onn ect i ons

Tw o-ph a s e Di a g ra ms
M ea n i n g of t h e Term C h ord Fa ct or .

s e I ns u l a
P ha t i on
R e conn ect i n g M ot ors t o M ee t N e w C on di t i on s .

P r oce du r e w h en C ons i deri n g aR econ n ect i on of Wi n di n g s

P ra ct i cal E xa m pl e for R e con n e ct i on C ha n g es i n V ol t a
—
ge
on l y w i t h a l l Ot h e r C on di t i ons R e m a in i n g t h e S a me
C ha n g es Of P h a s e Onl y —
C ha n g es i n Fre q u en cy —
C han g es i n

N u m ber of P ol es Tes t i n g aR e con n ect e d Wi n di n g

—
.
 C O N TE N TS

PA G
I

E fie ct s of Hig h a n d L ow V ol t a g e o n M o t or O p e rat i on

Oper a t in g Sta n da rd A -C M ot ors on Di fiere n t V ol t a g es a nd

Fre q u en ci es
Fa ct o rs whi ch L im i t a C ha n g e i n N u m ber of P ol es of a n I n du ct i on

M ot or
S i ng l e -ci rcui t Del t aa n d Dou bl e - ci rcui t S t ar C on n e ct i ons

C u t t i n g Ou t C oil s of a n I n du ct i on M ot or

P rocedu r e Wh en C onn ect i n g C oils of a n I n du ct i on M ot or

Win di n g
C onn ect i n g P ol e-ph a -
se g ro u ps of a W i n di n g
—
Gen e ra
l
Th eory on Wh i ch C on n ect i on Di a g ra ms a re C ons t ru ct e d

Det e rrn i ni n g N u m be r of P ol e s f rom Sl ot Th row of C oi l s

Typi ca l C i rcl e Di a g ram s fo r C on n e ct i n g I n du ct i on M ot ors .

C H A PTE R XI I
C OMMUT ATOR R EPAI R S
us es of C om m u t a
Ca t or Trou bl es
Troubl es R es ul t in g from Hi g h M i ca
R em edy for Hi g h a n d L ow B a
rs

P l ug g i ng aC om m ut a t or .

R e m ovi n g B a n d M i caS eg m e n t s f or R
rs a e pa
I rs

R epa i rin g aB u rn ed C om m u t a t or B a r

R e pl a ci n g aR e pa i red C om m u t a t or B ar

Ti g h t e n i n g u p aR epa i red C om m ut a t or
Ba k i ng C om m ut a t or wi t h E l ect ri c Hea t
Re m ovi ng a n d R e pa i ri n g Grou n ds i n aC om m u t a t or
T urni n g Down aC om m u t a t or wi t h ou t R em ov i ng A rm a
t u re
T e m pora ry C ov er f or U se Wh en Turn i n g Down a C om m u t at or
R e fil l i n g aC om m u t a t or
B ori ng Out t h e E n d of aC om m u t a t or .

M i caU s ed i n C om m u t a t ors
Sha p in g M i caE n d R i n g s

Te m pl et for M a kin g M i caE n d in g s R

M i ca ni t e a s aC om m u t a t or I n su l a
t i on .

P reca ut i ons wh e n Ti g h t e n i n g aC om m u t a
t or
Ma ki n g M i cani t e E n d R i n g s .

Ca uses of E x cessi v e C om m u t a t or Wea r

C Op per U s e d f or M a ki n g C om m u t a
t or B a rs

Tes t for Oil -sa t ed M i cai n aC om m u t a

t u ra t or
Bla ck e n i n g of aC om m u t a t or at E qu al l y S pa ce d P oi n t s

U n de rcu t t i n g M i caof C om m u t a t ors

Tool s for U n dercu t t i n g M i ca S i z e of C i rcu l a
— r Sa w R e qu i red
—
Fi n i s hi n g S l ot s an d C om m u t at or S urfa ce a ft e r U n d e rcu t
- Ha
t i ng —
B rus h es fo U r s e on U n d e rcu t C om m u t a t ors n d
Tool s for Undercut t i ng M i caof C om m u t a
t ors .
x vi i i C ON TE N TS

C HA PTE R XI I I
PA G E

A D J USTING B R USHES A N D C ORREC TING B RUSH TROUB LES

Fi t t i n g or Gri n di n g -in B ru s h es 326
A dj u s t m e n t of B rus h h ol de rs . 329
C a
us es of Ra
p i d B ru sh Wea
r 33 1
S tt i
.

t i n g t h e E l ect ri ca
M et h ods f or L oca l N eu t ra
l In e ng B ru s h es . 332
A ng l e a
t Whi ch B ru s h Is S et . 3 33
C h eck i n g B rus h S et t i n g 334
B rus h P r es s ur e . 334
C om m on B rus h Term s 3 34
P roce du r e for L oca
t in g C a
u s es of B rus h T r ou bl es 337
Too L ow B rus h P r ess u re I n correct S pa
—
ci n g Of B ru s h es
B ru s h es N ot O p e r a
t i ng on E l ec t ri ca
l N eu t r a
l I ncorr ect —

Thi ckn ess of B rus h es —

U s in g B ru sh es of Wron g C h a ract e r

i s t i cs .

C a
u s es a
n d R e m e di es for S p ark i n g a
t B rus h es
Ca
u s es a
nd R e m e di e s f or Fl a
t S pot s on C om m u t a
t or
Ca
u s es a
nd Re m e di es for B l a
ck e ni n g of C om m u t a
t or
Ca
us es of He a
t ing In aM ot or or Gen er a
t or
Ca
u s es a
nd R e m e di es f or H on ey-com bi n g of B ru s a
ces hF
Ca
u s es a
nd R e m e di e s f or B ru s h es P i ck i n g u p C opp er
Ca
u s es a
nd R e m e di es f or B ru s h es C h a t t eri n g
Ca
us es a
n d R e m edi es f or L oos e ni n g of B rus h S h u n t s

C HA PTE R XI V

I NSP ECTION A ND R E P AIR OF M OTOR ST ARTERS ,

M OTORS AND GE N

E R A T OR S .

C os t of irs for P ol yph a

R ep a s e M ot o rs

f Moto
.

P oi n t s t o C ons i der Wh e n E s t i m a
t ing C os t o r R epa
i rs .

I ns pect i on Ov erh a
a
nd u li n g of

Di r ect -C u rr e n t M ot or S t a rt e rs

A u t o—s t a r t e rs for A -C M ot ors

Dru m Type C on t r oll e rs

La rg e C m
o p ou n d D C M ot or
-

5 0-Hp I n du ct i on M ot or
.

2 5-H p S li p-ri n g M ot or
. .

S i n g l e-ph a s e C om m u t a t or M ot or .

D i rect -C urrent E ng i n e Ty pe G e n e r a t or .

C HA PTE R XV

D I AGNOSI S OF M OT O R A N D GENERAT OR T ROUB L ES

La ck Of P r op e r C l e a
ni ng

Ope r at i on i n D a m p Pla ces .

E x pos u re t o A ci d R i m es a n d Ga

Wo P a
s es .

La ck of Fre qu e nt I ns pe ct i on a n d R epl a
ce m e n t of rn rt s .
 C ON TE N TS
PA GE
C l ea ni ng M otors wi t h C om press e d Ai r 42 0
Tes t i ng ou t Ph a s e Ro t at i on 42 0
A n I n du ct i on M ot or Troubl e Due t o Wron g S t a t or C on n ect i on s . 42 1
Sta l li n g of Wou n d Ro t or I n du ct i on M ot or E x pl a i n ed 422
l o os e B e a ri n g C aus ed I n du ct i on M ot or t o Fa il t o S t a rt 42 3
Th ree -P h a s e M ot ors U s ed on S i n g l e -ph a
s e L i n es 42 5
A n A p pa r e n t Ov erl oad Trou bl e Th a t wa s Tra ced to a D e f e ct i v e
42 7
C a us e of N oi s e i n Th ree -ph a s e M ot or Dri v i n g E xh a us t Fa n . 42 8
C a us e of B u r n e d ou t S t a rt i n g Wi n di n g in a S i n g l e ph a
- s e M ot or 42 9
.

C a u s e of On e M ot or Fa il i n g t o S t a rt Wh il e A n ot h e r w a s Ru nnin g

on S a m e C i r cu i t 43 0
Ca us e of S y n ch ron ous M ot or Fa i lin g t o S t a
rt 43 2
E ff ect of Decre a s e d Freq u e n cy on I n du ct i on M ot or Ge n er a
-
t or S e t 43 3
S i m pl e R u l es for R econ n ect i ng A -C M ot ors 43 4
C ha ng i n g 440-v ol t M ot or for Ope r a t i on on 2 2 0 V ol t s 435
l
M u p e on
t i l C n ect i on i a r a
D g m fo A C M oto r Win di n g s
r - 43 6
B rus h a n d Sl i p-ri n g S p ark in g Tr a
ce d t o A bs e n ce of Ro t or B a lanc

i n g We i g h t s
Ove rh ea t i n g of a n I n du ct i on M ot or Tr a ce d t o V a ri at i on i n Fre

Re l i ef f or aHot B ea
ri n g

Sta t ic S pa rk s f rom B e l t s
.

Ra t in g s of A —C Gen er a t ors
A l t ern a s e Ro t a
t i n g C u rre n t M ot or Ph a t i on
E n d B ell s or Hea ds
S
.

B rus h es a n d B rus h Hol de r

Th e Ro t or
Th e S t a t or .

f f
S i z es o Fus es or A -C M ot ors

C HA PTE R XV I I

M AC HINE E Q UI P M ENT A N D T OO LS N EE D ED I N A R E P AIR S HO P

Arm a t u re Wi n de r s Tool s
’

Dev i ce for S h a i
p gn I nsu l a
t i n g C e ll s of A r m at u re S l o
.t s

Tool for C u t t i n g C e ll L in i n g a t Top of S l ot

S pe cia l Wi n di n g Tool s
R ep a i r Tool s t h a t ca n be M a de f r o m Ol d H ak s w B l a
c - a
de s
S peci a l C oil -wi n di n g De v ice
S tea d y i n g B ra ce f or R e pa iri n g S m a l l M ot ors
.

Ten s i on B l ock for U s e wh en B an di n g A rm a

t u res
A rm a t u re S l in g
P in i on P u l l er .

C oi l Wi n di n g M a ch i n es

C o ta
il -
p i n g M a ch in e s
 C ON TE N TS

C om m a
utt or-sl ot t i n g a
n d Gri n di n g Ma
ch i n es

A rm at u re B a ndi n g M a ch i n e

C om bi na t i on M a ch i n es

A PPE N D I X

D AT A A N D R EFE R EN CE TAB L E S
HOW t o Re m em ber t h e Wi r e Ta bl e
C op pe r for V a ri ons S ys t em s of Di s t ri bu t i on

C la s s i fica t i on Of Wi re Ga u g es

Ge ne ra l Wi ri n g Form ul a s for A-C a n d D C C i rcu i ts

Da t afor C on n ect i n g M otors t o S uppl y C i rcu i t s

V ol t a g e , Hors epowe r a n d S pee ds of M ot ors

Tra ns form e r R a t i n g for A -C M ot ors

S i z es of Fu s es , S wi t ch es a n d L ea d Wi r es for M ot ors of D i ff e ren t
S i z es on Di flerent V ol t a g es
C ircu i t B re a k ers for Overl oa d P rot e ct i on of M ot ors .

B e l t i ng
R ul es for Pul l ey S i z es .

C ha i n D r i ves
P oin t s t o C ons i der wh en C a l cu l at i n g S i z e of C h a
in
Hors e po w er Tr a n s m i t t e d by S t e e l Sh a ft i n g
Hors e pow er Tr ans m i t t e d by S in g l e Rop es

Ge ar Ta bl e
S om e Ha n dy R ul es

I N DE x
 A R M A TU R E I N DI N G
A ND

M OT OR R E P A I R

C HA P T E R I

DIR EC T C UR R EN T
- WIN DIN G S

Th e es se n ti al phys i ca l di ff e re n ce s be twee n acomplet e direct

curr e n t a nd a compl e t e a lter n a ti n g c urre n t a
- rm a tur e wi n di n g
i s tha t t h e form er is wou n d on t h e rota ti ng me mb er of t h e
ma chi n e W h i l e t h e l a tter i s woun d on t h e s ta ti on ery me mbe r
a n d th a t t h e di re ct curre n t wi n di n g re qui res acommuta
- tor
whi le t h e a lte rn a ti n g curren t wi n di n g doe s n ot Howe ve r
- .
,

s i n ce t h e p ra ct i cal ma ke u p a
-
n d co n s tr u ct i o n of wi n d i n g s

wi ll be di s cuss e d la ter for p a rt i cula r type s of di re ct a nd

a lte rn a ti n g curre n t ma
-
chi n e s , t h e g en e r a l the ory of a rm a

ture wi n di n gs will li ke wi s e be t a ke n up firs t for di re ct curr en t

-

a n d th e n f or a ltern a ti n g curr e n t m a
-
ch i n e s (s ee C h a pte r II)
.

A ct i on of aC om m u t a t or
.
—
Th é e m f a n d curr e n t pr odu ce d

in ea ch a rm a ture co n du ctor of adirect curr en t ge n e ra

- tor is
a lte rn a ti n g in cha ra ct e r
. I t i s t h e fu n ct i o n of t h e commut a tor
to deli ver from t h e a rm a ture wi n d i n g a n el ect r omot i v e fo r ce

a n d cu rre n t tha t is u n i di re cti o n a l tha

, t i s s u ch tha
,
t on e te rmi
na l wil l be a lwa ys of po s i ti ve pol a ri ty a n d t h e othe r of n e g a

ti ve pola ri ty . T h e commut a tor a n d i t s bru s he s a ccompli s h e s

thi s by be i n g con n e cte d i n seri e s be tween t h e ge n era tor l e ads

a nd t h e a rma ture wi n di n gs s o a s to r e v e rSe (i n e ff ect ) t h e con

n e ct i on s of t h e a rm a ture coi ls (co n n e cte d to t h e commuta tor

ba r s ) w i th re s pe ct to t h e m a chi n e l e a d s e v e r y t im e t h e e m f
a n d cu rr e n t i n du ce d i n th es e co i l s re v e r se upo n movi n g out of

t h e i n flue n ce of on e pol e i n to t h e field of t h e n e xt a dj ace n t

1
2 A R M A T UR E WI N D I N G A N D M OTOR R E PA I R

pole Th e a
. ltern a ti n g e m f a n d cu rre n t ge n er a te d i n t h e
a rm a ture wi n din g is thus re cti fie d or commuta ted in to au ni
d ire ct i o n al em f a n d curre n t .

I n t h e ca se Of a n a lt e rn a t g curre nt gener a
i n - t or no s u ch
re ct i fyi n g Of i n du ce d e m f a n d curr e n t is n e ce ss a ry so t h a t t he
co i ls or e l e m e n t s m a ki n g up t h e a rm a ture wi n di n g ca n be

co n n e ct e d d i r e ctly toge th er wi th t h e res ult i n g t ermi n a l s of

t h e wi n d i n g b e com i n g t h e t erm i n a ls of t h e m a chi n e .

C A n na t ur e W in di n g s I R ge n er a l a rm a
’
Type s of D - . . . ture
—
,

wi n d i n g s a re e i the r Of t h e O pe n ci r cui t or t h e clos e d ci r cu i t

type Th e la
. tte r i s used i n a ll mod e rn di re ct c urr e n t m a -

chi n e s wh le a
,
i lt n t g curre n t m a
e r a i n - chi n e s m a y h av e e i th e r

Ope n or clo s e d wi n d i n g s I n t h e close d ci r cu i t wi n di n g Of

.

t h e di r e ct curre n t m a
- chi n e t h e e n d jo i ns up wi th t h e be gi n

n i n g or r e e n t e r s i t se lf wi th t h e commut a
— tor t a pe d to t h e wi n d
ing a t e qu a lly di s ta n t po in t s I n t h e ca s e of op e n ci r cu i t
.

w in di n g of a n a lte r n a t i n g-curre nt ge n e ra tor wou n d on t h e

r e volvi n g m e mb e r t h e e n ds t e rm i n a
, t e in coll e ctor ri n gs a nd

t h e wi n d i n g i s thus Ope n u n til close d by t h e bri I s h e s Of t h e

e x te r n a l cir cui t Whe n t h e wi n di n g i s on t h e sta
. tor Of a n

a lte rn a ti n g curre n t m a
-
chi n e t h e e n d s a r e j o i n e d thr ough t h e

loa d ci r cui t Th e followi n g cl a

. s s i fi ca ti on Of close d ci rcui t or
d ir e ct curre n t wi n d i n gs m a
-
y b e m a d e

D ire ct urr e n t wi n di n gs (close d

-c
ci r cui t ) .

1 . Lap mult —
i p l e o r p a
r a
l l e l .

a
( ) S i n gl e l a p .

b
( ) M ult i pl e x l ap .

2 Wa. ve se ri e s or two cir cui t

— - .

a
( ) S i n gl e w a
v e .

( b) M ult i ple x wa ve or s er i es pa
ralle l wi n d i n gs -
.

Win din g P a
rt s a
nd formula
Te rm s for a
s. rm a
—
ture
In
w i n d i n gs an d i n la yi n g out are pa i r j ob cer ta i n t e rms a re u s e d ,

whi ch re fe r to pa rt s Of t h e a r ma ture wi n di n g t h e a rm a ture ,

cor e a n d de ta il s Of t h e a rr a
n ge m e n t Of t h e form er i n t h e s lots

on t h e s urf a ce Of t h e l a tter I n wha t follows thes e te rms a

. re

e x pl a i n ed I n mo s t ca
. s e s th e y are u se d a li ke both i n wi n di n gs
for d i re ct curr e n t a
- n d for a ltern a ti n g current m a chi n es -
.
 DI RE C T-C UR R E N T
’
WIN DI N GS

A rm a
tur e C on du ct or Tha t pa rt Of awi re
or I n du ct or .
—

whi ch li es i n an a rm a ture slot an d cut s t h e m a gneti c li n es Of

fo r ce or fie ld flux a s t he arm a tes , is ca
ture rot a ll ed an a rm a ture
co n du ctor or a n i n du cto r .

FI G . 1 .
—
D i fle re n t t y p e s O f coi l s us e d in a
rm a
t u re wi n di n g s .

( )
A O n e -p i e ce s e ri es d i am on d s t r ap c o il L e a d s a t e n d o f s t r ai g h t a
p t r 3 ) O n e - i e ce
p
ser i es d i a L ea ds a a a
. .

m on d coil t e d of s t i h
g t p r t ( )
C T w o - i e ce s en es on d coi l
n r p
a
.

a a a
. .

D O i
( )
(
n i m l t l d i m d o il L e d t O i n t o f d i m o d E ) T w o - i
fi
e n p e e
e ce u e o n c s
c
( F) C on ce n t ri c 001 1 be n t ow n a
:
.

mu l t i pl e 0n d c o t bot h en ds G) C on ce n t ri c
( H ) One i e ce wi r e w ou n d I n vol u t e cod L e a ds a
.

C OI I , s t r a om t of I n v ol u t e
.

Ig h t t
a a a e di a
. . .

T - i e ce i n v ol u t L d i f i l ( J ) T h d -i n t nd
'

w o p e o t p o n t o n v o u t e r e p m o
fl
c e s r
Le a on ti be f ore a ak
.

coi l ds a nd a K B ( a
t Oi n t of M ft e r p u l l i n g ( ) s e t o
I ) S m e
I
c
a s B Of t h r ea a a a ar a
. .

(M) S f h d d B n d I n v ol u t e
deI -in
t y pe m e s I ? o t r e e -In t
y p e
0) G r ou p of co n ce n t rI c a
. .

e n d con n e ct or . n d con n e ct or s .
(P ) on ce n t n o s h ov e d
t h r ou g h t yp e coil n t d own on on e e n d .

Wi n din g E l em e nt or S e cti on T h a t pa n a
rt Of a rma ture .
—

Wi n d i n g whi ch is co nn e cte d be twe en two commut a tor b a

rs i s
 A RM A T UR E WI N DI N G A N D M OTOR R E PA I R

c a lle d awi n d i n g ele m e n t I n i t s S impl es t form awi ndi n g

.

e l e m e n t co n s i s ts Of aco i l Of on e tu r n of w i re or two co n du e

to rs A n e le m e n t the re fore mus t h a

. ve a t le a s t two co n du e

tors but m a y c o n s i s t O f mo r e th a n o n e tu r n O f w i r e o r e v e n

n umb e r Of co n du ctors .

Am a t ur e C Oil . Whe n awi n d i n g ele m en t co ns is ts Of mo re

—

th a n on e tu r n Of wi r e or two co n du cto r s i t i s u s u a ,
lly k n own
a s aco i l a n d t h e wi n d i n g i s aco i l wi n d i n g a s d is t i n gu is h e d

from aba r wi n d i n g where t h e co n ductors i n t h e a

,
rma tu re
s lot s a r e coppe r b a rs .

From ame ch a n i ca l sta n dpoi n t a n a rm a tu re wi n di n g con

s i s ts of an umb e r Of co i ls co n n e ct e d to acommut a tor i n t h e
ca s e Of ad i r e ct curr e n t m a
-
ch i n e or co n n e ct e d tog e th e r i n t h e

ca s e Of a n a lter n a ti n g curre n t m a -
ch i n e to fo r m as e r i e s or

group E a . ch co i l m a y b e m a d e up O f o n e tu rn Of w i r e w i th
ea ch s i d e for m i n g on e a rma ture co n du ctor or i n du ctor or a ,

co i l m a y b e m a d e up O f s e v e r a l tu r n s O f w i r e o r O f C opp e r

s t r i ps . A cl a s s i fi ca t i on Of t h e d iff e r e n t types a n d u s e s Of

a r ma ture coi ls whi ch h a s be e n ma d e by R A S ma . ,

. rt

( E l e c t ri c J ou r r
t a
‘
l V ,o l V I I . N O 6 )
,
i s g i
. v e n i n t h e a e c om
pa n yi n g t a ble .

Th e s o ca — lle d form wou nd di a - mo n d co il s m e n t i o n e d i n t h e

,

ta ble a r e for m e d a n d comple t e ly i n s ul a te d be fo re be i n g a s

s e mbl e d on t h e a rm a t u re The y ca . n o n ly be u s e d i n op e n

S lot s C o n ce r n i n g t h e a dva n ta ge s Of d i a mo n d coil s i n volut e

rt h a
,

co i ls a n d co n ce n tr i c co i ls M r S ma ,
. s t h e followi n g to
,

sa y :
“
T h e g r e a t a dv a n t a g e O f d i a mo n d c o i l s i s t h e e a s y a n d
s i mpl e m a n n e r i n wh i ch th e y ca n be m a n uf a ctur e d e s pe ci a
,
lly
i n la r g e qu a n t i t i e s whi ch m a
,
ke s the m well a da pt e d for st a nd

a rd m a ch i n e s . S i n ce a l l t h e co i ls u s e d on one m a chi ne a re

Of t h e s a m e S i ze a n d s ha pe o nly on e wi n di n g mould Ove r

,

whi ch to form the m i s n e ce ss a ry M o re ove r t h e n umbe r Of

.
,

S pa re p a rt s wh i ch mus t be ke pt on h a n d for r e p a i ri n g i s r e
du ce d a n d re pa ir s ca n be m a de e a s i ly a n d qu i ckly . From
t h e e l e ct r i ca l poi n t Of vi e w t h e di a ,
mo n d type Of wi n d i n g
p o s s es s e s t h e a dv a n t a g e O f b e i n g a b s olut e ly s y m m e t r i ca l
.

H e n ce the re i s n o t e n d e n cy for u n b a la n ci n g Of volt a ges du e

to d iff er e n ce s Of s elf i n du ct i o n ; a - n d i n clo s e d w i n d i n gs th e re

i s n o t e n d e n cy to p rodu ce i n t ern a l ci rcula t in g curren ts ”

.
 A R M A T UR E WI N DI N G A N D M OTOR R E PA I R

e a s y to w i n d e i th e r on a mould or by h a nd The y ca n be a de .

q u at e l y i n s ul a t e d a n d c a
,
n b e s e cu r e ly b r a
ce d w i th s i mpl e a n d
re li able coi l support Howe ver t h e coi ls be lon gi n g to t h e
.
,

sa me group a re of d i ff e re n t s i ze a n d t h e co i ls i n di fi e re n t ,

gr oup s e xce pt on s i n gle pha

, s e ma ch i n e s a r e b en t i n a
- t lea st ,

two a n d oft e n i n thr e e di ff e r e n t s h a pe s This i s adi s a dva n ta ge .

from t h e ele ct ri ca l poi nt of vi e w s i n ce there will a lwa ys be a

,

t e n d e n cy towa rd un b a la n ci n g due to d i ff ere n ce s i n s elf

i n du ct i o n a ,
n d tow a r d t h e pr odu ct i o n of ci r cul a t i n g curre n ts
i n cl ose d wi n d i n gs A n d it is a ls o adi s a dva n ta ge fr om t h e
’

me cha n i ca l poi n t of vi e w si n ce for one m a ch i n e

,
al a r ge ,

n um b er of d i ff e r e n t mould s w ill be r e qu i r e d a n d co i ls ca n n ot

be i n te r cha n ge d H e nce t h e n umb er of s p a

. r e pa
,
rt s n e cess a ry

for re p a i r s i s gr e a tly i n cre a s ed a n d both t h e m a n uf a

,
ctur i n g

a n d re p a i r i n g of t h e wi n di n g wi l l r e qui re more t i m e a n d be

more e xpe ns i ve .

Wi n di n g P i t ch or C oil P i t ch Th e d i st a n ce b e tw e e n t h e
.
—

be g i n ni n g of on e wi n di n g e le me n t or coi l s i d e to t h e be gi n n i n g

an d a wa an d l a w i n di n g s
$
1 05 . 2 3 .
—
C om p r i so n of ve p .

A t t h e l s t aw a v e w i n di n s h ow i n g fr on t i t ch of c oi l a 31 ck
1 ; ba p i t ch a t ot a l
g p s s s 11 3;
i t ch 1! an d co m m u t a t or p i t ch a s uh A t ri g h t , aa ae
l p w m d m g wi t h t h e s m a
n ot t i ons
F
.

or t h e d i fi e r e n t p i t ch es of 001 1s .

of t h e ne xt ele me n t or coi l si de co n ne ct e d to t h e fir s t on e i s
ca lle d t h e tot al wi n d i n g pi t ch Thi s is s hown a s y for both l a .
p
a n d wa v e wi n d i n gs i n Fi g s 2 a nd 3 Wi n d i n g pi t ch i s mea
. s .

u r e d i n n umb e r of s lots or by n umb e r of e l e m e n t s or co i l

s i de s s p an ne d by a s i n gl e co i l or by t h e n umb er of commut a tor

ba r s b etw ee n t h e co n n e ct i o n s to t h e commut a tor of t h e two
e l e m e n ts or co i l s i d e s I n t h e th ir d ca s e t h e me a
. s ur e m e n t i s

k n own a s com m u ta tor pi tch a n d i n di ca te d a s yk i n Fi g 2 .

 DI R E C T-C '
UB R E NT WIN DI N GS
a
nd Fi g 3 . . I n thi s cha pter unl ess othe rwis e s ta te d coil
pi t ch wi ll be d es i g n a
te d by t h e n umbe r of w i n d i n g s pa ce s or

c oi l des s pa
si nne d There . a
re two wi ndi n g s pa ces per s lot

i n adouble l a yer win di n g .

Fron t P i t ch Th e d i s t a
. n ce be twee n two si de s of aco i l
—

co n n e cted to t h e s a me comm uta tor ba r me a s ure d i n co il , .

s i d es at t h e fro n t or commut a tor e n d of t h e a rm a ture is ca lle d ,

I t is i n d i ca te d a s yl i n Fi gs 2 a
'

t h e fr o n t pi t ch . nd 3 . .

Ba ck P i t ch Th e d i s t a
.
—
n ce be twee n two s i d e s of aco il ,

m ea s ur e d i n co i l s i d e s a t t h e ba ck e n d o
,
f the a rm ature i s
k n own a s t h e ba ck p i t ch I t is s hown a s yz i n Fi gs 2 a
. nd .

3 . Th e tot a l wi n di n g pit ch y is e q u a l to t h e a lge brai c s um

Fro . 4 .
—
La
p a
nd wav e w i n di n g s s h ow i n g co n n ec t i o ns o f for m e d coil s to t h e
co m m u t at or i n dou bl e l a y e r wi n d i n g s .

fro n t a n d ba Tha t is s i n ce i n al a
‘

of t he ck p i t ch es .
, p w i n d i n g
t h e fr o n t a n d ba ck p i t ches a r e of Oppos i t e s i g n be i n g l a id ,

off i n Oppo s i t e d i r e ct i o ns on t h e a rma ture t h e tot a l pi t ch 3; ,

will be t h e diff e re n ce b etwee n them I n awa ve wi n d i n g whe re

.

t h e fr o n t a n d ba ck p i t che s a re l a i d off i n t h e s am e di re cti on t h e ,

t ot a l p i t ch y will be the i r s u m .

Ful l P i t ch a n d Fra ct i on a l P i t ch C oil s Wh e n acoi l s pa —

. ns

e xa ctly t h e d is t a n ce b e tw ee n t h e ce n t e rs of a dj a ce n t fie l d pol e s
'

( k n ow n as p o l e p i tch ) i
- t i s s a i d to b e a ful l p i t c h c o i l I n -
.

ca s e s wh e r e aco i l is l e s s th a n full p i t ch i t i s s a i d to h a
, ve a
f r a cti on a l p i t ch o r to b e a s h o r t- i tch co i l
p S u ch a w i n d .i n g is

ofte n referred to a s as h ort-cord w i n d i n g .

Fra ct i o n a l p it ch wi n d i n gs a r e m u ch us e d be ca u se of t h e
foll owi n g a dva nt a ge s : ( 1 ) T h e y m a ke po s s i ble s horte r e n d
co n n e ct i o ns a n d th e re fo r e ca ll for le ss coppe r (2 ) A rm a ture .
 A R M A T UR E WI N DI N G A N D M OTOR R E PA I R

rea ct i o n is re du ce d s i n ce t h e cu rre n ts i n t h e n e ut r a
l zo n e flow
pa rtly i n Oppo s i t e d i r e ct i o n s an d ne utr a li z e e ach oth e r (3 ) .

In a ltern a ti n g curren t ge n er a tors as moothi n g out of t h e wa ve

of i n du ce d em f is produced so a s t o m ore n ea r ly appro a ch a

S ym bol s U s ed i nWi ndi ng Form ul a s Th e s ym bols wh i ch .

—

are mu ch u s e d i n wi n d i n g for mul as for t h e p a rt s of wi n d i n gs

d e fi n ed i n t h e preced i ng parag r a
phs ar e as foll ow s

Z l n umber of a
Tot a rm a ture condu ctors , (2 90) or (2 g K) .

C N umbe r of wi n di n g e l e m en t s or co i l s us ua
lly e qua
l to K .

9 N umb er of tur ns pe r wi n di n g e lem e n t or co il .

29 N umb er of co n du ctors per wi n di n g elem ent or coi l .

N N umb er Of co i l s i d es of wi n di ng .

y W i n d i n g p i t ch o r c o i l p i t c h .

y 1 F r o n t p i t ch O f w i n d i n g e l e m e n t o r co i l .

y z B a c k p i t c h of w i n d i n g e l e m e n t or co i l .

y ) C
. o m mut a to r p i t c h .

K N u m b er of commut a tor b a rs .

19 P a i r s of fi e ld m a g n e t pol e s .

21) N umb er of fi e ld m a g n et poles .

2a N umb er of se cti o n s of a rm a ture wi n di n g i n pa

rall el .

s N umber of slot s on t h e a rm a ture .

N um beri n g of C oil S i d e s i n A rm at ure S l ot s Fo rm wou n d .

—

c re u s u a
o i ls a lly arr an g e d i n t wo l ayers wi th on e s i de of e a
ch

FI G 5 —
Wi n di n g wi t h t w o FI G 6
. Win d i n g w i t h fou r coi l si d e s
—
.

ca
. .

coi l s i d e s pe r s l ot
. p e r s l o t T
. h e c oi l p i t ch i n t h i s se i s

7w i n di n g s p ace s or coi l s i de s .

co il pl a ce d i n t h e bottom of a s lot a n d t h e oth e r s i d e i n t h e

top For co n ve n i e n ce i n la
. yi n g out wi n di n gs t h e co il si des ,

fo rm i n g t h e top la yers i n t h e s lot a re g i ve n odd n umb e r s a nd

those formi n g t h e bottom la yers e ve n n umbers This s chem e .

of n umb e ri n g i s shown i n Fi gs 5 a nd 6 I n those ca

.
s es .

where t h e wi n di n g ele me nt co ns is ts of aco il Of an umb er of

turns of wi re i nst ea d of t wo c o n du c t ors o r b ars n um b e rs a r e ,
 DI R E C T-C UR R E N T
’
WI N DI N GS

a
s s i gn e d to t he uti ve bun dle Of condu ct ors or wires of
cons e c

whi ch t h e coi l is ma d e i ns t e a d of a s s ig ni n g n umbe rs to t h e

i n d i vi du a l con du ctors or i n du ctors a s th e y a re s om e t i m es

ca ll e d Whe n s u ch coils a
. r e use d t h e fr o n t a , n d ba ck p i t ches

a r e d e te rm i n ed by cou n t i n g co nse cu ti ve ha l f co ils be twee n t h e

t h e two co i l s i des Of a ny coi l be gi n n i n g fr om one co i l s i d e a nd

cou n t i n g fo rwa rd a s t h e coi l is l a i d off a n d co ns i d er i n g t h e

firs t si d e Of t h e coi l a s one Th a t is i n ca

. s e of a double l a
,
ye r
la p w i n d i n g w i,th o n e co i l s i d e i n t h e bottom of s lot 3 an d ,

t h e other s i d e i n t h e t Op of s lot 7 t h e b a ck pi t ch would be 7

,

cou n t e d a s follows there bei n g two coi l si des i n e a

,
ch s lot :

Fir s t coi l s i d e 6 next co i l s i des s pa

, nn e d a re 7 8 9 1 0 1 1 a nd , , , ,

12 . Th e n umbe r of s lot s s p a n ne d by t h e co i l is ca ll e d t h e
s l ot pi tch or th row of the coi l Th e t h row Of t h e co i l more
.
,

Oft e n ca lle d co i l thr ow i n t h e ca , se me n ti o ne d whe re on e si de ,

of aco i l is i n sl ot 3 a n d t h e other i n s lot 7 i s 4 s lots I n t he

,
.

ca s e of afour pole m a -
chi n e a nd a n a rm a ture h a vi ng 1 6 slots ,

this co il th row is afull pol e p it ch tha t is from t h e ce n te r of

, ,

on e fi eld pol e to t h e ce n t er of t h e next a n d t h e w i n d i n g is a

,

full pi t ch wi n di n g .

L AP —
M UL TI P L E OR P A R AL L E L WI N DI N G S

A la p w i n d i n g is s o call e d fr om t h e l a
pp i n g b a
c k of t h e coi ls

or wi n d i n g e le me n ts a s the y a r e wou n d on t h e a rma ture core .

T h i s is s hown i n Fi gs . 7a
nd 8 . A be tt er n a
me is amulti

FI G . 7.
—
La p wi n di n g s h owi n g t h e re l ati v h
p os i t i on of one wi n di n g e l em e n t

or coil of t w o t u r ns on t h e a rm a t u re o f a 4 pol e m a
ch i ne
— .

pl e p aa
or lle l wi n di n g b e ca
r use of t h e fa ct t h a t such awi n di n g '

co ns i s t s of a s ma n y ci r cui t s as th e r e ar e fi e ld pole s a n d th e s e

cir cui t s a re co n n ect ed i n p a ralle l be twee n t h e b rus hes T h e .

num be r of b rus h es re quir e d th e re for e e qua ls t h e number Of

10 A RM A T U R E WI N DI N G A N D M OTOR R E PA I R

arm a ture s e ct i o ns i n pa
rall e l a nd a l s o e quals t h e n umber o f
pole s Tha
. t is a p A l a p w i n d i n g
. can be d i s t i n gu i s h e d

7 8 9 1 2 3 4 5 6

FI G 8
. .
—
di a
g ra
Wi n di n g m f or t h e l a p wi n di n g of Fi g 7 s h o w i ng h ow
.

t h e fin i s h e n d of on e w i n d i n g e l e m e n t or coil of t w o t u r ns i s joi n e d t o

t h e com m uta nd t o t h e sta

t or a r t e n d of t h e n e xt coil u n d e r t h e s am e pa i r Of

a
FI G 9 .
(a.
) La
—
p wi n di n g s h ow i n g bo t h e n d c on n e ct i on s of e a ch coil ben t

t ow ar d ce n t e r of t h e coil ( b) W a. v e w i n di n g s h o w i n g e n d c o n n e ct i on s of

ea ch coil s i de be n t i n Opp os i t e di r e ct i on s .

f om a
r a lle d wa
so c
- ve wi n d i n g fr om t h e appe a ra n ce of t h e

e n d co n n e ct i o n s of co i l s I n t h e wave wi n di n g t h e fron t a
. nd
 DI R E C T- C U R R E N T WI N DI N GS

a
re r e n ds of t h e coils le a d i n oppos i te di re cti on s while i n t h e
la w i n d i n g th e y c o n t i n ue i n t h e s a m e d i re ct i o n ar ou n d t h e
p
arm a ture a s s how n i n Fi g
,
9 . .

Form u la s f or L a p W i n di n g T h e f
—
oll ow r n g r u l e s a n d r e s t r i c

t i o ns gove rn t h e a s s e mbli n g a n d us e of a la p w i n d i n g :

1 . Th e fron t n d ba
a ck pi t ch e s (in w i n di n g sp a
ce s or coi l s i de s )
bot h be Odd n urnbe rs a
m us t n d di ffe r by t w o or s om e m u l t i pl e

th ere of .

2 Th e fron t a
. n d ba ck pi t ch e s a re of oppos i t e s i g n ( on e posi t i v e

a n d t h e oth e r n eg at i v e ) s i n ce t h e y a re l a i d off i n oppos i t e di re c

ti ons on t h e a rm a ture .

3 Th e wi n di n g pi tch i s e q ua
. l t o t he a lg ebra i c s um of t h e fron t a nd

ba ck pi tch es Th a t i s i n ca
.
,
s e t h e fron t pi t ch i s 9 a nd t h e

ba ck pi t ch 7t h e a lg ebra
,
i c sum i s ( 9 7) or 2 .

4 Th e to t a
. l n u m be r of a rm a t ure con du ct ors or i n du ct ors m us t be
am ult i pl e of t h e n um ber of slot s on t h e a rm a t u re .

5 Th e n um be r of a
. rm a ture slots m a y b e o dd o r e v e n .

6 Th e n um ber of curren t col lect i n g poin t s or bru sh es on t h e com

.

m u ta tor m ust e qu a l t h e n um ber of poles .

7 Th e m a
. xim um em f betw ee n t w o con s ecu ti ve coi l s i des i s e q u a l
t o or ali ttl e les s th a n t h e t e rm i n a l v ol t a ge .

8 Th e e n d of on e coi l i s joi n ed to t h e com m u t a

. tor and t o t he

st a rt of a n oth er coi l (usua lly t h e next) un de r t h e s a m e pa i r of

pol e s .

Th e follo wi n g fo rmul a
s apply i n l a
p w i n d i n g s

N i b
Fr o n t pi t ch
2p
N j: b
Ba
ck pi tch
2p
Wi n di n g pi t ch y a i c su m of y a
lge b r a n d yz 1

C ommut a
to r pi t ch y 2 i 1

I n theformula s for f r o n t an d ba ck p i t ch e s N ( a s gi ve n o n ,

pa ge 8) is t h e n umbe r Of co il si des i n t h e wi n d i n g ; p t h e
n umb e r of p a i rs of poles a nd b a n y e ve n n umbe r whi ch wi ll

ma ke both y l a n d yz Odd whole n umb e rs a

.
nd a bout e qu a l to
t h e pole pi t ch Th e va lue of b s hould be t a ke n a s la rg e a
‘

. s

a llowa ble but n ot too l a r ge for th e n ther e i s li a bi li ty of t h e

two s i des of acoi l comi n g u n de r t h e i n flue n ce of poles of t h e
sa m e pola r i ty s o tha t t h e i n du ce d emfs would Oppos e e a ch
 A RM A T UR E WI N DI N G A N D M OTOR R E PA I R

other For b O t h e b a
. ck p i t ch yg be com es e qu a
,
l to t h e pole
pit ch Whe n b is posi t i ve yz becomes gre a
. te r tha n the
pole pi t ch whi le w ith b n ega
,
t i ve yz becomes les s tha
,
n

t h e pole pi t ch I n mo st ca
. s e s b is t a ke n n e g a
t i ve so tha t yz
i s e qu a
l to or less tha n t h e pol e pi t ch .

Fro l o — L a
. .
p w i n d i n g f or a4- ol e m a
p ch i n e s h o w i n g t h e di re ct i o n of cu rre n t

flow i n o n e of t h e fou r cu rr e n t p at h s f or t h e bru s h p os i t i o n s a s i ll u s t r a

te d
.

Th e curre n t (i ) whi ch flows in e a

ch co n du ctor of al a
p
wi n d i n g is ,
I
2 29
W he r e I is t h e tot a l a rm a ture curre nt or tha t flowi n g i n t h e
e xt e r n a l cir cui t Th e va. lue of (i ) s hould be co ns i d er ed whe n
s e le ct i n g t h e p rop e r s i z e Of w i r e i n m a ki n g up or or de ri n g coi ls .

Th e o n ly pra ct i ca l la p w i n d i n g f r om t h e s t an dpo i n t of
s ymm e t r y i s t h e on e i n wh i ch t h e n umb e r of p a i rs of ci r cu i t s
( c u r r e n t p a th s ) i n p a r alle l e qu a l s t h e n umb e r Of p ai r s of pol e s

or a p .

A la p w i n d i n g i s s ymm e t r i ca l wh e n 8 a a n d s p i s a
 A RM A T UR E WI N DI N G A N D M OTOR R E PA I R

A single l a p w i n d i n g a lw a y s h a s t h e s a m e n um b e r of c u rr e n t
pa ths betwee n brus h s ets a s th e re a r e fi e ld pol e s W hi l e a double
la p w i n d i n g h as tw i c e t h e n umb e r of c u rr e n t p a th s a s th e r e a r e

fie ld poles Th e tri ple l a.

p w i n d i n g h a s th ree t i m e s t h e n umb e r

of cu rre nt pa ths a s the re a r e fie ld pol es A s i n gle w a

. ve wi n d
ing a lwa ys h a s two cu rre n t p a ths be twee n br us h se ts whi le t he
double w a ve w i n d i n g h a s fou r curr e n t p a ths be twee n b rus h
s et s a n d t h e tri pl e w a ve wi n di n g h a s s ix s u ch pa ths be twee n
brus h se ts .

An a rm a tur e h a s one w i n d i n g (s i n gl e ) whe n t h e n umbe r of

commut a tor b a rs K a n d commut a tor pit ch y) ha ve n o common ,

fa cto r ; i t i s doubl e wh e n th e ir commo n f a cto r is two a n d it ,

i s tr i pl e wh e n th e i r commo n f a cto r is thr ee .

M ea ni n g of t h e Te rm R e e n t ra nt A wi n d i n g is ofte n s a
.
—
id
to be s i n gle or double re e n tra nt I n t h e ca se of as i n gle

wi n di n g thi s m e a
.

, ns th a t t h e wi n di n g closes on i ts e lf or re
turn s to t h e be gi n n i n g poi n t a ft er b e i n g tr a ce d through a ll t h e
co i l s upo n p a ss i n g o n ce a r ou n d t h e a rm a ture core A wi n d .
,

i n g i s doubly ree n tra n t i f i t o n ly r e e n t ers i t s e lf a

- fter ma kin g
two pa ss a ge s a r ou n d t h e co i ls of t h e a rm a ture A s i n gle .

wi n di n g m a y be e i th e r s i n gl e r ee n t r a n t o r doubly r ee n t r a n t .

I n t h e ca s e of doubl e a n d t r i pl e w i n di n gs t h e t e r m ree n t r a ,
nt

is s om et i m es u se d i n a n im m ope r se n se For th is re a
. s o n i t is

a dvis a ble to s pe ci fy type s of a rma tu re wi ndi n gs by t h e n um

ber of se p a ra te wi n di n gs us e d Thus as i n gle wi n d i n g a
,
. s a

s i n gle clo s e d ; two wi n d i n gs a

-
s double clo s e d a - n d th r ee wi n d

i n gs a s t ri pl e clo s e d e t c
-
. A wi n di n g m a d e up of two s i n gle
wi n d i n gs e a ch of whi ch re e n t e rs i t se lf
,
- wi ll therefore be a
,

double clos e d wi n di n g n ot a double ree n tra

- - nt on e .

M u l t i ple x L a p W i n d i n g s . A—
s e x pl a i n e d u n d e r t h e h e a d i n g
of M ulti plex Wi n di n g s al a
“
, p w i n di n g m ay b e m a d e u p of
on e t wo or thr e e s e p a
, ra te wi n di n gs i n order to ha n dle he a vy
a rm a tur e curre n ts I n t h e ca. s e of adouble l a p w i n d i n g two ,

si m i l a r wi n di n gs i ns ul a te d from e a ch othe r a re pl a ce d i n t h e

a rm a ture slots wi th t h e e ve n n u mb e re d commut a tor b a rs

co n n e ct e d to on e wi n d i n g a n d t h e odd n umb e re d b a rs con

n e ct e d to t h e othe r wi n d i n g I n t h e sa
. m e wa y f o r a t r i pl e

la p w i n d i n g on e -thi r d Of t h e commut a to r b a rs p r ov i d e d would

be co n n e cte d to ea ch wi n d i n g .
 .
DI R E C T-C UR R E NT WI N DI N GS

Th e formula
s whi ch a
pply in multi plex l a
p w i n d i n gs a
r e a
s
foll o ws
N b
Fr o n t pi t ch y,

N
?b
Z

Ba
ck pit ch ya
2 ?
Wi n di n g pi tch y y,

C ommut a
tor pi t ch 11 »
2

In thes e formula s m i s 2 for adouble W i n d i ng a n d 3 for a

tri ple wi n di ng et c Whe n t h e n umbe r Of commut a

, . tor b a rs

is e x a ctly di vi s i bl e by m t h e wi n d i n gs wi ll be e n t i re ly s e pa
,
ra te
fr om e a ch oth e r .

A double l a p w i n d i n g w i ll h a v e 2 x ( p)
2 c u rr e n t p ath s b e

twee n b r us he s whe re 2p is t h e n u m ber of pol es Tha

, . t is e a ch
,

wi n di n g for a4 pole m a — chi n e will h a ve four curre n t p a ths s o

t ha t adouble l a p w i n d i n g o n a 4 pol e m a-c h i n e w i ll h a v e e i ght
curr e n t p a ths be twe e n b rus hes .

I n o r d er tha t t h e t wo si des of awi ndi n g e le me n t or acoi l

ma y mov e s i mult a o u ly u d fi ld p o l es o i O p po s i t e
'

n e s n e r e

pola ri ty t h e tot a
, l n umbe r of co n du ctors m a ki n g up t h e wi n d
i n g e le m e n ts or co i ls of t h e wi n di n g d i vi de d by t h e n umbe r Of
field poles tha ,
t is Z 2p i s t h e a ,
ppr ox i m a t e va lu e for
both t h e fr on t a n d ba ck p i t ches a s i n t h e ca s e of t h e s i n gl e

la p w i n di n g . U n d e r s u c h c o n d i t i o ns t h e e l e c t r omot i v e fo r c e

i n du ced i n t h e two s i d es Of awi n d i n g e le me n t a dd up Th e

.

sma lles t fron t or ba ck p i t ch to s a t is fy this con di ti o n is t h e ,

di s t a n ce a cr o ss a s i n gl e pol e f a ce a nd t h e la r ge s t fro n t or b a ck

pi t ch is t h e dis t a n ce f rom on e pol e t i p to t h e ne a re s t pol e t i p

of t h e sa m e pola ri ty I f t h e fr o n t a
. n d ba ck p i t ches a r e mu ch

less tha n Z 2p the n acor d e d wi n di n g re s ult s

, .

S i n ce y l a n d yz mus t be Odd n umb e rs a nd a ppr ox im a t ely

e qu a l to Z 2 p where 2p is t h e nu m ber of fie ld pol es thi s
, ,

va lue wi ll he lp i n de termi ni n g t h e va lue of b to be use d i n t h e

formul afor fr on t p i tch (yl ) a n d ba ck p i t ch (yg ) .

Th e mult i ple x l a p w i n d i n g i s l a r g e ly c o n fi n e d to w i n d i n g s

for sm a ll a n d me d i um s i z e d m a chi n e s ca r r yi n g l a r ge cu rr e n t s

a n d us i n g coi l s m a d e up of wi re ra the r tha n coppe r s t r i ps or

 A RM A T UR E WI N DI N G A N D M OTOR R E PA I R

ba rs Th is is for t h e re a
. s o n that i n such awi n di ng for a
lar g e mult i pol a
r ma chi n e t he b ars would be too t hi n a nd a

me cha l co n st ru cti on res ult whi ch would m a

n i ca ke a n oth e r

type of wi n di n g a dvi s a ble p oba

r a
bly se ri es -pa
,
rallel d es i gn .

WA VE S E RI E S OR TW O-C I R C UI T WI N DI N G
'
—

Th e wa ve wi n di n g is so ca lle d fr om t h e z ig z a
g or w a
v e p a
th
th at t h e wi n di ng t akes t h rough t h e slots of t h e a rm ature as ,

s hown i n Fi g s 11 a nd 1 2 . Thi s type of wi n di n g is mo re

.

Fro . 11 —
. Wa
ve w i n di n g s h ow i n g re l at i v e p os i t i on o f on e w i n d i n g e l e m e n t or

coil of t w t
o u rn s o n t h e rm a a t u r e o f a 4-
p ol e m a c hi n e .

d fi t ly de s cri bed a
e ni e s as e ri es or two i rcui t wi n d i n g b e ca us e
-c

of t h e fa ct th a t half Of t h e a rm a ture coi ls or s e cti o n s a

re con

n e ct e d i n s eri e s an d t h e two h a lves a ra

r e co nn e ct e d i n p a ll el .

Thi s wi n d i n g th ere fo re h a s o nl y two curre n t pa ths i n pa ra l le l

-
r 1

Fro 1 2 . W i n di n g di a
.
—
g ra m fo r w a v e w i n di n g of Fi g 1 1 s h ow in g h ow t h e
.

fin i s h a n d of o n e coil i s joi n e d t o t h e co m m u t a t or an d co n n e ct e d t o t h e s t a
rt
O f t h e n e x t coil u n de r t h e n e x t p a
i r of p ol e s b i s aco n t i nu a
’
. t i o n Of b .

be tween bru s he s re ga r dle ss of t h e n umbe r of pole s On ly two .

se ts of br us h e s a re re qui re d for am a ch i n e of a n y n umbe r of

pole s but i mpr ove d commut a ti on i s brought a bout whe n t h e

n umb e r of b ru s h e s e qu a ls t h e n umbe r of field pole s Th e wa ve .

w i n d i n g i s u s e d i n s ma ll a n d m e d i um s i z e d m a ch i n e s wh e r e i t

i s d e s i re d to kee p t h e n umbe r of co i ls a s s ma ll as po s s i ble .

 DI R E C T-C UR R E N T WI N DI N GS

Form ul a
s f or Wa
ve Win di n g followi n g rul es a
—
Th e nd

r est ri c ti o ns g o v
ern t h e a
sse mbli n g a
n d use of awa ve win di n g :
1 . Th e front a
n d ba
ck pi tch es ( i n win di n g s pa
ces or coil s i de s ) m us t

both be odd .

2 . fron t a
Th e n d ba ck pi t ch es m a y b e e qu a l o r m a y d i ffer by t wo

or som e m ul t i pl e th ere of Th e form er condi t i on i s u s u a

. ll y t h e
ca se .

3 Th e fron t a
. n d ba ck pi tch es a r e of t h e sa m e s i g n s i n ce th ey a re

la i d ofi i n t h e sam e di re ct i on
'

4 Th e wi n di n g pi tch is e qu
. al t o t h e sum of t h e fr on t a n d ba ck

p i t ch es .

5 Th e com m u ta
. tor pi t ch a n d n um be r of com m u ta tor ba rs m us t

n ot h a ve acom m on fa ctor .

6 Th e n um be r of curren t col lect i n g poi n ts or brush es on t h e

.

com m u t a tor is a l way s t wo fo r an y n u m be r o f p o l es b u t t h e

ru s h es m a y e qua
o

nu m ber of s e t s of b l t h e n u m ber of pol es .

7 Th e m a
. xi m um e m f be t ween t wo conse cu ti ve coi l si de s i s
e qua l or n ea l t o t h e t erm i n a
rly e q u a l volt a g e of t h e m ach i n e .

8 Th e fini s h of on e coil i s joi ned t o t he a

. rm a ture a n d t o t h e sta rt

of a n oth er under t h e n e xt pa i r of pole s .

Th e s a
followi n g formula pply in wave wi n di n g

Wi n di n g pi t ch y 11 1

Fr o n t
pi tch y1
Ba ck pi tch 312
N umb e r p ai rs of pole s p
v in K 1
ommuta
l
C tor pi t ch ya
p

N umbe r c tor ba
ommuta rs K p X yr zt 1
2
.

N l: 2
-

Th e umber of coil des (N ) mus t be s u ch tha

si t
_

will be a n e ve n n umbe r w i th y l a n d yz both odd n umb e rs .

y l an d yz a r e u s u ally t ak e n e qu a l U n d e r th e s e. co n d i t i o ns

t h e ba ck p i t ch ( yg ) is n e a rly e qu a l to t h e pole pi t ch a n d t he

s um Of t h e fro n t a n d ba ck p i t ch es i s n e a r ly e qu a l to double
t h e pole p i t ch I f yz i s re duce d the n y l mus t be i n cre a
. s e d so

tha t yl y, w i ll b e c o ns t an t T h is i s wh
. a
t h a pp e n s i n a
chor d e d or fra ct i o n al pi tch wi n di n g .

2
 A RM A T URE WI N DI N G AND M O TOR RE PA I R

Th e ur re n t (i ) whi ch flows i n e a
c ch co n du cto r of awa ve
wi n d i n g is a lwa y s on e h a lf t h e tot a l a rm a-
ture curr e n t i .

I 2 Thi s va
. lue of (i ) s hould be co n s i d e re d whe n s ele ct
i n g t h e prope r s i z e of co n du cto rs for co i ls of w a ve wi n di ngs .

Th e clo s i n g fo rmul afor awa ve wi n di n g i s y! (K i a ) ,

p . W h e r e y! i s t h e commut ,a to r p i t ch K t h e n umb e r Of ,

FI G .
—
Wa
ve wi n di ng for a4 — a
p ol e m ch i n e s h ow i n g t h e di re c t i on of
cu rr e n t flow i n on e o f the a
t w o cu rr e n t p t h s f or t h e bru s h p os i t i on a s illu s

a
t r t ed .

c ommut a tor b ars a t h e pa i rs of p a

,
ra ll e l ci r cu its i n t h e wi n d i n g
a n d p t h e nu mb e r of p a i rs of pol e s Whe n a 1 i t is o n ly.
,

pos s i bl e to m a ke a s i n gle W i n d i n g Th e hi ghe st commo n .

fa cto r of yk a n d K g i ves t h e typ e of w i n d i n g wh e the r s i n gl e , ,

double e t c Th e n umb e r of coi l s i de s i n aw a

,
. ve wi n di n g e qua ls
t wi ce t h e n um b e r commut a to r b a rs .

Th e n umb e r of s lot s wi thout i dle coi l s mus t s a ti s fy t h e

fo rmula 3 ( )
2 K , N W h e r e K i s. t h e n umb e r c o m m u

ta tor b a rs a n d N t h e n u mbe r of co i l s i de s pe r s lot .

A wa ve wi n d i n g i s s ym m e t ri ca l whe n K a s aa nd ,

p a ar e whol
, e n umb e r s W h e r e K i s t.h e n umb e r of com
 DI R E C T-C U E R E N T WI N DI N GS

mut a tor b a rs a t h e n umb e r of p a

, ,
irs Of p a ra llel ci r cui ts i n
t he wi n d i n g 8 t h e n umb e r Of s lot s a
,
n d p t h e n umb e r of pa
,
i rs
of pol e s .

Whe n e qu a li ze d ri n gs a re n ee d e d wi th a wa ve w i n di n g t h e ,

u s e Of on e ri n g to e ve ry 1 5 to 2 0 commut a tor b a rs is good

p ra ct i ce .

M ul t i pl e x W a ve or S e ri e s -P a ra l l e l W in di n g I n as i n gl e .
—

wa ve or s eri e s wi n di n g t h e n umber of a rm a ture cir cui ts i n

pa ra lle l i s a lwa ys e qu a l to two whi le i n al a , p or mult i pl e w i n d
i n g t h e n umb er of ci r cui ts i n pa ra ll el is e qua l to t h e n umbe r of
field poles Th e se ri es p a
. ra lle l wi n di n g i s ad es i gn of wa
- ve
wi n d i n g i n whi ch t h e n umb e r of a rma ture cir cui ts i n pa ra ll el
ma y b e l ar g e r th an two a n d y e t s m a ll e r th an t h e n umb e r of
field pol e s I t is e s pe ci a
. l ly s u i t a ble for l a rge mult i pol a r a rm a

tur es whi ch u se wi n d i n g ele m e n ts m a d e up of coppe r b a rs .

Form u l a s f or S e ri e s P a ra l l e l Wi n di n g
- Th e followi n g
—

ru l e s govern t h e a ss e mbli n g a n d u se of t hi s w in di n g

1 . Th e fron t a n d ba ck pi t ch es ( i n w i n di n g s pa ce s or coi l s i des )

m us t be Odd n um bers Th ey m a
.
y b e e qu a l t o o r d i ff e re n t from

ea ch ot h er a l t h ou g h t h ey a re u s u a l ly e qu a l .

2 . Th e wi n di n g s h ould be sym m etri ca la s s h own by t h e n um ber

of fiel d pole s di vi ded by t h e n um ber of a rm a t ur e ci r cu i t s i n

p ar a ll el b e i n g a w h ol e n u m be r I f t h i s i s n ot t h e ca
. s e t h e fin a l
wi n di n g s h ou l d be m a de u p of a s u ffici e n t n um ber of i n de pe n de n t

wi n din g s t o m a k e t h e n um be r of fie l d pol es di v ide d by t h e n u m ber

of a rm a t u re ci r cu i t s i n pa ra l l el awhol e n um ber for e a ch of t h e

i n de pen den t wi n di n g s .

3 . I t i s n e ce ss a ry t h a t t h e n um ber of com m ut a t or ba rs di vi de d by

one h a
—
lf t h e n um ber of arm ature circui t s i n pa ra l l el s h a ll be
awh ole n um be r I f t h e con di t i ons of ( 2 ) a
. re ful fill e d t he ,

con di t i on n a m e d h ere i s l ik e w i s e sa t i sfie d a t t h e sa m e tim e

‘

4 . I f t h e n um ber of com m u t a t or ba rs a n d t h e com m u t a tor pitch

ha v e n o com m on fa ct or t h e w i n di n g i s a
,
s i n g l e on e ; i f t h e com

m on fa ctor i s 2 t h e wi n di n g i s doubl e or i f i t i s e q u a
,
l t o m t he ,

wi n di n g i s m u l t i ple x of m se pa ra te wi n di n g s Th e com m on .

fa ct or m ust h owe v er be s m a
, ,
lle r th an h a lf t h e n um ber of ci r cui ts .

A n i ll us t ra ti on wi l l brin g ou t t h ese con di t i on s I n t h e cas e Of .

a n 8 pol e m a
-
ch i n e wi t h 2 7s l ot s 54 com m u t a , tor ba r s 4 con ,

dil ct ors per sl ot , a n d acom m u t a t or pi t ch of 1 3 , t h e t w o s e ri e s

wi n di n g s a
r e s i n g l y cl os e d form i n g one wi n di n g , si n ce 54 a nd 1 3
 A R M A T UR E WI N DI N G A N D M O TOR R E PA I R

ha ve no com m on factor For am a . chi n e of 4 pol e s wi th 20sl ots

-
, ,

40 com m u ta tor ba rs 4 con duct ors per slot com m u ta

, tor pitch of
,

1 8 t h e wi n di n g m a
, y b e m ade u p of t wo se ri e s wi n di n g s t h e ,

va lues 40 1 8 a nd 4 ha
,
ve acom m on fa ctor of 2 Th i s m a kes t h e
.

wi n di n g doubly clos e d a n d con s i s ts of t w o s eri es wi n di n g s wi t h

ea ch i n tu rn cons i s t i n g of t wo oth er se ri e s wi n di n g s e a ch of t h e ,

la tter form i ng on e conti nu ous wi ndi n g .

5 . For la rg e m a chi n es us i n g se ri e s pa ra l l el wi n di n g s i t h a
-
s bee n ,

foun d a dvi s able i n m ost ca se s t o u s e e q ui pote n ti a l con n e ct

i on s an d conne ct a bout e ve ry fourth or ei g h th com m u ta t or
( See hea E qui poten ti a l C onn e ct ors on pa
.

secti on
”
. di n g g e

6 Th e
. ber of current coll e cti ng poi nt s or brush es on t h e com
nu m

m u ta l t o t h e num ber of a
to r i s e q u a rm at u re s e ct i ons i n pa
ral l el .

Th e s a
followi n g formula pply in t he a of as eri es pa
c se ralle l -

wi n d i n g :
Fro n t
pi tch y1
Ba
ck p i t ch yz

Wi n d i n g pi t ch y 31 1 yz
K i a
C om mut a
tor pi t ch 31 1.
P

N umb e r c ommuta
tor b a
rs K
2
Wh ere p i s n umb er of pa i r s of poles a
n d N i s t h e n umb e r

of coi l s i de s i n t h e wi n d i n g N must be su ch av a . lue th at

M is awhole n umber .

S ym m a l Wi n di n g s
e t ri c A ll a rm a
ture wi n d i n gs s hould
.
—

be m a d e s ymm e tri ca l i f poss i ble A wi n di n g i s s ymm e t ri ca

. l
whe n t h e tot a l n umb e r of s lots di vi d e d by on e h a lf t h e n umb er -

of a rm a tur e s e ct i on s i n p ara ll el i s awhol e n umb e r I f this .

i s n ot t h e ca s e t h e e mfs i n du ce d i n d iff e r e n t ci r cu i ts w il l pr o

du ce ci r cul a t i n g curre n ts A wi n di n g i s a . ls o s ymme tri ca l

if t h e numb e r of field pol e s d i vi de d by t h e n um b er of a rm atu r e
s e ct i o n s i n p ara ll e l i s awhol e n u mb e r or t h e n umb e r of com
muta tor b a lf t h e n umb e r of a
rs i s d i vi s i bl e by on e h a - r mature
sect i o n s i n p a ra ll el To be Sure th a
. ta n y w i n d i n g i s s ym m e t r i

ca l a ll thre e of these co n d i ti on s s hould be fu lfill e d .

22 A R M A T UR E WI N DI N G A N D M OTOR R E PA I R

S pa ce d t h e g a
, p m a y n o t b e u n i fo rm a n d ,s o o n I n g.e n e r a l :
pe rfe ct s ymme t ry must be re ga rd e d a s a n un a tt a ina ble i de a l
i n pra ct i ce a cco rd i n g to M r Sm i th who ca .
, ll s a tte n ti on to t h e
followi n g con di ti on s :
Owi n g to th e s e d i s s ymme tr i e s t h e p res s ure i n du ce d i n t h e
,

s e ve r a l a rm a tur e ci rcui t s va ri e s a ,
n d ca us e s e qu a l i zi n g cu rre nts
to flow through t h e brus he s Th es e e qu a . l i z i n g curr en ts if of ,

s uffi ci e n t s t r e n gth p rodu ce s p a

,
r ki n g a n d in a n y ca s e lo a d the ,

b ru s h e s i n a n u n de s i ra bl e m a n n er I t is i n t e r e s t i n g to n ot e
.

tha t e ve n whe n n o e qu a
,
li zi n g r i n gs a r e p r e s e n t t h e pos i t i ve ,

a n d n e ga ti ve colle cti n g ri n gs a ct a s e qu a li zer s a n d t h e te n d

,

e n cy of th e s e e qu a li zi n g curr e n ts i s to n e utr a l i z e t h e i n e qu a li
t i es i n t h e m a gn e t i c fi eld to whi ch the y a r e du e Whe n .

e qu a li zi n g ri n gs a r e u se d howe ve r l a
,
r g e e qu a
,
li zi n g curr e n ts
wil l flow a lo n g thes e a n d s t r o n gly d a mp out a n y i n e qu a l i ti e s
i n t h e fi e ld a ,
n d s o r e du ce t h e d iff er e n ce of pot en t i a l b etwe e n
cor re s po n d i n g poi n t s i n t h e wi n di n g C o n s e que n tly t h e
'
.

bru s hes a r e r e li e ve d a ,
nd a re s o mu ch b e tt e r a bl e to perform
the i r pr ope r fu n cti o n of colle cti n g t h e cu rr e n t .

E q ua li z in g ri n gs must n ot be re ga rded a s in a n y wa y e s

se nt ia l a
,
n d ma n y ma chi n e s wo r k qu i t e w e ll wi thout th e m .

N e ve rth e l es s th e y a
,
d d ace rt a i n fa cto r of s a fe ty whi ch t h e
ma n uf a ctu r e r i s oft e n gl a d to pur ch a se a t so sma ll acos t for ,

h e i s n ot o n ly s ur e r of h i s m a chi n e p a s s i n g t h e te st s a t is
fa ct or il y but a ls o kn ows th a t a fte r e ff e cts li k e we a
-
,
r of t h e

be a r i n gs ca
,
n n ot g i v e r i s e to s u ch s e r i o u s t r oubl e a s wh e n e qu a l
i z e rs a re a b s e n t C o ns e qu e n tly e qu a
.
,
l i z ers a r e s e e n on m a ny

la r ge ma ch i n e s wi th l a p wou -
n d a rm a tu r e s o r
,
w i th w a v e

wi n di n gs wi th mor e tha n two ci r cui ts E qua . li z i n g ri n gs

s hould h a ve a n e xt r e m e ly l ow r es is t a n ce S u ch p r a ct i ce

r e qui r e s n ot o nl y a n e x ce s s i ve a moun t of coppe r but le a ,

ds to
co ns i d er a bl e loss a n d he a t i n g i n t h e W i n d i n g A l l th a . t is
re a lly n e ce s s a r y i s to p r ov i d e a n a lte rn a t i ve p a th of n e gli gi ble
r es is t a n ce comp a r e d w i th th a t of t h e brus hes a n d for thi s
,

pu r pos e i t i s us u a lly s uffici e n t to m a ke t h e se cti on of t h e ri n gs

a bout h a lf tha t of t h e co n du ctor s .

R e ga r d i n g t h e n umb e r of e qu a li zi n g ri n gs mu ch de pe n ds,

Wi th l a
”
on t h e Op i n i o n of t h e d e s i g n e r .
p W i n d i n g s o n e r i n,
g
for e ve r y 6 to 1 2 s e gm e n t s is commo n pra cti ce but th is is ,
 DI R E C T-C U R R E N T WI N DI N GS

a ly fe a
s c rce s i bl e whe n p a for here t h e pote n ti a
, l pi t ch ,
1

y ,
K a m a
, y b e f a i r ly l ar g e a n d t h e n umb e r of r i n g s b e

com es pr o hi b i t i ve . I n s u ch ca se s ( w a ve wi n di n gs wi th mor e
tha n two ci r cu i t s ) on e ri n g f or e v er y 1 5 to 2 0 s e gm e n t s m a
, y
s uffice . T he re i s n o n eed to m a ke t h e pi t ch b e twe e n a ll t he
ri n gs t h e s a m e but d es i gn e rs ge n e r a
, ll y pr efer to s pl i t up y ,

i n to awhol e n umb er of pa r ts . I n th i s ca se t h e ta ppi n gs form

asymme tr i ca l polyph a s e s ys t e m of p r e s s ur es .

B e st D -C Wi n di n g s f or aR e pa
. . i r S h op t o U s e T o se cur e
—
.

good com muta ti o n a n d e li m i n a t e h ea ti n g troubles a ll wi n d i n gs

,

s hould be m a d e sym m ert i ca l T his a

. mo n g othe r th i n gs
me a ns th a t th er e must n ot be more a rma tur e cir cui ts i n pa ra l
l el th a n th e r e a re fi e ld pol es . Wh e re t h e num be r of a rma ture
ci r cui t s e qu a l s t h e n umb er of pol e s e i ther t h e l a p o r t h e w a v e

wi n d i n g m a y b e u s e d . Th e l a p w i n d i n g i s how e v e r mo s tly
use d i n s uch aca se . T h e wa ve wi n din g the n n ee d o nl y be
co ns i d e r e d i n tho se ca s e s wh e re t h e n umb e r of a r ma tur e ci rcui ts
i s to be l ess th a n t h e n umb e r of fi e ld pol es A s i n gl e wi n d i n g
.

i s mo re s i mple a n d s hould be u s e d i n pr e fe r e n ce to acompli

ca t e d on e wh er e co n d i t i o n s pe r m i t e i the r as i n gl e wi n d i n g
or two or mo re s e p a ra t e wi n d i n gs exce pt i n those ca s es wh e re

aver y he a vy curre n t is to be ca rri e d i n t h e a rma tur e I n .

ge n e ra l the n where cha

, n ges i n a rm a tur e wi n di n gs a r e n oce s

sa r y th a t ca ll for achoi ce of type s of wi n di n gs i t i s a ,

dvi s a bl e
to e mploy e ithe r al a p w i n di n g w i th a s m an y c i r c u i t s a s th e r e

a re pol e s or aw a ve wi n d i n g wi th two ci rcu i ts U s u a . lly al a p

wi n di n g is po ss i bl e i f t h e n umb er of coi l s is acommo n multi ple
of t h e n umbe r of poles a n d t h e n umb e r of s lot s T h e n umb er
.

of coil s i s e qua l to t h e n um b e r of co m muta tor b a rs .

N um be r of A rm a tur e S lot s T h e Ope n slot wi th p a

.
-
ra l lel
s i des is mo s t use d for l a r ge a rm a tu res s o th a t form wou n d
co i ls ca n be e a s il y a s s e mbl e d T he s e co i ls a
. r e h e ld i n pl a ce

by wir e b a n d s or by w ood or fib e r we dg e s dr i ve n i n to gr oov e s

a t t h e t i p s of t h e t ee th a s s how n i n C h a pte r III Th e n umbe r

.

of slots per pole i s usu a lly n ot l es s th a n 10 For mult i pol a

. r

a rm a tur es there a re a t le a s t fr om thr ee to four s lot s i n t h e s p a ce

Th e pot e n t i a
1
l pi t ch i s t h e n u m be r of com m u t a t or bar s be t w ee n su c

cess i v e e u i pot e n t i a
q l poi n t s i n t h e w i n d i n g w h i ch ca n be j o i n e d t og e t h e r

wh en e u a q l i z i n g ri n g s ar e n e e de d .
24 A R M A T UR E WI N DI N G A N D M OTOR R E PA I R

be twee n pole ti ps I n t h e ca . s e of hi gh s pe e d m a chi n es ha vi ng

la rg e pol e pi t ch th e r e m a y b e f r om 1 4 to 1 8 s lots per pole .

For m a chi n e s a bove s a y 5 hp t h e a r

.e a of t h e s lot w il l a pp r o x

im a t e one s qu a re i n ch A rough r ul e for t h e ca

. pa ci ty of

as lot of t hi s a re ais a bout a m p tur n s for m a . ch i n e s

un d e r 500 volt s .

V ol ta g e b e t w e e n C o m m u t a t o r S e g m e n t s F o r d i r —
e ct -cu r

re n t m a ch i n e s w i thout i n t e r pole s a bout 1 5 volts b etwe e n

,

s e gm e n t s of t h e commut a tor is t h e m a xi mum a ll owe d whi le

double thi s va lue ca n be co n s i d e re d a s t h e ma x i mum for m a

chi n e s e mploy i n g commut a t i n g i n te rpoles This va . lu e of

volt a ge b e twe e n s e gm e n ts ca n be obt a i n e d for a n e x is t i n g

ma chi n e by m e a s u ri n g th is volt a g e b e tw e e n plu s an d m i n u s

bru s he s a n d di vi di n g by t h e n umb e r of commut a tor se gme n ts

be twee n thes e bru s hes Th e volt a . ge b e twe e n apos i t i ve a nd

n e ga t i ve bru s h wi ll d e pe n d upo n t h e n umber of i n du ctors ( wir es

ma ki n g up on e s i d e of acoi l ) co n n e cte d i n s eri es be twe e n t h e
brus hes For ca
. l cul a t i n g wi n d i n gs for m a ch i n e s P rof S t il l ,
.

gi ves t h e followi n g r e l a ti o n s hi ps be twe e n m a chi n e volt a ge

a n d volt s b e tw e e n commut a tor se gm e n ts for good oper a ti o n :
V O LTAGE B ETW EEN S EGME NT S or C OM M U T A I OR S
'

M a
ch i n e v ol t a
ge

N u m ber of C om m ut a
t or Ba
proper m um ber of
rs .
—
Th e
commut a tor b a rs for a pa r t i cul a r wi n d i n g d e p e n d s on t h e volt

a g e b e tw ee n c ommut ator b a r s T h e n umb e

. r of b a r s m a y b e

amult i ple of t h e n umbe r of slots For low volt a . ge m a chi n e

the re m a y b e o ne two o r ,
th r e e b ars p e r s lot wh il e i n h i gh e r

volt a ge slow S pe e d m a chi n e s the re m a y ,

b e as m a n y as fou r

or fiv e b a r s pe r s lot Whi l e i mpr ove d commut a

. ti on r e sults
from ala rge n umb e r of commut a tor b a r s t h e d i ffi cult y i n

r e pa ir a nd a s s e mbly f r om a m e ch a n i cal st a n dpo i n t Off s e t

the ir a dva n ta g e over fe we r b a rs for t h e s a m e con d i ti o n s of

W i n di n g a nd ma chi n e op e r a ti o n .
 DI R E C T-C U R R E N T WI N DI N GS

U s ua
l S pe e ds a nd P ol e s for Di fi e re n t S i z e s OfGe n e ra t or s .

For dir e ct curre n t g e n e r ators P rof S ti ll .

1
gi ves t h e followi n g
re la ti ons h i p b e twe e n n umbe r of pole s a n d s pe e d for di fi e r e n t

ra ti n gs of ma chi n e s ble re prese n ts us u a

T hi s t a . l pr a ct i ce

by des i gn e rs .

N UM B ER OF P OL E s AND U s U A L S PE E D Lm '
r rs or D -C
. . G ENERA TORS

S p e e d i n rp m
Ou t p u t kw N be r of p ol es m a
xi m u m a
um
n d m i n im
in
um
.

Sa f e A rm a t ure S pe e ds a fe s pe e d of a
—
. Th e n a
s rm a tur e
va
r i e s w i th t h e arm ature co ns t ru ct i o n Dir e ct curr e n t m a .
-

chi n e s a re bui lt w i th ape r i phe r a l s p ee d of to fee t

p e r m i n ut e I
. t i s n ot a dv is abl e to e x ce e d an ar m a tur e p e r i ph
e ra l s pee d of fe e t pe r mi n ut e i n m a ch i n e s whi ch a re

n ot d e s i g n e d to t a ke ca re of t h e m e ch a n i cal s tres s es i n ci d e n t
to t h e hi gher s pe e d s .

1
P ri n ci pl es of E l e ct ri ca
l De s i g n , pa
g e 81 .
 C HA P T E R I I

A L TER N A TIN G -
C U R R EN T W IN DIN G S

In ma
the i n t h e wi n di n gs for a
,
lte rn a ti n g curre n t motors -

a n d ge ne r a tors a re a l i ke For thi s r e a

. s o n de ta i l s of t h e w i n d
i n gs th a t ca n be u s e d for e i th e r m a chi n es w i ll be g i ve n It
s hould be n ot e d a t th is po i n t th a t dir e ct cu rre n t a nd a
.

-
lter
na t i n g curr e n t wi n d i n gs d i ff er e s se n ti a
-
lly by t h e form er b e i n g
of t h e clos e d ci rcui t typ e whi le mos t a
-
lte rn a ti n g curr e n t wi n d -

i n gs a r e of t h e op e n ci r cu i t typ e
-
E i th er ope n or clo s e d
.

ci r cu i t typ e s of W i n d i n gs m a how e v e r be e mploye d i n a lt er

y
na ti n g curre n t m a
- ch i n e s but t h e Op e n typ e i s i n mo s t commo n
,

u se . B y aclo s e d wi n di n g i s m e a n t on e wh i ch h a s a co n t i n uous

pa th thr ough t h e a rm a ture a n d r e e n t e r s i t se lf to fo r m a

-

clos e d ci r cu i t S u ch ad i r e ct curr e n t w i n d i n g a
.
-
lwa ys h a s a t
le a s t two cu rr e n t p a ths b e twee n br us h es I n t h e ca .s e of a n

ope n cir cui t a

-
lte r n a ti n g cir cu i t wi n di n g the r e is aco n ti n uous
-
,

pa th through t h e co n du ctors of t h e coi ls of e a ch ph a s e of t h e

wi n di n g wi th t h e e n ds of thi s p a
,
th formi n g two free e n ds .

S u ch awi n d i n g do e s n ot clo se on i t s e lf .

I n t h e clo s e d ci r cu i t w i n di n gs of d i r e ct cur r e n t m a
- ch i n e s
-
,

t h e ba r s of t h e commut a tor a r e s i mply co n n e ct e d a t e qu a ll y

d is t a n t po i n t s a rou n d t h e wi n d i n g I n t h e Op e n cir cui t w i n d
.
-

i n g of a n a lter n a ti n g curr e n t ge n e ra
-
tor wi th r e volvi n g a rma

tur e t h e t e rm i n a
,
ls of t h e comple t e d wi n di n g a r e co n ne ct e d to

coll e cto r r i n g s a n d t h e w i n d i n g i s op e n cir cui t e d u n t il clo s e d

-

by t h e co n n e ct i o ns b e twe e n t h e br us hes C los e d cir cu i t wi n d .

-

i n gs a r e o n ly u s e d for s p e ci a l a lt e rn a tin g cu rr e n t m a ch i n e s
-
.

Th e co n d i t i o n s wh i ch us u a l ly ca ll for aclos e d cir cui t wi n d -

i ng a re t h e follow i n g

1 . An at ern a
l t i n g cu rren t m
-
a
ch i n e w h i ch m us t del i ver a la
rg e

curre n t at l ow vol t a g e I n
. s u ch a c a s e t h e w i n di n g usually
con s i s t s l si m il a
of s e ver a r pa t h s con n e ct e d i n pa ra ll el to t h e
“

26
 A L TE R N A TI N G-C UR RE N T WI N DI N GS
term i n a ls of t he a rm a ture th us form i ng one or m ore cl osed ci r
,

cu i t s wi thi n t h e arm a tu re wi n di n g .

2 . I n des i g n s bf m a t m u st h a
ch i n e s t h a n dl e dire ct and alt e rna
ti n g
curren t a s i n doubl e curre n t g e n e ra
,
t ors a n d i n rota
ry con ve rte r s .

In g e n e ra l it m a y be s ai d th a t a d i r ec t -curre n t wi n d i n g m a
y
be cha n ge d so th a t t h e ma chi n e ca n be us e d a s a n a lte r n a tor ,

but an a lter n a t n g curre n t win d i n g ca

i - n n ot be us e d for a di re ct
cu rre n t ge n e r a tor s i n ce i t is n ot re e n tra nt .

Type s of A C Wi n di n g s
- . Wi th refere n ce to t h e a
. .
—
rr a nge

m e n ts of co i ls use d in a n a lt ern a ti n g curre n t a rm a tu re wi n d -

,

i n gs m a y be d i v i d e d i n to two g e n e r a l c l a
s s e s a s follow s :

I . D is tr i bute d Wi n d i n gs .

1 . S p i ra
l or cha in .

2 . La
p .

3 .Wa ve .

II . C on ce ntra
te d Wi n di ng s .

1 . La
p .

2 . Wa
ve .

Di s t ri bu t e d Win di n g s .
—
a
Anrm ature wi n d i n g whi ch h a s

i t s i n du ctors of a ny on e s e u nde r as i n gl e pol e pl a

pha ce d i n

s e ve ra l S lots is sa i d to be d is tri bute d

, Whe n th es e in du ctors .

a re b u nch ed toge ther i n on e s lot pe r pole pe r ph a s e t h e , ,

win d i n g is ca l le d con ce n tra ted I t is us ua l i n ad is tri but e d

.

wi n di n g to dis tri bute t h e s eri es i n du ctors i n a n y ph a s e of t h e

wi n di n g a mo ng two or more S lot s u n der e a ch pol e T hi s .

te n ds to d i m in is h a rm a ture re a ct an ce a n d g i ves a be tter e m f .

wa ve be s i des ofieri n g abe tter di s tr i buti o n of t h e he a

, ti n g du e
to a rm a ture cop pe r loss tha n i n co n ce n tr a t e d wi n d i n g s .

C on ce n t ra t e d Wi n di n g s Th e u ni -S lot or co n ce n tr a
.
—
te d
wi n di n g gi ves t h e l a r g e s t po ss i ble em f f rom a gi ve n n umbe r of
i n du cto rs i n t h e wi n di n g T ha t is for ad e fi ni te fix e d S pe e d
.

a n d fie ld s t ren gth i n a n a lt e r n ator t h e co nce n tra t e d wi n d i n g

,

r e qu i r es a less n umbe r of i n ductors tha n a dis tri bute d wi n di ng ,

but i n cre a s es t h e nu mb er of tu rn s pe r co i l .

S pi ra l or C h a i n Wi n di n g I n th is wi n d i n g a
.
—
s s how n i n

Fi g 1 4 the re is o nly on e coi l S i d e i n as lot

. A n Odd or e ve n .

n umb e r O f i n du ctors pe r s lot m a y be us e d but se v e r a l S h ap e s

of coil s a r e re qu i re d S i nce t h e co i l s e n clos e e a ch oth e r a n d mus t

 A RM A TUR E WI N DI N G AND M O TOR RE P A IR

ha ve s pecia l e n d s ha pe s t o cl e ar e a
ch oth e r T h i s arr a
n g e .

me nt howe ve r m a , kes poss i ble good i ns ula

, ti o n of e n d con
n e ct i ons thr ough a d e qu a te se pa ra ting ai r s pa ce s i n h i gh vol

ta ge m a ch i n es Th e nu mbe r of coi ls re qui re d i n thi s wi n d i n g

.

Fm . 14 .
— A a
sp i r
l or ch a
in w i n d i n g fo r a2 -p h a
se , 4 - ol e m
p a
chi n e wi t h
the coil s o f on e pha
se in pl ce a
a nd co n n e c t e d . Th e co il s o f t h e o t h er ph a
se

g o in t h e s l ot s s h ow n by t h e fu l l l i n e s i n s i de t h e coil s .

is a ls o s ma ll compa re d wi th oth e r wi n d i n gs Thi s type of .

wi n di n g i s ma i n ly use d i n a lte r n ati n g cur re n t gen e ra tors - .

La p an d W a v e W i n di n g s B oth d i s t r i but e d a n.d —

co n e e n

t rat ed wi n di n g s m a ke use of l a p a n d w a v e c o nn e ct i o ns T h es e .

h e . l 5 .
—
S i n g l e-p h a
se l a
p w i n di n g f or t h e s a
m e co n d i t i o n s a
s the w a
ve
wi n di ng i n Fi g .

Fro . l 6 .
—
S i n g l e~p h a
s e di s t ri bu t e d w av e w i n di n g w i t h t w o s l ot s !
in p ol e p e r
p ha se a n d o n e c oil s i de p e r s l ot .

arr a r e i n pri n ci pl e t h e s a
n g em e n t s a me a s us e d in d i r e ct cu rren t -

wi n d i n g s ( S e e C h a pt e r I pa ges 9 a nd Th e d i a gr a
ms of
a
.
,

Fi gs 1 5 a n d 1 6 S how S i n gle-p h a
. s e dis tri but ed l a p n d w av e
30 A R M A T UR E WI N DI N G A N D M OTOR R E PA I R

coi ls i s e x p re sse d i n te rm s of coi l si de s (wi n di n g S pa ce s ) i n

ste a d oi S lots .

Wh ol e coil e d a
- n d Ha l f coil e d Wi n din g s
-
Wh en t h e coi ls .
—

of a n a lte rn a ti n g curre n t wi n di n g a re con n ect e d s o th a t there

are a s ma n y co i l s pe r ph a se a s th er e a re pol e s t h e w i n di n g is ,

call d whol coi le d Wh en t h e coi ls a r e co n n e ct e d s o th a t

“
-
”
e e .

the re i s on ly on e coi l pe r pha se per p a i r of pol e s t h e wi n di n g i s ,

calle d ha lf coi le d Th e m a i n d i ff e r e n ce be tw ee n the se t wo

“
- .

con n e ct i on s i s i n t h e m e thod of m a ki n g t h e e n d con n ecti on s

A — W h ol e-c oi l ed wi n di n g B —
Ha
l f-coi l ed w i ndi ng
Fm .18 .A 6 —p ol e s t a
—
t or w i t h w h ol e-coil e d a nd ha l f-coi l e d w i n di n g s .

Th e w h ol e-coi l e d w i n di n g , A h a s a s m a n y coil s p e r p h a
, se a s t h e re a r e p ol e s .

Th e h a
l f-coi l e d wi n di n g B h a s on l y on e coil p e r p h ase p e r p a i r o f p ol e s .

for t h e coi s l . whole coi le d wi n di n g e a

I n t he -
ch s lot con

ta i n s two co i l s i d e s I t i s n ot howe ve r s tr i ctly adouble

.
, ,

la ye r wi n d in g a s t h e coi l s i d e s a
,
re pl a ce d s i d e by S i d e a nd

n ot on e a bove t h e othe r I n t h e ha . lf coi le d wi n di n g how

“ ” -
,

e ve r e a ch co i l m a h a
v tw umb of tu of a whol “
, y e i ce t h e n e r r n s e

co i l e d
”
wi n di n g or t h e two coi l s un de r an or th or south pole
of t h e l a t t e r typ e m a y b e c o n n e ct e d i n s e r i e s a n d t ap e d to
ge the r to form on e coi l i n ca s e of ach a n g e i n con n e ct i o ns .

Th e ha
“
l f co i l e d - wi n di n g h a s the a dva n ta ge tha t when ,

us e d wi th la r ge g e n er a tor s t h e a rm a ture fr a me m a y be s pli t

i n to t wo se cti o n s for S h i pme n t or re pa ir wi thout d i s tur b i n g
,

ma n y of t h e e n d con n e ct i o n s .

S i ng l e ph a- se a n d P ol yph a s e Wi n di n g s Th e wi n d i n g of.
—

aS i n gle pha -
se moto r or ge n e r a t or h a s o n ly on e gr oup of i n du c

tors pe r pole pl a ce d i n on
,
e s lot or s e v e r a l s lot s de pe n di n g
upon whe ther or not t h e wi n di n g i s con ce n tra te d or di st ri b
 AL TE RN A TI N G-C U R R E N T WI N DI N GS

FI G . 19 .
—
A si m pl e si n g l e -p h a
se w i n di n g .

FI G . 20 — . S i m p l e 2-p h a
s e w i n di n g .

FI G . 2l —
. S i m p l e 3-p ha
s e w i n di n g .

Sta
r or Y C on n e ct i on

22 — A 3-ph a w i n di n g s h ow i n g h o w i t m a
y be c o n ne c t e d i n de l t a
FI G . . se
or s t a
r .
 A R M A T UR E WI N DI N G A N D M O TOR R E PA I R

ut ed S u ch as n gl ph a
. i e- s e co n ce n t ra
te d wa
ve wi n d i n g for
afour pole a
- r ma
tu re i s s how n i n Fi g 1 9 . .

Tw pha
o- se a n d thr e e ph a se wi n d i n gs m a
-
y be co n s i d e r e d
a s ma d up of si n gl ph a
e e- se w i n di n gs p rope r ly pl a ce d on t h e

sa me a rm a ture For t h e two pha

. s e w i n d i n gs two s e pa
- ra te
s n gl e ph a
i - se wi n d i n g s a r e u se d S p a ce d 90 e l e ct r i ca l de gree s
a pa rt . Th i s i s s hown i n Fi g 20 For t h e thre e ph a . . se wi n d -

i n g three S i n gle ph a
, s e wi n di n gs a
- re u s e d s p a ce d 1 2 0 d e gree s ,

a pa rt ,a s i llus t r a te d i n Fi g 2 1 A lthough t h e S i n gle pha

. . se -

wi n d i n g s a r e i n d e p e n d e n t of e a ch oth e r th e i r t e r m i n a ls a re ,

co n ne cte d i n s t a r or d e lt a a s S hown i n Fi g 2 2 . .

C oil P i t ch .
—
I n t h e ca s e of atwo ph a se w i n d i n g t h e tot a
- l ,

n umb e r of S lot s s houl d be j u s t di vi s i bl e by two s o th a t ea ch

pha s e w i ll h a ve t h e s a m e n umb e r of w i n di n g e l e m e n t s or
coi l s pe r pol e
’

. I n t h e sa m e wa y f o r a th r e e ph a se
,
w i n d i n g -

t h e tot a l n umbe r of coi l si de s or t h e tota l n umbe r of S lots

S hould be ju s t d i vi s i ble by th ree ( t h e n umb e r of ph a s es )

a n d s om e ti m e s by t h e n umb e r of pol es T hi s w i ll re s ult i n .

afull pi tch win di n g tha t i s awi n di n g i n whi ch acoi l s pa

, ,
ns

e xa ctly t h e d i s t a n ce b e twe e n t h e ce n t e rs of a dj a ce n t pol es .

I f t h e co i l s p a n s l e ss th a n th i s di s ta n ce s o th a t i t s two Si des ,

a re n ot e x a ctly u n d e r t h e ce n t er s of a dj a ce n t pol e s a t t he sa me
ti m e i t i s s a
, i d to h a ve afra ct i o n a l pi t ch Whe n afra -
ct i o n a
. l
pi t ch i s u se d i n a ltern a tors on a ccoun t of t h e e l e ct r i ca l fa cto rs

of t h e de s i gn s u ch a, s to se cu r e a s nea rly a s po s s i bl e as i n e

wa ve sh a pe of e m f t h e tota ,
l n umbe r of slot s per pha s e mu s t

be awhol e n umbe r A fra ct i o n a

. l pi tch i s a ls o wi d ely u s e d
-

i n i n du cti o n moto rs .

C o i l pi t ch i s e x pre ss e d a s afr a ct i o n of t h e pol e p i t ch i n ,

s lot s ,
i n e l e ct r i ca l de gre e s or i n win di n g s p a ce s (co i l S i d e s ) .

I n t h e ca se of as i x pol e m a - ch i n e h a vin g 72 sta to r s lots a nd ,

adouble la - yer wi n di n g t h e pole pi tch would be 1 2 slots I f

, .

t h e coi l p i t ch w e r e gi v e n a s 35 t h i s wo u ld be 1 2 0 d e g r ees
,

or e i ght S lot s or 1 3 w i n d i n g s p a ce s ( coi l si d e s ) A full co i l .

p i tch for thi s w i n di n g wo u ld be 1 80 d e gr e e s 1 2 s lots or 2 1 ,

wi n di n g s p a ce s .

P ha s e S pr e a d of Wi n di ng s Th e s p re a. d or s pa
—
ce o ccupi e d

by ea ch S i n gl e ph a -
se w i n d i n g i s k n ow n a s t h e ph a s e s p re a d
of t h e wi n din g For atwo ph a
. s e w i n di n g t h e ph a
- s e s p re a d
 AL TE R N A TI N G-C U R RE N T WI N DI N GS

is ( 1 80 2) or 90 d e grees . Forph a ath

se wi n di n g i t i s
ree -
,

( 1 8 0 3 ) o r 60 d e g r ees I n a s i
. n gl e ph a se w i n d i-n g t h e pha se ,

s pre a d i s theore ti ca lly 1 80 d eg rees P rof A lfre d S till poin ts

. .

out howe ver i n h i s book on P ri n ci ple s of E le ct ri ca

, ,
l De si gn ,

tha t n othi n g i s ga i n e d by w i n di n g a ll t h e S lots on t h e a rm a ture

s urf a ce of asi gl e ph a
n - se m a chi n e Af ter acer ta . i n w i dth of
wi n di n g h a s bee n re a ch e d t h e filli n g of a ddi ti o na l s lots merely
in cre a ses t h e re s i s t a n ce a n d i n du ct a n ce of t h e wi n di n g wi th

out a ny a pp re ci a ble ga i n i n t h e de ve lope d volt a ge I n pra c .

ti ce on ly a bout 75 per cen t of t h e a va

. il a ble S lot s pa ce i s

uti li z e d m a ki n g t h e pha s e s p re a d for aSi ngle pha - s e wi n di n g

a bout 1 3 5 e le ctri ca l de gree s .

Th e fa ct th a t in polypha
,
se m a chi n e s t h e whole of t h e a , r ma

ture s urfa ce i s a va il a ble for t h e wi n di n g whi le o nl y aporti on ,

is utili z e d i n aS i n gl e pha se a- ltern a tor a ccoun t s for t h e fa

, ct

tha t t h e output of t h e l a tter i s less tha n tha t of t h e polypha se

ma chi n e u s i n g t h e s a m e S iz e of fra me I n athree-pha . se

ma chi n e i t i s o n ly n e cess a ry to om i t on e of t h e ph a se w i n di n gs
e n t ir e ly a n d co n n e ct t h e two re m a i n i n g pha s e s i n se r i e s to

obt a i n aS i n gl e pha - s e ge n e r ator S u ch amodi fie d ge n era

. tor
wil l gi ve a bout two th i rds of t h e output of t h e polypha
- se

con ne ct i o n . A th re e ph a se s t a
- r co nn ecte d i n du ct i o n motor

ca n a ls o be us e d a s aS i n gl e- pha s e moto r by p rope rly con

n e ct i n g two pha se s of i t ( se e C h a pter XI ) .

Two ph a- s e fr om Four ph a - s e Wi n di n g s I n ma n y ca ses t h e

—
.

two-pha s e i n du ct i o n motor i s des i gn e d a s a four pha se ma ch i n e -

wi th t h e co n n e cti ons be twee n co n du ctors of t h e wi n ding

a rra n ge d s o a s to p e rm i t Ope r a ti o n on atwo pha s e s upply
’

-
,

ci rcui t . As S ho wn i n Fi g 2 3 atwo ph a .
, s e wi n d i n g m a
- ybe
se cure d fr om a four pha se gr oupi n g of co i l s by con n e ct i n g t h e
-

firs t a n d thi r d gr oups i n se ri e s a n d t h e se co n d a n d fou rth

gr oup s i n se ri e s .

Thr e e p a- h se from S i x ph a - se Win di ng s Fe w s tri ctly .

—

three pha - s e i n du ct i o n moto r s a re bui lt Th e desi gn m a .

y b e

more p roperly ca lle d as ix pha s e w i n di n g wi th t h e thr e e ph a

-
se s

s pa ce d 1 2 0 e l e ct ri ca l de gre e s a n d t h e co n n e ct i o n s of co i ls

s u ch a s t o pe rmi t t h e motor t o be ope ra te d on athre e pha se -

ci rcui t . A s s hown i n Fi g 24 i n aS i x ph a . s e wi n di n g t h e co i l s
-

of t h e s ix pha -
s es a re s p a ce d 60 e l e ctri ca l deg ree s For three .

3
34 A R M A T UR E WI N DI N G A N D M OTOR R E PA I R

ph a
s e ati on t h e coi ls of pha
oper se s on e a n d four t h ree a nd ,

Six an d five a
,
n d two a re co n n e cte d i n se ri e s Th e t e rm i n als .

of phase s two fou r a n d six a r e co nn e ct e d t o a

, commo n po i n t .

FI G . 23 C for fou r wi n di n g s S p a
on n e ct i on s l de g ree s a
ce d 9 0 e l e c t r i c a part
—
.

t o s e cur e a2 -p h a s e m o t or T h e re a re r e a
. l l y fou r p h ase s s h o w n t h e fir s t a nd ,

t hi rd a n d t h e se con d a n d f ou r t h ar e c on n e ct e d i n se r i e s T h e fu ll l i n e s a
. re

fr on t conn e ct i on s o f coil s a n d d ot t e d lin e s t h e ba ck con n e c t i on s S a nd F .

i n di cat e t he st art a
'
n d fini s h of t h e di ff e re n t g r ou p s of coil s .

FI G 2 4 C a6 p
o n n e c t i on s h a
fo r w-i di d i n o a 3 -
pha
—
. . s e n n g e s g s se
w i n di n g i s s e cu re d T h e s i x w i n di n g s a
. re spa ce d 6 0 e l e c t ri cal de g re es
apa rt. I n t hi s di a gra m pha s e s on e a n d fou r t h r ee a , n d si x , a n d fiv e a n d t wo

a re con n e c t e d i n S e r i e s a n d t h e t e rm i n a l s F2 F4 a n d F0 joi nte d t o aco m m o n

.

p o i n t. T h e 3 - ha
p se l eads a re 81 Si, a nd
, St T h e fu ll li n e s i n di ca
. te
fr on t co n n e c t i o n s an d d ot t e d l i n e s ba c k co n n e c t i o n s 8 a n d F i n di ca
. te th e
st a rt a n d fini s h of t h e di ff ere n t g r ou p s of coi l s .

Wi r e , S tr a
p a
nd Ba
r W oun d C oil s .
-
oi ls use d i n
For t h e c

s ma
ll motors roun d i n s ul a
t e d wi r e i s mo s t e mploye d These .
 A L TE R N A TI N O-C U R R E N T WI N DI N GS

c oi ls a re e i t h e r woun d i n t h e s lots by h a n d or a s se mble d by

use of s pe ci a ll y fo r me d co i ls woun d i n fo rm s a n d i n s ul a te d
befo re be i n g pla ce d i n t h e slots S u ch fo rm e d co i ls a
. re u s u

a lly used exce p t i n ca se s whe re t h e S lots a re clo s ed or n e a rly

clo se d . For fur th er i n fo rm a ti o n on forme d coi l s see pa ge 4 ,

C ha pt e r I a
,
n d pa ge 1 4 1 C h a pte r V I
,
.

For la r ge motor s a n d ge n e r a tors where t h e a mperes t o be

ca r ri e d i n ea ch a r ma tur e cir cui t i s ala r ge va lue coppe r s tra ps ,

a re fr e que n tly e mploye d for m a kin g up t h e a rm a ture coi ls .

I n ve ry la r ge m a chi n e s acoppe r ba r i s u se d i n s te a d of t h e
copp e r s t ra ps I n s u ch aca
. s e on e ba r s e rv es a s t h e i n ducto r

of aco i l ha vi n g on e turn pe r S lot A two -la yer ba

. r wi n di n g

ma de up of t wo ba rs pe r co i l a n d four b a r s pe r Sl ot i s a ls o
use d . Th e coppe r b a rs a re co n n ect e d t o t h e en d co n n e ct i o n s

of t h e coi ls by b ra zi n g weldi n g or bolti n g I n a

,
ll ca s es .
,

wha t e ver t h e co n st ru cti on of t h e coi l use d t h e s lots mus t be ,

prope rly i n s ula t ed wi th fulle r bo a r d m i ca fis h p a pe r or other

, ,

s ui ta bl e i ns ula t i n g ma l For da
t e ri a taon slot i n s u la
. ti on see
C ha pt e r V I I .

Th e curre n t d ens i ty i n a lt e rn a tin g curren t wi n din gs i s -

a bout 2 500 a m p pe r s qu a r e i n ch of a rm a ture co n ductor i n

sma
.

ll ma chi n es 20 , 00 a m p i n me di um s i z e s a
. n d 1 500 a m p in .

hi gh -volta ge des i g ns E xce pt i n hi gh-s pe e d m a

. ch i n e s i t i s

n ot s a fe to u s e t h e ma xi mum l i mi t owi n g to d a ma g e t o wi n d
i n gs from ove r h ea ti n g .

M E TH ODS FOR L A YI N G OU T A N D C ON NE C TI N G AL TE R N A TI N G
C URR E N T WI N DI N G S

In wi n di n g a
re n a lte rn ati n g-curr e n t ma chi n e t h e n umb e r of ,

S lot s on t h e s t a tor t h e Ope r a

,
ti n g volt a ge s pee d pha se a nd , ,

fre que n cy of t h e s upply ci rcui t a re po i n t s th a t mus t be con

s i de re d i n l a yi n g out ane w wi n di n g or recon n e cti n g a n e x i s ti n g

on e . Th e fu n d a me n ta l re qui re me n ts of wi n di n gs a n d t h e wa ys
i n whi ch the y ca n be fulfill e d a s outli n e d by M W Ba r tm e ss . .

( E l ectr i c J o u rn al V o l ,
V III N o .5 ) a r e g i v e n,
i n . w h a t follow s .

G r ou p Wi n di n g s G r oup wi n d i n g m a
.
—
y b e d e fi n e d as tha t
cl a ss w h e re i n t h e tot a l wi n di n g i s di vi d e d i n to se pa ra te p a rt s ,

compo se d of a dj ace n t co i ls or co n du ctors Th e g r oupi n g i s .

,

i n t h e ca se of l a a d w a v e wi n di n g s a n a r bi t r ar y o ne t h e
p n , ,
36 A RM A T URE WI N DI N G AND M O TOR RE PA I R

c oi ls be i n g a l l S i mi l ar a n d di vi d e d i n to g rou p s s ol e ly by th e i r

con n e ct i o n s Th e n umbe r of coi ls pe r gr oup m a

.
y e qu a l t h e

n umb e r pe r p a i r of pole s di vi d e d by t h e n umbe r of pha se s or ,

t h e n umbe r pe r pole d i vi d e d by t h e n umbe r ph a ses Th e la tte r .

me thod of gr oupi n g i s ge n e r a lly u s e d on mode rn ma chi n es

‘

I n t h e ca s e of as i x pol e th re e ph a -
s e wi n d i n g of 3 6 s lots t h e
,
-
,

n umb e r of co i l s
pe r g r oup i s 3 6 ( 6 X 3 ) or 2 W h e n t h e .

n umbe r of S lots i s n ot e ve n ly d i vi s i bl e by t h e p r odu ct of pole s

Fri} . 25 .
—
M e t h od s O f con n e c t i n g p ol e - h
p a
se g r ou p s s h ow n in (a
) ( b)
, a
nd ( c) .

(a) Four - ol e
p wi n di n g wi t h a
l t e rn a
tely p os i t i v e a
nd n eg a
ti ve p ol e - h
p a
se g r ou ps .

( b) F ou r - p ol e wi n d i n g Of the co ns e q u e n t p ol e t y pe
’

. ( )
c T w o -p o l e wi n d i n g Obt a
i n ed
f r om ( b) by r econ n e ct i n g t h e p ol e-p h a
s e g r ou ps al t e r nat e l y p os i t i v e a
nd neg a
t ive .

a n d ph a se s di ssi mi la
,
r gr oups mu s t be e mploye d I n s uch .

ca se s i t i s a d vi s able to a rra n ge t h e gr oup i n g s o th a t al l t h e

pha s e s ha ve a n e qu a l n umbe r of coi ls a n d i f po s s i ble t h e gr o
,
up
i n g s hould be a rr an ge d s ymm e t ri ca lly wi th re s pe ct to t h e core
i t s e lf . To p re ve n t lo ca l curre n ts whi ch m a y p r ov e
,
i n ju r i ou s ,

a l l ci r cui t s whi ch a re i n p a ralle l mus t ha ve a n e qu a l n umbe r of

coi l s a n d S hould be s ymm e tri ca lly a r ran ge d wi th r e s pe ct to

ea ch oth e r a n d to t h e oth e r ph a se s .

A lthough on e turn coi l s o n ly a r e s how n i n Fi g s 2 7to 2 9 .

,

t h e sa me co n n e cti on s a re a ppli ca ble to wi n di n gs ha vi n g

 38 A RM A T UR E WI N DI N G AND M O TOR RE PA I R

S lots i s n ot e ve n ly di vi si ble by t h e p rodu ct of pha se s a n d poles ,

t h e full pi t ch i s fre que n tly n ot aun i t a n d he n ce af ra ct i o n a

l
pi tch i s n e ce ss a ry I n t h e ca s e of ath ree-ph a
. se four pole ,

wi n di n g wi th 30 S lots 30 coi ls two coi ls pe r slot ful l pi t ch

, , ,

cove r s a s pa n of slots a n d t h e ne a re s t lowe r e ve n pi tch g i ves

athrow Of 1 8 —
.

l f ra
I n ge n e r a cti o n a l pi tch a
, ff e cts t h e pe rfo rm a n ce of t h e

a pp a ra tus si mi la rly to are du ce d n umb e r of tur ns i n t h e wi n d

( ) 6 f )
FI G . P ossi bl e p i t ch f or on e coil p e r S l ot wi n di n g s
26 .
—
.

(a ) F ull p i t ch efi ect i v e s p a
,
'

ce 1 2 act u al s p ace 1 1 t h r ow l t o 1 2 ( b) Fu l l p i t ch
. , . ,

e ff e ct i v e s p ace 1 2 act u al s p ace 1 3 t h r o w l t o 1 4 ( c) F r act i on a

. , l p i t ch eff e c t i v e
. ,

s pa ce 1 0 a l spa
ct u a t h r ow l t o 1 0 ( d ) Fr a ct i on al p i t c h e fi e ct i v e s p a
'

, ce 9 . . ce 1 0
, .

ac t u a l s pa t h r ow l t o 1 6 ( e ) C on c e n t r i c g r o u p f u l l p i t ch e fi e ct i v e s p a
'

ce 1 5 ce 1 2
'

. , . , .

act u a l s pa ce 9 a nd 1 1 t h r ow 1 t o 1 1 . ( f ) C o n c e n t r i c g r ou p f u l l p i t ch con s e q u e n t
.
, ,

p ol e s .
’

e fl e ct i v e s p a
ce 1 2. a
ct u a
l sp a
ce 9, 1 1 , 1 3, an d 1 5 , t h row l to 13 .

i ng , but ame proporti on I n age nera

in t h e tor thi s re
'

n ot s .

d uce s t h e volt a ge of t h e ma chi n e In a n i n du cti o n moto r t h e

.
,

ma xi mum a va i lable tor que i s i n cre a se d but t h e d e n s i t i es i n t h e

ma g n e ti c ci rcui t a re a ls o i n cre a se d w i th a res ulti n g re du cti o n of

powe r f a ctor
-
For ei the r motor or gene ra
. tor con si de ra ble ,

copp e r m a y thu s b e s av e d i n t h e co i l e n d s an d a s t a n d ar d
fra me m a y fr e qu e n tly b e us e d f o r s p e c i a l pu r po ses .

S i m me Wi n di ng Di a g r am I t i s e v i d en t th
. a
—
t f o r a l l com

bi n a t i on s t h e n umb e r of di a gr a ms n e ce ss a ry would be u n l i m i te d .

A s i mpl i fi e d d i a gr a m ma y b e e mploy e d wh i ch w i ll n o t o n ly
r e du ce t h e re qui re d n umbe r of s u ch di a gr a ms but wi ll a ls o
 AL TE R N A TI N G-C U R R E N T WI N DI N GS

mi ni mi ze t h e la bo r i n tra ci n g out t h e co n ne ct i o n s T hus i t wi ll

.

be s e e n th a t t h e di a gr a m i n Fi g 2 7 wi ll s a
.
, ti s fy ma n y re qu i r e

me n ts for con n e cti o n s of groups I n a . ddi ti o n to thi s i t wi ll

a pply for a n y si mi l a r ly co n n e ct e d three pha s e fou r pole s e ri e s
-
,
-
,

s ta r la p
-wi n d i n g i rre
,
s p e ct i v e of t h e n u mb e r of c o i l s p e r

group ( provi d e d t h e gr oup s a r e r e gul a r ) or of t h e th r ow of t h e

co i ls ,
th a t i s w he the r t h e wi n di ng i s full or fra
, cti o n a l pi t ch .

Thi s i nf orm a ti o n for t h e thr ow of t h e c oi l s a n d t h e n umb e r of

co i l s pe r g r oup m a y b e c a r r i e d
on t h e s a m e s pe ci fi ca ti on wi th
the r e ma i n i n g w i n di n g con
st a nts . Th e gr oup s a r e fo r me d

by con n ecti n g t h e re qui re d n u m

ber of coi ls tog e th er t h e e n d of
‘
C
,

t h e firs t coi l to t h e b e gi n ni n g of
t h e s e co n d e t c
,
. t h e b e gi n n i n g
,

of t h e firs t coi l a n d t h e e n d of

t h e la s t coi l i n t h e g roup fo rm i n g

t h e b e gi n n i n g a n d e n d of t h e

group S u ch di a
. gr a ms m a y b e

ma de for a n y n umb e r of ph a

a
se s , F m 27 G , .
—
a l w i di g d i
e ne r n n g

pol es or poss ble pa i ra l lel c rcui ts

i ,
t}? Siai fgf fi fiéfi
h p
m fiffé
a n d for a
e u
n y d e s i re d m e thod of i i ta
n se r e s s r.

co nn e ct i o n of t h e gr oup s . In
ca se t h e coi ls pe r gr oup a r i rre u l a
e g r or u n b a l an ce d i t i s a d vi
, s a
bl e to h a ve as pe ci a l di a gra m gi vi n g t h e n umbe r of coi ls i n e a ch

group thei r lo ca
,
ti on a nd a n y oth e r i n fo rm a ti on n e ce ss a ry .

R e conne cti ng aWi n di ng —

I t i s Obvi ous th a t i f awi n di n g
gi ve s sa ti s f a cto ry op e r a ti o n on acer ta i n volta ge asi mi la ,
r

wi n di n g of on e h a - lf t h e n umbe r of s e ri es co n ductors but of ,

double t h e curre n t ca rryi n g ca pa ci ty wi ll gi ve s a

,
t i s fa cto ry

op e ra ti on on on e h a - lf t h e volt a g e . T h i s l att e r c o n d i t i on m a y
be obt a i n e d by pa ra lle li n g t h e gr oup s a s i n Fi g s 28 a
, n d 2 9 or
.
,

whe re thi s i s i mpossi ble by p a ra lle li n g t h e se ri e s con ductors i n

t h e S lot s . For e x a mple i f t h e full volta
,
ge con n e cti on of a
1 4-pol e moto r co rre s po n d s to t h e p a ralle l co n n e cti o n t h e o n ly
me thod to cha n g e to h a lf volt a ge would be to cha n ge t h e wi n d

i ng i tse lf Si n ce 1 4 pole s does n ot p er mi t of af ou r p a ra lle l -

connecti on . Aga in a n i rre g ul a ri ty of coi l s pe r g r oup wi ll a t

40 A RM A TURE WI N D I N G AND M OTOR RE P A IR

ti me s p reve n t doubli n g t h e p a ra lle l ci rcui ts where othe rwi se

thi s mi ght be po s s i ble .

Wh e n i t i s d es i re d to use one wi n di n g for ei the r full or ha lf

volta ge t h e wi n di n g i f possi ble i s la
, , i d out for e qua
, ll y sati s
fa ctory ope r a ti on ou ei ther con n e cti on a n d for t h e mi n i mum
,

a moun t of la bor re qui re d to connect from on e to t h e othe r .

T his i s ex e mpli fie d by Fi g s 28 a n d 29 .I t i s evi d e n t th a

. t any

ecce n tri ci ty of t h e rotor wi th res pe ct to t h e s t a t or wi ll a fiect

e qua ll y t h e ci r cui ts whi ch are i n p a ra l l el .

S ini pl e M e t h od f or I ndi ca t i ng P ol a
ri t y of C oil Groups .

A s i mple m e thod for obt a i n i n g t h e prope r pola ri ty of t h e gr oups

i s i n di ca
te d i n Fi gs . 27a
n d 28 for three -pha
se a
nd Fi g . 29

FI G 2 8 — W i n di n g di a
. .
g ra m f or a
A B A ”B
3 -p h a se , 4—p ol e m o t or w i t h p ol e ‘ ‘ ’
.

p h a s e g r ou p s c on n ec t e d i n 2 - a
p r a
l l e l Fro . 29 .
—
di a g ram for a
Wi n di n g
st ar . T h i s i s t h e w i n di n g of Fi g 2 7 . 2 -p h ase , 1 4-p o l e m ot o r wi t h p ol e
c on n e ct e d i n p a ra l l el
.
ph a se g ro u p s conn e cte d i n 2 p ara
l l e ls .

for two pha se wi n di n g

— I n athr e e ph a
. se s t ar w i n di n g by
-

tr a ve li n g from e a ch Of t h e thr e e le a ds t o t h e s t a r po i n ts t h e ,

di re cti on of tra ve l i s r e v e r s e d i n a dj a ce n t g r oups I n at w o .

ph a se di a gr a m t h e on ly n ece ss a r y p re ca uti on i n de te rmi ni ng

t h e p r ope r pol a ri ty i s to r e me mb e r th a ta dj a ce n t g r oup s of t h e

sa me pha se a r e re ve rs e d B y ma . r ki n g t h e g r oup s A B 0 , , ,

et c . an d i n di ca
, ti n g t h e di recti on of tr a vel i t i s aS i mple ma ,
tte r
to conn e ct the m i n t h e prope r di re cti on A ddi ti o n a l i n d ex
.

ma r ks m a y b e g i v e n o n t h e di ag r a
m to a i d i n c o n n e ct i n g t h e

wi n din g by ma , r ki n g thos e gr oup e n d s whi ch a re j oi n ed by th e

 AL TE R N A TI N G-C UR R E N T WI N DI N GS

s a
me co nnect or wi th , t he a
me n ume ra
s l . For further det a
il s
in us i n g thi s me thod see C ha
pter X I .

r t o De l t a
ng i ng S ta
C ha C onn ect i on ta r di a
.
—
gra m ca
A ny n s

be re a di ly ch a n ge d i n to acorre s po n di n g d e lt adi a g ra m by
ope ni n g up t h e s ta r poi n ts a n d conn e cti n g t h e i n n e r e n d of

pha s e A t o t h e oute r e n d of ph a s e B or C t h e i n n er e n d ,

of pha s e B to the out e r e n d of pha s e C or A a n d t h e i n n e r e nd,

of pha s e C t o t h e oute r e n d of ph a se A or B I f t h e st a r .

di a gr a m i s n ot s ymme tri ca l wi th r e s pe ct to t h e three pha ses

i t i s n e ve r a dvi sa ble to cha n ge ov er to d e lt a .

A C Wa
.
- . ve Wi n din g s I n aw a
.
—
ve wi n di n g corres po n d ,

i n gly pl a ce d con du cto rs u n d e r a dj a ce n t pole s a r e co n n ecte d

i n s e ri es t h e ci r cui t p r o cee di n g fr om pole to pole on e or more

,

ti mes a r ou n d t h e co re a n d n ot fo rw a
,
rd a n d ba ck upo n i ts e lf

a s i n al a p w i n d i n g T h.e c i r c u i t s a r e th e n i n t e r co n n e c t e d in

s u ch am a n ner a s to gi ve t h e re qui si te ph a s e re la ti o ns Th e .

tota l n um be r of thes e ci r cui ts mus t be amulti ple Of t h e n um ber

of ph a se s a n d i s o r di n a ri ly twi ce t h e n umb e r of ph a s es Du e to .

ce r t a i n li m i t a
ti ons thi s type of wi n di n g i s n ot us ed to a
,
s gr e a t
a n e x te n t a s the la p o r t h e c o n c e n t r i c w i n d i n gs I t s u s e o n .

s ma ll m et e rs i s li m i te d t o ph a s e wou n d s e co n d a
- ri e s S i n ce a .

two pha- se s econ d a ry would r e qui re fou r coll e ctor ri ng s or i f ,

co n n ecte d for athr e e wi r e s y s te m would ov e rlo a

-
,
d on e of t h e
ri n g s whi le a
,
three-pha s e wi n d i n g r e q ui r e s but thr ee ri n gs t h e ,

la tter o n ly i s ge ne ra l for such a ppli ca ti o n s .

a
P r og re s s i ve n d R e tr og r e s s i ve A Wa ve Wi n di n g s
.
-C Th e. .
—

n umb er of S lot s for aw a ve wi n di n g ( plus or m i n us on e ) is

S O cho se n a s to be di vi s i ble by t h e n umb e r of p a i rs of poles
or pre fe ra bly by t h e n umbe r of pole s If plus on e i t i s s a . id ,

to be apr og ressi ve wi n di n g s i n ce a fte r trave li n g on be a

,
r oun d

t h e ci r cui t i t re tur ns to t h e s t a rti n g s lot plus on e I f mi n us .

on e , it is s a
i d to be retr og r es s i ve si n ce t re t u r n s t h e
the ci rcui

wi n di n g to t h e sta r ti n g s lot mi n us on e Wi th thi s a r ra n ge.

men t i t i s i mpos si ble to b a la n ce t h e ph a se s e x a ctly but t h e ,

e ff e cti v e u n b a lan ci n g i s s m a ll wi th ala rge n u mb e r of s lots .

Si nce a n un b a la
n ce d thre e ph a s e wi n d i n g i s l e ss Obj e ct i o n a
- ble
tha n at w o ph a s e w i n di n g t h e s ch e m e i s us e d ch i e fly for t h e
—
,

form e r A g a . i n si n ce a
,
n un ba lan ce d wi n di n g i s l e ss de t ri

m enta l i n aseco n da ry ci r cui t th a n in a p ri m a r y t h e p r i n ci pa l ,

42 A RM A TUR E WI N DI N G AND M OTO R RE P A IR

a ppli ca ti on of thi s typ e of wi n di ng h a s bee n i n s e co n d a ry

ci rcui ts .

Th e di a gr a m of Fi g 30 re pres e n ts atwo con ductor pe r s lot .

wi n di n g s uch a s aba
,
r a n d e n d co n du ctor typ e but i s e qu a lly
a ppl i ca ble to stra p or wi re wou n d coi ls of two or more s e ri es
turns pe r co i l i n w hi ch ca s e t h e co n n e ctor on t h e re a
P

,
r end

of t h e coi l ta ke s ca re of i t se lf a n d t h e f ro n t e n d i s co n n e ct e d

i n a ma nn e r si m i la r to t h e

S ke t ch There a re s e v e r a l .

m e thod s of co nn e cti n g up t h e
thr ee pha s e s de pe n di n g on t h e -

des i re d volt a ge Th e pri n ci .

p al c o n n e ct i o n i s i n d i ca t e d i n

Fi g 3 0 B y co n n e cti n g t h e . .

e n d of e a ch s e r i e s ci cui t to
r
t h e b e gi n n i n g of t h e n ex t a nd

ta ki n g ofi l e a d s to t h e po i n t
of co n n e cti on of s e ri e s 1 2 —
,

F IG 30
. V a w i di g
.
—
f a 3
V 4 ve
5 6 i n s t e a
n
d O f t
n
h e c o n
or ,
—
)
’

3 ph a 4 p l m t
- se . - h ai g 1 9 l t
o e n e ct i on s
o or . b e twe e n t h e s e ri e s
v n s o s.

a
19 il
co tw s, il p l t th w 1 t
o co s er s o ro o
h OW D l n Fl g o
.

3 0
,

6 wi t h ba l a d ph a
un t d
n ce
8 c
se s con n e c e
n n ec

ti o n i s obt a i n e d for on e h a
,

in i ta
se r e s s r lf -

i
Fi t
t
rs

l
i b i
se r es

12
s ot S
i b tt
d i
l t 6
b i b
d
eg ns
volt a g n
e A l l 86 pe r ce n t
o om s o , en

ot
s
. .

volt a ge t a
n op e c on s e r es eg ns

t m of
.

tom l t 17
s o d t p l t 4, Th i d
en is o p
s o I n .
e r s trh ese r e s

F o ur t h be g i n s bot t o m s l ot 1 e n d s
s e r i es .

t op S l ot 7 ure d by con n e ct m g t h e
Fi f t h s e r i es be g i n s bot t o m
.
ls sec

e n d of s e r i e s 2 to t h e b e gi n
8 1 0 1) 1 2 e n ds
, t o p 8 10 t 1 8 S i x t h se r i e s .

be g i n s bo t t om s l ot 4 , e n d s t op s l o t 1
m u g of s e ri es 3 t h e e n d of
.

s e ri e s 4 to t h e b e gi n n i n g of s e r i e s 5 t h e e n d of s e ri e s 6 to ,

t h e b e gi n n i n g of s eri e s 1 To co n n e ct i n s t a r j oi n t h e e n d s .

of s e ri es 1 s e ri es 3 a n d s e ri e s 5
, a n d ta ke ofl le a ds a
, t the ,
’

be gi n n i n g se ri e s 6 se ri e s 2 a n d s er i e s 4 S i n ce thi s co n n e c
, , .

ti o n re duce s t h e volt a ge wi thout i n cre a s i n g t h e cr o ss s e cti o n

of t h e copp e r t h e wi n di n g wi ll be l e s s e ffi ci e n t on a ccou n t of

hi gh e r coppe r lo ss for t h e s a me output Thi s i s a ls o true of .

t h e 50 pe r ce n t volt a ge co n n e cti on si n ce for t h e output t h e

.
-
,

cu r r e n t d e n s i ty i n t h e wi n di n g s i s 1 5 pe r ce n t g r e a te r than .

for t h e full volt a ge co n n e cti o n .

I t i s po ssi ble by ch oosi n g a n umb er of slot s whi ch i s di vi si bl e

,
 AL TE R N A TI N G-C U R R E N T WI N DI N GS

by t h e produ ct of t h e number of ph a se s by t h e n um be r of

poles to l a ,y out a w i n d i n g wh i c h i s b a l a n ce d F o r s uch a .

wi n di n g t h e ci rcui t a fter pa ss i n g o n ce a r ou n d t h e a r ma ture ,

r e t u rn s to t h e s t a rt i n g s lot I t i s the n o n ly n e ce ss a
. ry to

s upply aS pe ci a l co n n ector t o j oi n i t to t h e con ductor i n t h e

s ta rti n g s lot plus or mi n us on e Thi s wi n d i n g thu s e mbodi es
.

t h e b e s t fe a tur es of both types a s for e x a mple a n e l e ct r i ca

, l ,

ba la n ce a nd a mi ni mum n umbe r Of s pe ci a
,
l co n n e cti on s whi ch ,

me a n s av e ry comp a ct a nd ea s i ly a s se mbl e d wi n d i ng Th e .

n umb e r of s peci a l con n e cti ons i s comp a ra ti ve ly s ma ll wi th

res pe ct to t h e n umb e r of co i l s a n d thi s fe a t ure i s mo re pro
,

n ou n ce d a s t h e n u mb e r of poles i s i n cre a se d H e n ce for a .

wi n d i n g for al a r g e n umb e r of pol e s 1 2 to 40 t h e n umb e r of , ,

s pe ci a l co n n e cti on s b e come s i ns i gn i fi ca nt .

C onn e ct i on s f or C oi l s of P ol yph a s e Wi n din g s

‘
A t wo .
—

pha s e wi n di n g for afour pol e a lte rn a to r i s S hown i n t h e s i m

-

p l e s t po s s i bl e fo r m a s a ,

ra di a l di a gra m in Fi g 3 1 ,
. .

I t i s aco n ce n tra te d wa ve
wi n d i n g h a vi n g on e S lot pe r
,

pol e pe r ph a se full pi tch , .

E a ch ph a se h a s on e e l e m e n t
'

of wi n di n g or on e s l ot u n de r , ,

ea ch pol e a n d t h e e le men t s
,

of pha se B a r e di s t a n t fr om

t h e co rr e s po n di n g e le m e n ts
of pha se A by e x a ctly 90

e l e ct r i ca l d e gree s Th e .

whole wi n di n g i s thus di
F Ra d a l da g a f a2 p h a
0

31
V i de d i n to t w O e x a
—
m IG i i r o -
se
ctly S l m
. .

wi d i g f a4 p l m ah i n n or - o e c ne

il a r ha lve s ele ctri ca

.

l ly di s
,

ti n ct from e a ch othe r ju s t li k e two s i n gl e ph a

, se s th e ir po s i t i o n s ,

be in g re l a ti vely fix e d s o th a t S pa s se s u n de r m i ddl e N 1 ju s t
.
,

on e qu a r t e r pe r i od a
- fte r (or b e fore d e pe n din g on dir e cti o n ,

of rota ti o n ) S b p a ss e s t h e s a me po i n t The y a re thu s ti e d .

1
Th e fol l ow i n g d e s cri pt i on s a
nd i l l u s t ra
t i on s of
w i n d i n g s , p g es 43 t o a
51 , h a
v e be e n t a
k e n by pe rm is s i on from Al t e rn a
t i n g -C u rr e n t E l e ct ri ci t y
by W H . . Ti m bl e a
nd H H Hi g bi e (J oh n
. . Wi l ey S ons , I n c .
, N ew York,
N .
 A R M A TUR E WIN DI N G A N D M OTOR R E PA I R

toge ther i n pha se re l ati o n thro ugh t h e m a gn e ti c field a nd

t h e m ech a n i cal di stri buti on of t h e wi n di n g Th e s li p ri n gs .

of pha s e A would be co nn e cte d to S an d Fa a n d t h e ri n g s

, ,

of pha se B to S b a nd P b .

A three ph a - se wi n d i n g for afo ur -pole m a chi n e 1 8 S hown i n

Fi gs 3 2 to 34 Th e wi n di n g
. .

i s t h e si mples t pra cti ca ble one

to ma ke occupyi n g only one ,

S lot pe r pol e pe r ph a se Thi s .

wi n di n g i s l a i d out a s fo l lows :

Fi rs t ma ke s ure tha t t h e tota

, l
n umbe r of S lots i s di vi s i bl e by

3 ( ph a ses ) an d 4 ( poles ) T he n .
,

holdi n g t h e r otor s t a ti on a ry ,

ma rk on e e l e m en t (or s lot )
I dila a a as belon in g to phase A an d
u. u n de r t h e m i ddl e of e a ch pole

F m 32 . .
g m f r go ,

3 ph a
- w i di g f
se a4 p ol m a con n e ct t he m
n n or - e
op ly t o
h t a- o t d
p r e r _

ge the r i n se r1 e s so th a
c 1 ne , s r c n nec e
t thei r
.

e mfs a dd toge th e r w he n the y a r e i n t h e po s i ti o n whe r e t h e

ma x i mum i n s t a n tan e ou s e m f for t h e whole gr oup i s i n du ce d

a how M a k d of th i i 8 a i
'

( s s n i n F i g r . o n e e n s se r es s n ,

FI G . 33 .
—
D e v e l op e d d i agr am of the 3 -p h a
co n n e c t e d .
se w i n di n g of de l t a

Fi g 3 2, a
other en d F a Wi th t h e rotor s ti ll fixe d i n
nd t he .

t he sam e posi ti o n a n d s ta r t i n g from S p r oce e d to coun t t h e o,

s lot s or co i l s i n on e di r e ct i o n a r ou n d t h e a rma ture un til t wo

thir ds of tho se whi ch li e be twe en t h e mi ddle of a dj acen t
46 A R M A T UR E WI N DI N G AND M OTOR RE PA I R

( S to F ) a re 1 2 0 e l ectri ca
, l de grees a p a r t s u cc e ss i v e ly i n

t h e sa me dir e cti on thr ough t h e close d mes h or s e ri es .

Thi s r e l a ti on g i ve s aresulta n t e m f of z e r o volt s a r ou n d

t h e mes h .

I f t h e w i n d i n g i s to o ccupy two slo t s per pol e per ph a se ,

re qui ri n g 3 X 4 X 2 24 S lots a ltoge ther t h e con n e cti o ns ,

for atwo l a ye r l a p w i n d i-n g ar e

s hown i n Fi g 34 T h e re a re a
. s .

ma ny coil s a s s lo t s and a ll ,

coi l s a re e x a ctly a l i ke E a ch .

s lot co n t a i n s two coi l s i d es (Fi g - .

T h e on e a t t h e bottom i s
t h e ri ght h a nd s i d e of a coi l-

lyi ng to t h e le ft of t h e S lot a nd ,

t h e one a t t h e top i s t h e l e ft
ha n d S i de of aco i l lyi n g to t h e

ri gh t of t h e S lot T h e e l e m e n ts
F m 34 Th p ha wi di g
.
—
r e e- se n n

a t t h e bottom of t h e s lot a
. .

h ai g t w
v n l t p p l p
o s o s erpha o e er se .
re
Tw ph a
o ly a
s e s on h w re s o
s how n i n dotte d li n e s
n .

S u ch a n a rr an ge m e n t of coi l s i s typ i ca l of a ll la p wou n d -

di re ct curr e n t m a
- ch i n e s and s y n ch r o n ou s
,
co n v e rt e rs ; but

it m a y b e u s e d f or an y s o rt of a n a l t e r n at i n g c u rr e n t w i n d i n g -
,

clo s e d or ope n I f t h e s i mi l a
. r e n d of e ve r y coi l a t i t s s ta rt i n g

e n d i s la be l e d S a n d t h e oth er e n d F ( a
,
s i t i s wou n d up on a

form for i ns t a
,
n ce ) the n a clo s e d wi n di n g i s obt a
,
i n e d by si mply
s old e r i n g t h e F of on e coi l to t h e S of t h e on e lyi n g i n t h e n e x t

s lot a,
n d s o on a ll a r ou n d t h e a r ma ture u n ti l t h e l a st F is

s olde r e d to t h e firs t S Thi s clos e d wi n di n g co u ld be t a

. ppe d
a t e qui d i s t a n t poi n t s de pe n di n g on t h e n umbe r of poles
,
.

Or thi s clos e d wi n di n g co ul d be o pe n e d up a t two or mo re

poi n ts a n d t h e pa r ts co n n e cte d i n se ri e s a s a n Ope n wi n d i n g f or

a ny n umbe r of ph a s es Th e wi n di n g of Fi g 3 5 m a
.
y b e .

re cog n i z e d for a four pole s ta tor be ca

- us e e a ch coi l s p a,
n s on e

qua rt e r of t h e ci r cumfe r e n ce To g e t t h e gre a te r e m f i n a

.

coi l i t s oppo s i te s i de s S ho u ld both com e a

,
s nea rly a s pos s i ble

s i mult a n e ou s ly u n de r t h e m i ddl e of a dj a ce n t poles The re a re .

2 4 coi l s a ltoge the r for thre e pha ,

ses a n d fou r pol e s whi ch a llows ,

two coils pe r pole pe r pha se Th e se two wil l of cou rs e be a

. dj a
, ,

ce n t coi ls i n o r de r tha ,
t their e m f s s ha ll be a s nea rly a s po ss i bl e
 AL TE R N A TI N G-C U
RR E N T WI N DI N GS

in pha s e wi th e a ch o t he r s o a s to g e t the gre a

tes t poss i ble
re s ult a
n t e m f fr om t h e s e ri es
. .

Dou bl e -
a l ye r i n —
a
W di n g , L p C onn e ct e d I n con n ecti n g a .

wi n di n g s u ch s s how n i n Fi g 3 5 , choo se a
a coil lo ca
te d e x a
. ctly

un de r t h e mi ddle of N 1 a nd S I a n d la be l i t A 1 , . Ma
rk i t s

s ta
r ti n g e n d S C on n e ct t h e fin i s h e n d of coi l
o. A I to t he
r ti n g e n d of coi l A 2 whi ch i s a
s ta dj a ce n t to coi l A 1. N ow

Fm . 35 .
—
T aye r w i n d i n g f or a3-p h a
se ,
4-p ol e m a
ch i n e .

FI G . 36 .
—
VVi n d i n g of Fi g . 35 , de l t a
-co n n e c t e d .

FI G . 37 .
-
W i n di n g of Fi g . 35 . st a
r con n e c t e d
- .

loca te coi ls A 3 a nd A al s o be lon gi n g prope rly to ph a

4, se A ,

be ca us e th e y a r e lo ca te d wi th rel a ti on to pole S I a n d N 2 jus

'

ex a ctly a s coi l s A I a nd A 2 a r e lo ca te d wi th re l a ti o n to pol e

N1 a nd S I .S i mi l arly lo ca te A 5 a n d A 6 un de r pol es N 2 a
,
nd

S2 a ,
nd A 7 a n d A 3 u n d e r pole s 8 2 a nd N 1 T he n gr oup A 3 .

a nd A 4 i n a d di ti ve s e ri e s by solderi n g t h e fi ni s h of A 3 to t h e
s tart of A 4 S i mi l a
. rly co n n e ct A an d A 6 tog e th er
,
and A 7 5 ,

a n d A 3 to g e th e r N ow s i n ce t h e e m f i s clo ckw is e a
.
,
r ou n d

coi l s A 1 a nd A 2 cou n t e r clo ckwi s e a

,
r ou n d co i ls A 3 a
- nd A
48 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

lo
c c kw i s e a r ou n d A 5 a n d A 5 a n d c ou ,
n t e r- clo ck wis e a r ou n d

A 7a n d A s i t wi ll be s e e n th a
,
t i n order to g et these groups of
,

coil s toge the r i n to a ddi ti ve s e ri es A I A 2 A 5 a n d A ; mus t be

, ,

con n e cte d toge the r s i mi l a rly but A 3 A 4 A 7 a ,

n d A s opposi te ly
, .

I f t h e s eri es of coi l s compos i n g pha se A a re ca re f u lly tra ce d

s ta rt i n g a t S a n d go i n g ri ght th r ough to Fa i t wi ll be s e e n
, ,

tha t t h e i ns ta n ta n e ous e mfs a re a ll i n t h e s a me di re cti on a t

a bout t h e s a me ti me when t h e e m f s i n duce d i n t h e coi ls of
pha se A a re gr e a tes t (whi ch is a bout t h e posi ti on s how n i n t h e
di a gr a m) .

P ha se B h a s b ee n s t a rt e d a t on e en d S (s i m i l a r to t h e e n d
, ,

of aco i l lo ca t e d 1 20 el e ctri ca l de g rees from coil A I a nd ,

from this poi n t thr ough to Fb t h e co n n e cti o ns a nd a rr a n ge m en t

of coi ls a re a n ex a ct dupl i ca te of pha se A e x ce pt a s to a, ctu a l

pos it i o n i n t h e m a g n eti c fi eld Li ke wis e ph a
. se C is a dupli ca te
of pha se A 1 but S i s lo ca
, 6 te d 1 20 d egre es further a lo ng i n t h e
sa me di re cti o n from S b or 240 degree s from , T h is g i ves
t h e s i x t e rm i n a ls of t h e thre e pha s es a l l pr ope rly l a b ele d I n .

Fi g 3 6 a
. r e s how n t h e prope r co n ne ct i o n s be tw ee n th e s e s ix

te r mi n a ls to gi ve athree pha s e d e lt a I n Fi g
-
3 7a
. r e s how n .

t h e con n e cti o n s b e twe e n t h e s a me six te rm in a l s to gi ve a

three pha -
se s ta r

C onn ect i ng a C h a i n Wi n di ng Th e ch a —
i n wi n di n g h a s

b ee n s ome ti me s us e d by ma ke rs for a ltern a ti n g cu rre n t ge n e ra -

to rs i n a
,
ddi ti o n to t h e two la yer wi n di ngs Fi g 38 re pre
- . .

se n t s ath re e ph a s e fou r pol e ch a

- - i n wi n d i n g u si n g t w o s lots ,

p e r pol e p e r ph a s e o n t h e s am e 24 -s lot a r m a tu r e wh i ch w e h av e

bee n us i n g thr oughout for i llus tra ti o n I n orde r not to confuse

.

t h e di a g ra m ph a se s A
,
B a n d C ha
,
ve b e e n d r a wn out s e p a
ra t e l y i n Fi gs 3 8 3 9 a
,
. n d 40
, N oti ce th a
. t they a re e xa ctly

a li ke ex cept a
,
s to r e l a ti ve pos i ti on on t h e a rma tu re P ha se .

B i s 1 20 electri ca l de grees from ph a se A a n d ph a s e C i s 1 20

,

e l e ct ri ca l de gre e s further i n t h e s a me di re cti on from pha se B , ,

or 2 40 e l e ct ri ca l d e grees from ph a se A t h e po s i ti ve d i re cti o n

,

of e m f i n e a ch ph a se b e i n g fr om t h e S e n d to t h e F e n d .

Whe n t h e thre e pha ses a re a ss e mble d a ltoge the r a s i n Fi g 4 1 .

,

i t i s s ee n th a t there mus t be adiffe re n t s h a pe or le n gt h of coi l

for e a ch ph a se i n o rd e r th a t t h e e n d s of t h e coi ls s h a ll n ot
i n t e rfe re wi th e a ch oth e r Th i s i s ex pr e ssed us ua
. lly by s a yi n g
 AL TE R N A TI N G-C UR R E NT WI N DI N GS

th a r e i n th re e r a
t t h e e n d-be n d s of t h e coi ls a n g es Thi s i s du e .

to t h e f a ct th a t t h e wi n di n g i s asi n gle la ye r wi n di n g (t h e

FI G . 38 .
—
P ha
se A of a3 -
ph a
se ch a
in wi n di n g . Two s l ot s pe r p ol e pe r
ph a
se .

FI G . 39 .
—
P ha
se B of t h e 3-p h a
se ch a
i n wi n d i n g of Fi g . 38 .

FI G . 40 —. Pha
se C of t h e 3-p h ase ch a
in w i n di n g of Fi g . 38 .

FI G . 41 Th r e e -p h a
.
—
se ch a i n wi n d i n g f or w h i ch t h e s e p a rat e ph ases a re
s h ow n i n Fi g s 3 8 , 3 9 a n d 40
. E n d c o n n e c t i on s o f p h a
. s e A on l y a
re s h ow n .

Th ree f orm s of coi l s a re n e ce s s ary .

coi ls 01 atwo l a y e r wi n d i n g a
-
re a ctly a
l l e xa li ke ) and a ls o ,
‘

beca
u se a
l l co i l s i n e a ch ph a se h a de t h e sa
ve b ee n m a me s h a
p e .

4
 A RM A T UR E WI N DI N G A N D M OTOR R E PA I R

I n Fi g 4 1 t h e e n d-co n n e cti o ns
. be twee n coi ls are s hown o n ly

f or ph as e A , to a voi d confus i on Th e s ys te m of co n n e cti o n s

.

would be e xa
ctly the s a
me a
s i n othe r figures whi ch a re

comple te

Ot h e r C om m on Wi n di n g s .
—
A fe w othe r typ i ca
l form s of
w i n d i n gs a
r e i llu s t ra
te d i n Fi gs . 42 to 40 Fi g 42 i s a . .

FI G . 42 .
—
s e ba
T h re c~ p h a r w i n di n g ( w ave ) using o n e s l ot pe r p o l e p e r p h a
se ,

st ar-c o n n e c t e d .

Fm . 43 .
—
S ke w w i n d i n g w i t h al l co il s a
l i ke , e a
ch ha
ving on e s i de s h or t e r

t ha n t h e ot h e r .

FI G 44 . S h or t—coil w i n di n g w i t h e a
.
—
ch coil o n l y t w o-t h i r ds of t h e pol e
T h e e m f s of t h e t w o s i de s do n ot a dd t o s u ch g ood a dv anta ge a
’
p i t ch . s

i n ot h e r t ypes .

th r ee- ph as e ba r w i n d i n g ( wa ve ) us i n g on e s lot per pole pe r

ph a se It m a.
y b e e x t e n d e d as s how n f or an y n um b e r of
pa i rs of pol e s an d is d r a wn sta r co n n e ct e d Fi g 43 i s k n own -
. .

a s a s k e w co i l
“ ”
wi n d i n g ; a lthough there i s o n ly on e coi l
-

s i de i n e ach s lot a ll co i ls a r e of t h e s a
,
me s ha pe for a l l ph a s es .

C o n fli cts of t h e co i l e n ds a re a voi de d by m a
- ki n g one si de of
 AL TE R N A TI N G-C UR R E N T WI N DI N GS

ea ch co i l lon ge r tha n t h e othe r s i de Fi g 44 ill us t ra te s . .

wha t is ca l le d a s ho rt coi l wi n d i n g for athree pha

- se m a -

chi n e us i n g two s lots pe r pole pe r ph a se B y ma ki n g t h e .

b re a dth of e a ch co i l o nl y of t h e pole pi t ch overla ppi n g of ,

co il s i s a ltoge ther a voi de d a nd a l l co il s i n t h e e n t i re wi n d i n g

,

are e x a ctly a l ike Th e s eri es e mfs compos i n g e a

. ch ph a se a re

n ot a dd e d to a s good a dva n tage a s i n oth e r type s of w i n d i n g

usi n g co ils n e a re r fu l l p i t ch a n d the re fo re mo r e coppe r would

-
, , ,

FI G 4 5 — C r ee p i n g wi n di n g i n w hi ch coil s h a
. . v e afr a ct i o n al p i t ch . T h re e
coi l s cov e r f ou r p o l e s Th e sm a ll da
. sh l i n e s re p re s e n t s l ot s l e ft v ca
a nt

for cl e ar ne s s .

FI G . 46 .
—
S i n g l e -p h a
se , w h ol e-coil e d w i n di n g for 8 p o l e s usi ng 3 s l ot s

pe r p o l e A rm a
. t u re h a
s 6 4 s l ot s .

be n ee ded for t h e sa m e ca pa ci ty Th e w a ve form i s a .ls o

li ke ly to be more pe a ke d Fi g 45 s hows a cre e p i n g wi n d
. .
“

i n g i n whi ch t h e co i ls a re of fr a ct i o n a l p i t ch a n d t h e s e r i e s of
”

co i ls i n e a ch ph a se a re a rr a n ge d s o a s to g a i n or los e one or more -

poles a r ou n d t h e a rm a ture I n Fi g 4 5 t h ree a . dj a ce n t co i ls .

ea ch s pa n ni n g 240e l e ct r i cal de gree s toge the r cove r 720 de gree s ,

or fou r pol es Fi g 46 s hows as i n gle pha

. . se whole co i le d - -

wi n di n g for e i ght pole s us i n g th ree s lots pe r pole for a

,
n ,

a r ma ture ha vi n g a ltog ethe r 64 s lots .

E a s il y R e m e m ber e d R ul e s f or Ar ra n g e m e nt of C oil s i n a n

I n du ct i o n M ot or Th e follow i n g a
—
. re rul e s tha t ca n be
ea s i ly re m e mb e r e d a n d cov e r co n d i t i o n s f r e qu e n tly e n cou n

t e red i n l a yi n g out a lte rn a ti n g curr en t w i n d i n gs - .

1 N um ber of coil s pe r pol e ph a

. s e g rou p N o sl ot s
- .

p o l es X N o ph ase s). .
 A R M A TU R E WI N DI N G A N D M OTOR R E PA I R

2 . Wh en t h e n um ber of slots i s venly di vis i ble by t h e n um ber

n ot e

of pole s ti m es t h e n um ber of ph a s es di ss i m il a ,r g rou ps m u st be

em pl oyed Thes e g r ou ps sh oul d be a

. rra n g e d s o th a ta l l t h e ph a s es

ha ve a n e q ua l n um ber of coil s Th e g roupin g sh ould a

. lso be sym
m e tri ca l wi th res pe ct t o t h e core
,
.

3 A full pi tch wi n di n g i s on e i n wh i ch t h e s pa
. n of acoi l e qu a ls
t h e n um be r of sl ots di vi de d by t h e num be r of pole s Th a t is in a
.

3 6 s l ot s i x pol e thre e ph a
,
-
,
-
s e wi n di n g 3 6 6 , 6 s lot s or t h e a r c of t h e

sta tor covered by on e pole A coil wi th as pa . n of 6 sl ot s m a k es t h e

wi n di n g afull pi tch wi n di n g Wh e n t h e coil s pa . n i s l ess t h a n thi s ,

t h e wi n di n g i s kn own a s a fra cti on a l pi t ch wi n di n g .

4 I f apa
. rti cul a r w i n di n g h a s g i ve n l a t i sfa ct i on on a ny pa r t i cula r

volta g e as i m i la
, r wi n di n g of on e h a l f t h e num be r of seri es con du ctors
-

bu t of double t h e curre n t ca - rryi n g ca p a c i t y w i ll a l s o g i v e s a t i s fa c ti o n

on on e h a b
lf t h e volta ge Thi s la
. t t er con di ti on ca n us ua lly be ob
ta i n e d by pa ra l le li n g t h e g rou ps of coi ls Or wh e n am a . chi n e h a s

t wo wi n di n g s con n ect e d i n s eri e s s a y f o r ,

44 0 v o l t s t h ey c a n
,
b e c on

n e ct e d i n pa ra llel for 220 volts .

5 I n awa
. ve wi n di n g corres pon ding ly pla
, ce d con du ct ors un der

a dja ce n t poles a r e con n e cted i n se ri es a n d t h e ci rcui t procee ds from

,

p o l e t o po l e o n e o r m ore ti m es a r o un d t h e c o re T h e c.i r c u i t s a r e

the n i ntercon ne ct e d t o g i ve t h e re q ui si t e ph a s e rel a t i on s Th e .

tota l n um be r of th e s e ci rcu i ts m u s t be am ul t i pl e of t h e n u m be r of
p h a se s an d i s o r d i n ar i ly t w i ce t h e n u m b e r of p h a se s Th e n. u m b e r

of sl ot s for th i s wi n di n g ( pl u s or m i nus on e ) s h oul d be di vi s i ble

by t h e n um ber of pa i rs of pol e s or pre fera bl y by t h e num ber of poles .

I f pl us on e t h e wi n di ng i s prog re ss i ve s i n ce a
, fter tra
,
velin g on ce
a rou n d t h e ci rcui t i t re tu rn t o t h e s t a rt i ng s l ot pl us on e I f m i n us
.

on e i t i s sa
, i d t o be re trog re s si ve s i n ce t h e cir cu i t r e turns t h e wi n di n g
t o t h e sta rti n g s l ot m i nus on e To h a
. ve aba la n ce d wa ve wi n di ng ,

t h e n um ber of sl o ts m us t be di vi si bl e by t h e produ ct of t h e n um ber

of pol e s a n d ph a se s .Thi s wi n di n g returns t o t h e s t a rti n g sl ot a fter
g oi n g on ce a roun d t h e core a n d s pe ci a l con n ectors m u st be u se d t o
conne ct t h e finis h e n d t o t h e con du ctor i n t h e sta rti n g slot plus or
m i n us one .

S i m pl e R ul e for C h e cki ng P roper P h s e R e l ti on shi p i n a a

a o or Thr e e ph a
Tw -
se Wi n di n g —
l con si d era
m en t a
A fu n d a .

ti o n whe n che cki n g t h e i nst a n e ou s flow of curre n t i n a

n ta thre e
ph a s e ci r cui t i s to i m a gin e th a
, t whe n t h e curren t flows i n
t h e sa me di re cti o n i n two le gs of t h e ci rcui t i t flows i n t h e ,

opposi te di recti o n in t h e thi rd l eg Thi s pri nci ple ca n be .

54 A R M A TU RE WI N DI N G A N D M OTOR R E PA I R

Fl o 5 0 A 3-p h a
. .
—
se , 6 -p ol e w i n d
in g ha vi n g t h re e coil s p e r p ol e-p h a se

g r o u p on as t a t or of 54 sl o t s T hi s .

w i n d i n g ca n be co n n e c te d f or 2-p h a se

o pe r a t i on w i t h a n o d d g r ou p i n g of

coil s a s s h own i n Fi g 5 1 . .

FI G . 51 . A 2 -p h a
—
se , 6-p ol e wi n d

i ng on a st at or of 5 4 s l ot s The
.

3-p hase . 6-p ol e wi n di n g i s s h ow n i n

Fi g 5 0
. .

FI G .52 A 3 -p h a
.
—
se , 6-p ol e w i n d

i n g s h ow i n g t h e a rr a n g e m e n t of od d

g r o u p s o f coi l s T h e .
g r o u p s of t w o

coi l s a re l o c a t e d di ag on a l l y op p os i t e
ea ch ot h e r T h e sm a
. ll a r cs n u m

bore d I t o V I e a ch s p a n o n e p ol e

c on t a i ni n g 8 coi l s T h e s t t or i n
. a
a a
t h i s c se h s 48 sl ot s .
 A L TE R N A TI N G-C U R R E N T WI N DI N GS

A si mple a n d mo re re li a ble me thod for t h e re pa i rma n to

u s e i s s hown i n Fi g 4 7 . I n thi s s che me i t mu s t be s uppo s e d

tha t curre n t flow s i n a l l thr ee l e a d s of t h e sta r co n n e ct i o n to

wa r d t h e po i n t of t h e s t a r co n n e ct i o n A n d tha
. t i n t h e ca se

of ad e ltaco n n e cti o n t h e cur ren t flows a r ou n d t h e thre e s i d e s

of t h e de ltai n t h e s a me di recti on The n i n ei the r ca

. se for

athree ph a -
se wi n d i n g t h e pol a
,
ri ty of e a ch of t h e pol e ph a se -

gr oup s wi ll a lte rn a te re gula r ly a r ou n d t h e w i n d i n g a n d ca n

be i n d i ca te d by a r r ow s a s i n Fi g 4 7
. A s s hown f or athr ee ,

pha se w i n d i n g th e r e w i ll be th r e e ti m e s a s ma n y pol e ph a se -

gr oups a s th e r e a r e pol e s . B y t h e u s e of th i s s ch e m e th e r e i s
n o ch a n ce for a r e ve rsa l of apha s e to be p a s se d by n ot n ot i ce d

whe n che cki n g t h e wi n di n g .

In a doptin g thi s s ch e me for atwo ph a se w i n d i n g i t n e e d

-

on ly be re m e mbe re d tha t both group s of coi ls i n e a ch ph a se

mu s t re ver s e a lt e rn a t e ly th a
,
t i s the y s hould be so i n d i ca
,
te d
on t h e d i a gr a m by a r r ows a
,
s s how n i n Fi g 29 p a .ge 40 ,
.

B y ma rki n g e a ch of t h e pol e ph a -
s e g roup s on ad i a gr a m ,

A B C to i n d i ca
, , ,
te acomple te pha se group a
- n d pl a ci n g t h e
,

a r r ow s on e a ch s i n gl e gr oup a s s hown i n Fi g 47t h e a . rma,

ture
wi n der wi ll ha ve li ttle tr ouble i n un de rs ta n di n g t h e di a gr a m
a n d ma ki n g t h e p roper con n e cti on s To ma . ke i t s ti ll e a s1 e r ,

t h e gr oup e n d s th a t a re t o be j o i n e d by t h e sa me con n e ctor

ca n be m a r ke d on t h e di a gr a m wi th t h e s a m e n umbe r .

T h e us e of t hi s m e thod f or re g r oupi n g co i l s of athr e e

ph a s e wi n di n g f or ope r a ti on on atwo ph a s e ci r cui t a
-
n d for

a n y odd gr oupi n g of coi ls i s s how n i n Fi g s 50 to 52

. .
 C HA P TE R I I I

RE P AIR S H OP M E TH ODS FOR RE WI N DIN G

DIR E C T C UR RE N T AR M A TUR E S
-

Di s m a
nt l i n g aD .
- C . A rm a
tu r e Whe n a.
-
n a r ma ture i s to
be e n t i re ly r e wou n d i t mu s t be s t ri ppe d a
,
n d re i n s ul a te d
thr oughout Fi r s t re move t h e we dge s i n t h e s lots whe n
.

ba n d i n g w i re s a r e n ot us e d I f th e r e a
. re b a n di n g wi res ,

re mov e th e m by fil i n g i n two p a rts When us in g aha

. mme r
a n d chi se l i n cutti n g b a n di n g wi re s be ca re ful n ot to m a sh the

a rm a ture t ee th out of s ha p e N ow look ove r t h e co n ne c

.

ti on s to t h e commuta tor a n d t h e e n d co n n e ct i o n s of t h e coi ls

to de term i n e whe the r al a p o r a w av e w i n d i n g w a s u s e d. I n

al a p w i n d i n g w i th fo rm e d c o i l s t h e s
,
t ar t an d fi n i s h t e r m i n a l s

a r e co n n e ct e d to a dj ace n t commut a t or b a rs wh i l e i n t h e w a ve
wi n d i n g t h e t e rm i n a ls of a n y co i l a r e aco n s i d er a ble di s t a
a
n ce

a pa rt a r oun d t h e commut a tor Th i s d i s t a

. n ce i s pp r o x i
ma t ely e qua l t o t h e n umb e r of commuta to r b a r s di vi d e d by

one h a
- lf t h e n umb er of pole s A ls o i n al a.
p w i n d i n g t h e e n d
co n ne ct i o n s of t h e coi l s a t both e n d s of t h e a rm a ture be n d
towa r d t h e ce n t e r of t h e co i l or i n t h e s a m e di re cti on whi l e
,

i n aw a ve wi n d i n g the y be n d i n Opposi te di rect i on s .

T h e wa ve w i n d i n g u s u a lly h a s e i the r two or four s e ts of

bru s he s T wo se ts of b rus he s on ly a
. re nee d e d re g a r dle ss of

t h e n umb e r of pol e s i n t h e m a ch i n e s i n ce th e re a re o n ly two

curre n t pa ths i n p a ra lle l through t h e a r ma ture wi n di n g

( s e e F i g . I n t h e l ap w i n d i n g th e r e a r e a s m a n y p a th s

for t h e curre n t a s th e r e a re pol e s i n t h e m a ch i n e (s e e Fi g 1 0) .

a n d the re a re u s u a lly a s ma n y s e t s of b r u s h es a s the re a re

pole s S i mply be ca
. us e the re a re o n ly two b r us h hold e rs on a

multi pola-
r ma ch i n e ,
h owe ve r do e s n ot a,
lwa ys m e a n th a t a
wa ve wi n d i n g i s us e d Th e commut a
. to rs of s om e fe w l a p
woun d ma ch i n e s h a ve i n t e r n a l cros s co n n e cti on s s o th a
-
t t he
com m ut a tor ba r s of t h e s a me pot e n ti a l a r e jo i n e d to e th e r
g .

56
 RE WI N DI N G DI R E C T-C U R R E N T A R M A TU R E S

T hi s per mi ts t h e us e of o n ly two s ets of b rus hes . In uch a s

ca se a n e x t ralon g commu t a tor i s use d whi ch wi ll se rve as an

i n di ca
ti o n of s uch co n n e cti ons .

Wi n di ng Dat a N e e d e d f or t h e Di s m a nt l e d A rm a tu r e . .

A ft e r ha
vi n g ma de a n i n s pe ct i o n of t h e w i n d i n g , e n t e r t h e

followin g d a
tain an ote book :
1 . N umb er of ar ma ture s lots .

2 . N umber of co i l s i des pe r s lot .

3 . N umbe r of commut a t or b a
rs whe n the re a re two coi l
—

s i de s pe r slot t h e n umbe r of b a
,
r s w i ll e qu a l t h e n umbe r
of a r ma ture s lots i n both l a p an d w av e w i n d i n g s .

4 . C oi l th r ow i n s lots .

5 . C o m muta tor p i t ch .

6 . N u m b e r of tu rns pe r coi l a n d s i z e of wi r e us e d .

A o n ve ni e n t cha
c rt a n d di a g ra m for re cordi n g th es e d a taa re

s ho wn i n Fi g s 5 3 a . n d 54 a s use d by a la r ge m a n uf a ctu re r In .

ca s e n e w co i l s mu s t be o rd e re d thi s i s t h e i n fo r ma
, ti on tha t the
ma n uf a ctu re r n e e d s I t i s agood pla
. n to h a ve an ote book
wi th dup li ca t e p ri n te d p a ge s s o tha t t h e re co r d ma de on t h e
firs t p a ge ca n be t ra ns f e rre d to t h e n e x t by a pi e ce of type wri te r
ca r bo n p a pe r Th e firs t s hee t ca
. n the n be g i ve n to t h e

a r ma ture wi n de r a n d t h e copy ke pt i n t h e book a s a n o ffi ce

reco r d f or u s e i n ca s e t h e wi n d e r d e s t roys hi s copy for u s e i n ,

ma ki n g up abi ll for t h e j ob a n d f or re f e re n ce i n ca s e fu r th e r

rep a i rs s hould be l a te r n e e de d on t h e s a me ma ch i n e S u ch a .

reco r d of re p a i rs ofte n he lps i n t h elo ca ti on of n e w trouble i n a

re p a i re d m a ch i ne .

R e m o vi ng t h e Ol d C oil s Th e n e x t op era
.
-
t i o n i s to un s old e r
t h e le a d s from t h e commuta tor a n d p r o ce e d to re move t h e
,

coi l s . Th i s ca n be do n e u s u a lly by ra i si n g t h e top s i d e s of

t h e co il s for ad i s t a n ce of t h e co i l thr ow when t h e bottom s i d e ,

of acoi l ca n be re a ch e d a n d t h e oth e rs t a ke n out on e a fte r t h e

othe r I n re movin g t h e coi ls t ry a
. n d p re se r ve on e i n i t s
,

or i g i n a l s ha pe t o u se a
, s a gu i de for w i n d i n g n e w on es E n te r .

i n t h e n ote book t h e n umbe r of turn s pe r co i l a n d w i th aw i re

,

ga uge de te rm in e t h e s i z e of wi re A ls o n ote whe the r t h e w i re

.

i s s i n gle or double cotto n cove r e d I f t h e commuta . tor co n ta in s

t w i ce a s m a n y b a
r s as th e r e a r e s lot s o n t h e a r ma tu re th e n ,
 A RM A TUR E WI N DI N G A N D M OTOR R E P A I R

ah a
e c rm ature coil wi ll co n ta i n two co i ls t ape d toge the r .

S ome a r ma lly those des i gne d for low s pee d m a

tures e s pe ci a , y ,

i n th ree or e ve n fou r t i mes a

co n t a s ma ny ba rs a s s lot s By .

F m 53. .
—
C on v e n i e n t t awh e n
for m for u se i n re cor di n g wi n di n g d a n e w coil s

m u st be or dere d from t h e m a n u fa
ct u r e r
.

thi s co ns tru cti on t h e i n du cta n ce a n d t h e curre n t pe r coi l i s

,

ke pt low a n d t h e volt a
,
ge b etwee n b a r s r e du ce d .

W en t h e a
h r m a tu re h a s b e e n s t r i pp e d all old
,
i n s ul a
t i o n

s hould be r e mov e d f r om t h e s lot s by s c r ap i n g a n d bu r ni n g w i th

 R E WI N I N
D G DI R E C T-C U R RE N T A R M A T U R E S

FI G . 54 .
—
D ia
g ra
m s for re c or di n g c oi l t h r ow an d com m u t a
t or t h r ow wh e n
s t ri p i n g n a
a rm a
t u re or when or de r i n g n e w coil s .

Th es e di a g ra ms a r e us e f u l f o r ch e c i n g u p aw a k v e w i n di n g t h a t m us t d u p li ca t e th e
ori g i n al on e I n t h i s ca
. s e ce n t e r p u n ch m a r s a re m a k
d e on t h e com m u t a t or ba rs a nd

s l ots t o i n di ca t e t h e coil t h r ow a n d com m u t a t or conn ect i ons of one of t h e ori g na l

coi l s a s i n di ca t ed i n s ect i on ( E ) of t h e i ll us t r a t i on H e re t w o p u c. ma r s i n d i ca
te k
t e rm i n a l for coil s i d e i n bo t t om of s l ot a n d on e p un ch m a r k
f or t h e t e r m i n a
l of t h e
coi l s i d e i n t h e t op of t h e s l ot T w o cross es ( X X } i ndi ca
. t es t h e sl ot i n w h i ch t h e coil
si d e is a
t the a n d on e cr oss ( X ) t h e s l ot i n w h i ch i t i s a
bot t om t t h e t op Wh e n t h e
.

ce n t e r l i n e of t h e coi l i s m a r k ed on t h e d r a w i n g t o s h ow w h et h e r i t fa l l s on aco m m u t a t or
ba r or a m i cat h e com m u t a
. t or ca n be r e m ov e d a n d r epl a ced t o l i n e u p wi t h t h e ori g i n a l
ma r ki n g s For ot h e r d e t a
. i l s of d e t e rm i n i ng t h e co m m u t a t or t h r ow es pe ci a
, l l y wi t h
de a d coi l s s ee Pr a c t i ca l M et h od f or L oca t i ng Fi rs t C onn ect i on t o C om m u t a t or f o r a
“
,

Wa v e W i n di n g on p a g e 1 05 S e ct i on ( D ) of t h e a
. bov e i ll us t r a t i on s h ows t h e us e of t h e
di a g ra m f or m a r k i n g t h e coil t h r ow of al a p w i n di n g S e ct i on ( A ) i s fil l ed ou t t o i n
.

d i ca t e i t s us e i n s p e ci fy i n g n e w coi l s f or awa v e wi n d i n g .
 A R M A TURE WI N DI N G A N D M OTOR RE P A I R

at orch a n d ea ch s lot fil e d to re move a ny bu rrs or r ough pl a ce s .

The n cle a n t h e co re thor oughly w i th a bla s t of compre s se d a ir .

Th e co re i s n ow re a dy for i t s i n s ulat ion a n d ane w w i n d i n g .

De ta il s are g i ve n i n t h e follow i n g p a ra g r a ph s f or i n s ul a
t in g
an d w in di n t h e d i ff ere n t type s of a rm a tu res a cco r d i n g to t h e
g
type s of slot s us e d a n d t h e re qui re m e n t s of d iffe re n t s iz e s a nd

type s of m a ch in e s .

I . W I N DI N G D .
- C . AR M A TU R E S H A VI N G P A R TI A L L Y C L OS E D
S L OT S

Di re ct curre n t moto r s of t h e i n du str i a

- l type in s iz es of
from on e to fiv e horse power a re oft e n bu i lt w i th p a r ti a lly
clos e d s lot s Whe n win d i n g t h e a
. rm a ture of s u ch amotor a ,

wi re wo un d thre a
-
,
de d i n coi l i s u se d P ra- ct i ca l de ta i l s for .

r e w in d i n g a n a rm a ture of th i s k i n d wi th re comme n d a t i on s
for t h e i n s ul a ti o n of slo t s a n d te s t i n g a s outl i n e d by G I . .

St a de ke r i n t h e E l ectri c J ou rn a l V ol V I I N o 7 a re gi v e n i n
,
.
, .
,

wha t follows :
Wi n di ng aTh re a d e d i n C oil E a ch compl e te co i l i s u s u a
- .
—
lly ,

woun d wi th from on e to four s e pa ra te wi re s double cotton

cove re d on as pe ci a
,
l form or mould Whe n w i n d i n g t h e co i l .

t h e two or mo re w i res a re he ld toge the r i n t h e h a nd a n d wou n d

a s on e w i re S u ch aco i l i s the n m a
. de up of two or more
Se pa ra t e co i ls a n d the re w i ll be a s ma n y be g i n n i n g e n d s or
‘

te r m i n a ls an d fi n i s h e n d s to t h e co i l a s the re a re w i re s in -

ha n d whe n w i n d i n g E a ch of the se e n d s or te r m i n a
. l s should
be pr ov i d e d w i th a n e x tr ai n s ul a ti on in t h e fo r m of wove n
cotto n s l e e ve s As a .n a i d wh en co n ne cti n g t h e te rm i n a ls to
t h e commut a to r s le e ve s of d i ffe re n t color s s hould be u se d
,
.

For acoi l woun d w i th th re e w i re s bl a ck wh i te a n d r e d s l ee ve s

, ,

ca n be u s e d Th e s a
. me color of s le e ve mu s t be us e d on t h e
s ta rt a n d fin i s h e n d s of e a ch of t h e w i r e s u s e d i n w i n d i n g t h e

co i l . T o ma ke sure of thi s two s le e ve s of t h e sa ,

me color
s hould be s li pp e d ove r e a ch w i r e befo r e b e g i n n i n g to w i n d t h e

co i l . Whe n s ta r t i n g to w i n d t h e co i l on e se t of t h e cotto n ,

sl e e ve s s hould be s l i pp e d dow n to t h e e n d of e a ch w i r e a nd

a djust e d to re a ch a bout th re e qua r t e r s of a n i n ch a

- lo n g t h e
body or s lot s i d e of t h e coil Th e othe r se t of cotto n s le e ve s
.

ca n h e s li pp ed b a ck a lo n g t h e wi re s a s t h e co i l i s b ei n g wou n d .
62 A R M A T U RE WI N DI N G A N D M OTOR R E P A I R

vi dua l s tr a n ds m a y b e fo r ce d i n to t h e s lot w i th a fla t fi b e r

dri ft A s e a
. ch co i l i s put i n pl a ce t h e lowe r le a ds should be
i n se rte d i n t o t h e sli t s of t h e prope r commu t a t or b a rs ca re ,

be i n g t a ke n th a t t h e difie re n t colored le a ds a re con n ecte d

'

a lw a ys i n t h e sa me orde r ( For de ta . i l s of con n e ct i on s for

la p a n d w av e w i n d i n g s s ee
, C h a pt e r
“
M a k i n g C o nn e ct i o n s

to t h e C ommut a tor pa , ge
A ft e r a ll t h e co i ls a re i n pos i t i o n in t h e bott om s of t h e s lot s ,

t h e p r o t e cti n g e dge s of t h e i nn e r ce ll e n clo s i n g t h e low e r

co i l s i d e s hould be d r a wn up a s fa r a s t h e coi l si d e w il l a llow ,

the n cut off close to t h e slot a n d folded i n . Wi th afibe r drift

a nd ma lle t for ce t h e wi res a n d ce ll i n t o pr ope r po s i t i o n i n

t h e low er h a lf of t h e slot in orde r to m a ke r oom for t h e

uppe r coil si de Th e un protecte d w i res of t h e coil whi ch cr os s
.

t h e e n d of t h e co re s hould n ow be ta pe d up w i th cotton ta pe
for a bout t wo thi r ds of the i r le ng th st a
-
, rt i n g up clo se to t h e

co re a n d e n clo s i n g t h e e n d s of t h e lowe r ce ll s whi ch p r oj e ct

,

from t h e slot .

S t ee l d ri vi ng
sl id e

FI G . 56 —
. D e vi ce for dri vi n g w ood a
nd fibe r w e d g e s i n s l ot s .

Whe n re a dy to i n se rt t h e top si des of t h e coi ls t h e uppe r ,

ce ll s of tre a te d cloth should be i n se rte d i n t h e slot s pre fe r a bly

on e a t ati me N ow fa
. ce t h e commut a tor a n d cou n t t h e

throw a l re a dy ca l cula te d for t h e w i n d i n g i n acoun te r clo ckw i s e -

di re ct i on from t h e firs t slot pre pa re d w i th i t s i n s ul a

t i n g ce ll ,

in or d e r t o de te r mi n e wh i ch coi l s hould go i n to th i s s lot Th e .

prope r coi l s hould the n be be n t i n to s ha pe i t s str a

,
n ds wa x ed

a n d i n s e r te d i n t o t h e slot Th e e dge s of t h e p r oj e cti n g ce ll

.

ca n n ow be cl i ppe d a n d fold e d i n a n d ha mme re d ti ghtly in to

pl a ce w i th t h e m a lle t a n d d r if t T he n dr i ve i n afibe r we dge
.

over t h e co i l by u s i n g awe dge d ri ve r su ch a s s hown i n Fi g 56 . .

Th i s co n si s t s of ahollow re ct a n g ula r pi e ce of s t ee l fitte d w i th a

s l i d i n g s tee l s t r i p a bout t h e s a m e si ze a s t h e we d g e Th e w e dge

.
 ,

RE WI N DI N G B I R B On oU R R E N T A R M A T U R E S

is i n se rte d i n t o t h e d ri ver , i t s e n d be ve le d a
n d for ce d i n to t h e

s lot by t a ppin g on t h e s te e l s tri p of t h e dri ve r wi th am a llet .

t in g Ove rl a
I n s ul a i E nd C onn e cti on s of C oil s A ft e r
a
pp gn —
.

t he we dg e h a s be e n d ri ve n i n t a ke api e ce of cotton t pe a
, nd

wr a p firmly a r oun d t h e co i l a n d t h e pr oj ecti n g t i p of t h e we dge

clo se up a ga i n s t t h e core a n d co n ti n ue t o t a pe up t h e e n d con

'

n e ct i on of t h co i l to t h e po i n t wh e re i t w a s i n s ul a t e d f rom
e
t h e bottom upw a r d wh e n t h e oth er s i d e wa s pl a ce d i n t h e

bottom of t h e s lot Glue t h e e n ds of t h e ta

. p e where the y
mee t .

Whe n two or three of t h e top si de s of coi ls ha ve bee n pl a ce d

i n po si t i o n in s ert one or mo re s tr i ps of t rea

,
te d du ck
be twee n t h e e n d con n e cti on s of t h e uppe r a n d lowe r co i l s

whe re the y cross e a ch othe r a t ea ch e n d of t h e a r ma ture .

A s t h e re ma i n i n g uppe r s i d e s of t h e co i ls a re pla ce d i n t h e

s lot s,
these str i p s s hould be wou n d a roun d t h e a rm a ture
s o th a t they fin a lly for m acomple te b a n d of i n s ul a ti o n b e twee n
t h e uppe r a n d low e r co i l s E a ch co i l a s i t i s fin a lly pla ce d
’

s hould be s h a pe d a t i t s e n d s w i th am a lle t a n d fib er dr ift s o

i
tha t on e coi l fit s s nugly a ga i n s t t h e othe r a n d there i s a

ri gi d co n s t ru cti o n whe n t h e a rma ture i s comple te d .

C onn e ct in g Fi ni s h E n d s of C oil s t o C o m m u t a t or Th e .
—

e n d s of t h e uppe r s i de s of t h e co i ls ca n n ow be co nn e cte d to

t h e commut a tor u si n g ate s t la mp C on n e ct t h e colore d le a

i n pr ope r o rd e r a s e x pl a ine d on p a
C o n n e ct i o n s to t h e C ommuta
”
tor
. ds
ge 1 01 u n der M a kin g
B e fo re s old e r i n g t h e
.

co i l e n d s t h e e n ti re w in di n g mu s t be te s te d for groun d s
,

wi th p rope r volta ge a n d f or s ho rt ci r cu i ts a n d op e n ci r cui t s .

( S e e p ag e 1 22 u n d e r t h e h e a d i n g of T e s t i n g A r m atu r e W i n d
I f n o fa ults a r e d i s cov e r e d t h e e n d s of t h e co i ls ca n be

s old e re d to t h e comm ut a tor a n d t h e la tte r tu rne d a n d fi n i s he d

wi th s a n dp a pe r Th e a . r ma ture i s n ow re a dy f or b a
.
n di n g .

Loop Wi n di n g s for S m a l l M ot or s S ma ll di re ct curre n t

— -

a rma tu res for fa n mo t ors a n d ge ne ra l uti li ty use a re oft e n

,

woun d by h a n d u s i n g wh a t is s ome ti me s ca lle d aloop wi n di n g .

I n t h e ca se of a2 pol e a -
r ma ture ha vi n g 1 5 slots a n d 1 5 com

mut a tor ba rs s u ch aw i n d i n g m i ght be m a

,
de up a s follows

Wi n d slots N os 1 a .n d 8 ha lf full usi n g double cotto n cove re d

,
-

wi re l e a
, vi n g t h e e n ds al i ttle lo n ger the n n ee de d to con ne ct t o
 RE WI N DI N G DI R E C T- C U R R E N T A R M A T U R E S

t he ommuta
c tor a n d w i thout cutt ing t h e wi re w i n d as i mil a r

co i l i n s lot s 2 a nd 9 a n d b r i n g out ase co n d loop P r o cee d .

i n thi s w a y t h r oughout a ll t h e p a i rs of n e ar ly oppo s i t e s lo t s

un ti l on t h e se co n d roun d t h e slot s a r e compl e t e ly fill e d wh e n

t h e be g i n n in g a n d t h e e n d of t h e w i re ca n be tw i s t e d toge th e r

for t h e 1 5t h loop C otton s le e ve s ca

. n n ow be i n se r te d ove r

t h e loop s a n d co nn e cti o n s m a de to t h e commut a tor Fi gs . .

57 to 59 s how a n arma ture b e i n g wou n d by thi s me thod .

I n t h e i llu s t ra ti on s t h e n e ce ss a r y i n s ul ati on on t h e s h a ft close

to t h e core a n d on t h e co re a t t h e e n ds of t h e slots is s how n .

Th e s lot s s hould be i n s ul a te d i n thi s ca s e w i th he a vy fis h

pa pe r a bout 1 0 mi ls thi ck .

Ba n di n g aS m a ll D C - A rm a t ur e
. Wh e n a
. pplyi n g t h e
.
—

ba n di n g w i re t he a rma
,
ture s hould be i n se r t e d i n ala the .

FI G . 60 .
-
D i ss e m bl e d v i e w of as m a
ll di r e ct -c u rr e n t m ot or s h ow i n g ba
n de d

a
rm a
t u re (Fi de l i ty E l ectri c C om p a n y)
.

Th e firs t ope ra ti on i s to ha mme r down t h e e n d s of t h e co i l s

un ti l the ir d i a me t e r at t he a rma ture e n d s i s n o gre a te r tha n

tha t of t h e core E x t re m e ca . re mu s t be t a ke n n ot to i n ju re
t h e i n s ulat i o n wi th t h e ma lle t A s ab a s e for t h e b a
. n di n g

wir e s two b a,
n d s of co t to n t ape s e parate d by ab a n d of v a r

n is h e d p ape r s hould be wou n d ove r t h e e n d con n e ct i o n s n e a r

t h e co re a n d t h e whol e t ie d dow n w i th s e ve r a l laye rs of twi n e .

Short s tr i ps of t i nn e d co ppe r a bout by i n ch in cr os s

5
66 A R M A T URE WI N DI N G A N D M OTOR R E P A I R .

se c ti o n s hould be s li ppe d u n der t h e te mpora ry b a n d i n g tw i n e

a t i n terva ls of two or three i n che s wi th two ex trao n e s use d

whe re t h e ba n d i n g w i re i s st a rt e d a n d e n de d For t h e b a
. n di n g

wi re of s ma ll a r ma ture s N o 1 4 to N o 1 7B
. . S ga . uge ti n n e d .

s tee l w i re ca n be u se d Th e s t a
. rt s hould be fa s te n e d to a p g
e

s l i ppe d i n to a n a i r du ct or fa s te n e d to t h e en d of t h e b a n di n g

twi n e a n d t h e fir s t l a ye r gu i de d s o tha t i t crosses i t se l f to

re l i e ve t h e s t r a i n on t h e e n d fa s te n i n g A ft er two or th re e
.

re volut i o n s of t h e b a n d w i r e t h e te mpo r a ry b a n d i n g tw i n e

ca n be cu t off a n d t h e ba n d i n g w i re wou n d on t i ghtly a cr o s s

t h e p r ote ct i n g t a pe A fter t h e re qui re d wi dth h a

. s be e n

woun d t h e coppe r s tri ps a

, t t h e st a rt e n d s hould be tu rn e d

up a n d cl i ppe d off s o th a t a bout on e q u a r te r i n ch pr oj e ct s

-

from un de r t h e b a n d i n g w i re Th e n ben d t h e s t ri p s ove r to

.

hold t h e b a n di n g wi r e i n po s i t i o n .

Wi thout cutti n g t h e b a n d i n g w i r e i t s ho ul d be gu i d e d a
, cro s s

t h e co re to t h e oppo s i t e e n d of t h e a r ma ture a n d wou n d i n t h e

sa me m a n ner a s b e fo re to w i th i n a bout aqua r te r of a n i n ch

of t h e e dges of t h e e n d con n e cti on s Th e cli ps a . t be g i n n i n g

a n d e n d ca n n ow be be n t ove r a n d s olde re d Th e ba n di n g
.

wir e s on both en ds of t h e a rm a tu re s hould n ow be dri ve n up

clo s e tog e th e r a ,
l l t h e cl i ps be n t ove r a n d t h e w i re s s olde re d

toge the r I n t h e s olderi n g of b a

. n d wi r e s n o a ci d s hould be

us e d A s oluti o n of ro si n i n a
. lcohol i s re comme n de d A fte r .

t h e s olde ri n g ope r a t i o n i s comple te d t h e s ur plu s turn s a nd

cr o s s ove r s of t h e b a n d i ng w i re ca n be cu t off Th e a rm a
. tu re
i s n ow comple t e d ex ce pt for t h e b a la n ci n g ( S e e p
. ag e 1 5 0
un der t h e he a di n g of B a la“
n ci n g a n A rma ture ) ”

II . WI N DI N G D -C . . A R M A TUR E S HA VI N G OP E N S L OTS

M oto rs i n a bove five hor s e power tha

z
si e s t na ve a rm a ture
co r e s w i th ope n s lot s m ay b e wou n d w i th co i l s m a d e up of w i re

or of copp e r s t r a p Th e coi l s m a
.
y be of t h e fo r m wou n d o r

p ul l i n type s but a re fully i n s ul ate d be fore b e i n g i n se rte d i n to

t h e s l ot s I n ge n e r a
. l two type s of ope n slot s a r e fou n d on e ,

w i th we dge gr oove s i n t h e t 0p of t h e slot i n wh i ch we dge s ca n

be d ri ve n to h old t h e coi l s i n po s i t i o n ; wh i le t h e othe r i s as lot

wi th smooth si de s re qu i ri n g ba n d i n g w i r e to hold t h e co i l s i n
'
 RE WI N DI N G DI R E C T- C U R R E N T A R M A T U R E S 67

pla ce Groove s a
. re u s u ally provi de d on t h e a r ma ture for
ba n ds in a ddi t i on to t hos e ove r t h e e n d con n e ct i on s V e ry .

ofte n t h e sa me a r ma ture core wi th ope n slots i s used for d iff e r

e n t types a n d s i z e s of m a chi n e s Th e co i ls m a th e re fo be
y . r e

s ma ll e r in s ome ca se s th an t h e ori gi n al on e s an d do n ot fill t h e

s lot s . I n the se ca se s fillers mu s t be u sed to fill out t h e s i de s

a n d b e low t h e co i l s i n t h e slot s o tha t t h e we dge s or b a n d w i re

F1 a 61
. .
—
Di re ct -curr e n t arm at u re s h o wi n g d u ck or a a
c nvs pa
d h e l d by
cor d a g e on ri n g w hi ch s u p p ort s coil s

T h is i ns ul at i on i s us ed t o pr e v en t c oils f r om ru bbi n g on t h e f r a m e a n d g i v es al a r g er

ni a r of s a fe t y a g a
xn s t g r ou n ds S l ot i ns u l a
t i o n m a
d e of t r e a
t e d p r es s boa r d 1 s s h o w n
a rat ors be t w e e n coi l s i n e a ch s l ot a a
r e m d e of t h e s a me m a t en a l bu t a
.

li t t le
.

i n p ce
k
t hi c er ( R ot B r ot her s A: C om pa
.

n y) .

wi ll pres s fir ml y on t h e t op of t h e coil s a n d p re ve n t a n y p os

si bl e mot i o n of t h e co i l s i n t h e s lot s th a t wi ll re sult i n cha fin g

a n d da ma ge to t h e i n s ula ti on Fi lle rs mo st u se d con s i st of
.

stri p s of t re a te d fulle rboa r d or t re a te d wood I f aco i l i s .

on ly s li ghtly loose i t i s be tter t o a dd i n s ul a t i on to i t .

Wi n di n g a n d I n s ul a
ti n g C oil s I n ca se co i l s mu s t be wou n d
—
.

fo r a p ar t i cul a r job p r o ce e d a s outl i n e d u n d e r t h e h e a

d i n g
 WI N DI N G R
“

68 A R M A T UR E
'
A N D M OTO RE P A I R

of Fo rm s f or Wi n di n g C oi ls on pa
“
ge 1 4 1 I n re wi n di ng
, .

aba r wou n d a rma ture i t wi ll se ldo m be n e ce ss a

, ry to for m n e w

co i l be ca u ea ch co i l con s i s t s of a s i n gl e tu r n of h e a vy opp
s , se c e r

s t ri p wh i ch i s n ot a
,
s ea s i ly d a ma ge d a s a re w i re wou n d co i l s .

I n thi s ca se a l l that wi ll ge n e ra
,
lly be n e ce ss a ry i s t o re in s ula
te
t h e co i l s and t he a r ma ture core Whe n a ll t h e co i l s h a
. ve bee n
woun d they should be cove re d wi th cotto n ta
, pe a bout three

FI G . 62 —
Ar m a
t ur e . a aa
m Fi g 6 1 wi t h ap r t i l l p w i n di n g i n p l ce
sh ow n a .

Th e i ns ul a t i on on e n ds of c oi l s a n d m e t h od of i n t e rl a ci n g coi l s s o t h a t t h e y occu py
am i n i m u m am ou n t of s a ce ar e s h ow n C oi l e n ds a re la t e r t o be f a s t e n e d t o s u p p o rt i n g
s p i d e r ri n g w i t h t re a canva k
an d cord a Ba n d w i r es a
.

t s or d u c ge r e w ou n d on core
wi t h s t r i p e s or p a ds of t h i n can va th a
.

s u n de rn e a ft er w i n d i n g 18 com p l et e d ( R oth B r ot her s

( 2: C om p a
,

n y) .

qua r te r i n ch i n w i dth Th e e n d of t h e t a
. pe wi n di n g ca n be

ma de fa s t w i th a p ie ce of thre a d ca ke n t o h a
re b e i n g t a ,
ve t h e
taped e n d on apa r t of t h e co i l th a
t doe s n ot go i n to t h e s lots ,

as t h e t hi ckn e s s of t h e th re a d on e a ch s i d e m a y b e s u ffi ci e n t
to ca u se t h e coi l to s ti ck whi le b e i n g pl a ce d i n po s i t i on on t h e

co r e .Th e fin i s he d co i l s s hould go i n to t h e i n s ula te d slots

wi thout un due dr i vi n g Th e coi ls should n ow be gi ven acoa
. t
 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

is move d fiv e s lot s from t h e bott om s i de of t h e sa

re me coi l .

Th e top h a lf of co i ls N os 1 2 3 4 a n d 5 ( ca. ll e d t h e thr ow

, , , ,

co i l s b e cau se the y cove r ap a rt of t h e a r ma tu re e qua l to t h e

t hr ow of a co i l ) a
re l e ft out of t h e s lot s as s hown a s t h e bottom ,

ha lf of other coi ls wi ll ha ve t o be pl a ce d i n the se s lot s be fo re

t he se top ha lve s ca n be put i n Whe n t h e bottom ha lf of coi l

.

N o 6 i s pl a
. ce d i n s lot 1 1 i t s top s i d e m a y b
, e pl a c e d i n s lot 6 ,

b e ca use t h e bott om s i de of co i l 1 i s loca t e d i n th i s slot C on .

t i n u e to pla ce t h e co i l s on t h e co re t r a ve li n g i n t h e d i recti on ,

i n d i cate d by t h e a r r ow Th e botto m ha . lf of coil N o 7is .

Fro . 63 .
—
M e t h od of pl a
ci n g t h r ow coi l s on the a
rm a
t u re of al a
p wi n din g .

pl a ce d i n s lot 1 2 a n d t h e top h a
,
lf i n s lot 7 B efore i ns e rti ng .

t h e coi ls i n t h e s lots i t i s agood pla n to r u b t h e s i d es wi th

pa ra ffin w a x T hi s h e lps i n i n s erti n g t h e co i ls a

. n d p r e ve n ts

da ma gi n g t h e i n s ula ti o n .

A s t he a r ma ture i s b e i n g wou n d as tri p of hea vy pre s s bo a ,

rd

( a bout i n ch th i ck ) s hould b e pl a ce d i n t h e s lo t s b e tw e e n

co i l s to tho roughly i n s ul a te the m from e a ch othe r Wh e n a ll . l

t h e co i l s h a ve be e n i n ser te d t h e top s i de s of coi ls N os 1 2 ,

.
, ,

3 4 a,
n d 5 ca
,
n be pl a ce d i n t h e s lot s A s ea ch co i l i s put i n .

po si ti on t h e e n d co n n e ct i on s s hould be ca
,
r e fully s h a pe d to
t h e cor e .

S ha i
p g n E n d C o nn e c t i on s T h e e n d co n n e c t i
. o —
n s a re s h ap e d
by me a n s of a wi n di n g dri ft Thi s co n s i st s of as te e l ba
. r a bout
1 2 i n che s lo n g on e i n ch w i de a
,
n d ta pe re d i n thi ckn e ss from
on e h a lf to on e e i ghth i n ch ha
- - vi n g a l l t h e co rn e r s rou n de d
,
 RE WI N DI N G DI R E C T-C U B R E N T A R M A T U R E S

a
n d s mooth .Th e t i p of th is drift s h oul d be pl a ce d aga ins t t h e
i n n e r s i de of t h e e n d con n e ct i o n of t h e co il a
n d ta ppe d w i th a
ma lle t forci n g t h e uppe r pa
,
rt of t h e e n d co nn e ct i o n out from

t he a rm a tu re an d a wa y from t he lowe r ha lf E a ch co i l a
s it
.

h e 6
. 4 —
. Re a r a
'

n d com m u t a to r e n ds of aw a v e -w ou n d a
rm a
t u re u si n g

st r a
p coil s N ot e t h e i n su l a
. t i on of sl ot s a n d t h e i n su l a
t ed su p p or t of r e a
r

e n d con n e ct i on s ( Ge ner al E l e ct ri c C o m p an y)
.

is put pla
in ce ca r ly s h a
n be s i m i l a pe d s o th a t whe n t h e a rm a

ture is comple te ly wou nd acir cula r a ir ch a mbe r i s forme d

be twee n t h e upper a n d low e r h a lve s of t h e e n d con n e ct i o n s a
t
both fron t a n d re ar Th i s pr o ce s s s hould be con t i n u e d un ti l
.

th e firs t slot i s aga i n re ache d .

76 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

Trui ng U p t h e H e a d s of t h e Wi n di n g Whe n t h e wi n di n g
.
—

is comple te d , b e n d t h e l e a
ds ba ck ov er t h e s u rf a ce of t h e co re

so a s to e xp o se t h e he a d of t h e wi n di n g Thi s mus t be true d .

by re volvi n g t h e a r ma ture a n d ma r ki n g t h e h i gh pl a ces w i th

ch a lk The se hi gh s pot s ca n be dr i ve n dow n w i th a ra whi de

‘

ma lle t a n d t h e low pl a
, ce s r a i se d e ve n w i th t h e othe rs Th e .

ba ck h e a d s hould a ls o be ca re fully t ru e d up s o a s to pre se n t a

good a ppe a ran ce whe n run n i n g Tr i m off t h e p roj e ct i n g

.

s lot i n s ul ati on e ve n wi th t h e surfa ce of t h e a rma ture if b a n din g

wire s a r e t o be u se d I n ca . se t h e co i l s are t o be he ld i n pl a ce

by wood or fibe r re t a i n i n g w e dge s l a p th i s i n,s ul a

t i o n dow n

ove r t h e coi l s a n d d r i v e i n t h e w e d ge s I f the a r ma

. ture le a ds
a re n ot cove r e d w i th t a pe the y mus t be p rotecte d in som e
,

ma n n er a n d for th i s cotto n sl e e v i n g ca n be u s e d .

FI G . 73 —
. I n sul at i on of e n d c on n e ct i on s s h o w i n g f ri ct i on cl ot h bl a
n ke t i n

pl ace a t the com m u t at or s ap r ot e c t i o n for t h e l e a

end a ds .

I n s ul t i on a B e t we e n uta C om m
t or E n d C onn e cti ons A .
—

fri ct i on cloth bl a n k e t s hould be pl a ce d ove r t h e e n d co n n e c

ti o n s on t h e commuta t or e n d a s s how n i n F i g
, 73 a s a .
,

prote ct i on for t h e t e rm i n a l s of t h e co ils I t i s good p r a .ct i ce

to s h a pe t h e e n ds or term i n a l s of t h e s i de of t h e coi l s i n t h e bot

tom s of t h e slot s a s s ho w n i n th i s i llu s t r a ti o n a n d to b e n d
’

ba ck over t h e co re t h e t e r m i n a ls of t h e top s i de s of t h e co i ls .

Thi s h e lp s i n a rr an g i n g t h e co n n e ct i on s fr om t h e co i l s in t h e

bottoms of t h e slots whi ch ca ,

n n ow be m a de .
78 A R M A TURE WI N DI N G A N D M OTOR R E P A I R

formed of b a re copper s tra p They a re usu a

. ll y of t h e on e
pi ece or t wo pi ece one turn d ia , m o n d type wi th t h e n um be r
,

of co i ls e qua l to t h e n umbe r of co m muta tor b ars To s e cure .

bes t po s s i ble s p a ce fa cto r a n d for oth e r m ec h a

,
n i ca
l re a s on s ,

s i n gl e co i l s a re O fte n bou n d tog e th e r i n to al a rg e r co i l e a ch ,

s i n gl e te d from t h e othe r a
co i l b e i n g i n s ul a n d e l e ctr i cally
se p a ra te d I n s u ch aca
. s e t h e n umb e r of s lot s i s o n l y a

f ra ct i o n of t h e n umb e r of commu t a tor ba rs .

FI G 74
. .
—
La
p -w ou n d a
rm a
t u re u si n g a a
t wo-p r t s t r p coil s . N ot e t h e
fo u r la
y e rs of i n s u l at i o n be t w ee n e n d c on n e c t i o n s at c om m u t at or e n d (Gen e r a
l
E l ect ri c C om p a n y) .

Th e m ethod of i n s ula t i n g thi s type of coi l de pe n ds upon

t h e s i z e volt a
,
ge a n d ope ra ti n g co n di ti on s of t h e ma ch i ne and

on t h e n umb e r of s i n g le co i ls compo s i n g a co m pl e t e co i l .

Whe n the re a re l ess th a n fou r s i n gl e co i ls pe r compl e t e co i l ,

t h e e n d s of e a ch s i n gl e co i l a re ta p e d wi th on e la yer of cotton
ta pe ha
,
lf ove rl a ppe d Thi s ta. p i n g e xt e n d s asu fficie n t di s
ta n ce a lo n g t h e s tra i ght p a rt t o a s s u r e th at t h e j o i n t be twe en
it a n d t h e r e s t of t h e i n s ul a ti o n w i ll be we ll pr ote cte d Th e .

s t ra i ght p a rt s a re th e n w r a ppe d wi th afis h p a pe r a n d m i ca

wra p pe r i n t e rw ove n be twee n t h e s tra ps i n s u ch am a nner a s to

,

furn is h i n s ula ti o n be twe e n t h e s i n gle co ils a n d the n w

,
ra ppe d
se v e ra l ti m e s a roun d t h e compl e te co i l t h e ex a ct n umber of
,
 RE WI N DI N G DI R E C T-C UR R E N T A R M A T UR E S 79

turns de pe n d i n g on t h e si z e volt a ge a n d ope ra

, tin g con di ti on s
of t h e ma ch in e .
( S ee C o i l I n
“
s ul a t i o n p a g e s ,
1 6 3 to
Whe n the re a re fou r or mo re si n gl e co i l s per comple t e

co i l a
,
lte rn a te s i n gle coi ls s hould be wra ppe d wi th on e tur n
Of fish p a pe r a n d m i cah e ld i n pl a ,
ce by a n on ove r l a ppi n g la
-
ye r
of cotton ta pe Th e s i n gle coil s a
. r e the n a s se mble d a nd a

ce ll of fis h p a pe r a n d m i ca wr a ppe d over t h e whole Th e co i l .

s hould th e n be t a pe d wi th ala ye r of cotto n t a pe n on over ,

-

la ppi n g ove r t h e wr a ppe r a n d ha l f la ppe d over t h e e n ds .

The n b ru s h w i th or di p i n abl a ck fin i s h i n g va rn i s h a nd a ir
dry . A fte r thi s di p tw i ce i n i n s ul a ti n g va rn i s h a n d dry i n

a n ove n for twe lve hours a fte r e a ch i mm e rs i o n B e fo re .

t h e co i l i s u se d i n t h e a rma tu re t h e le a d s s hould be cle a

,
ne d

of i n s ula ti o n a n d va rn i s he d a n d tho roughly t i n n e d .

La p an d W a ve W i n d i n g s f o r L a r g e A r m a t u r e s I n .t h—
e

ma in t he sa m e con di ti o n s outli n e d on p a ge 1 1 2 u n d e r t h e
he a di n g Wa “
ve L a p v s D i r e c t c
. u r r e n t W i-
n d i n g s
”
a pply i n

t h e ca se of l a rg e a rm a ture s T h e wa ve w i n d i n g h a
. s t he

de ci de d a dva n ta ge howe ve r th a
, t n o cro s s co n n e cti on s a
,
- re

re qu i r e d . I t ha s th e r e fo r e a
,
wi d e u s e i n ma
,
chi n e s wh e re t h e

s i z e Of co i l r e qu i r e d do e s n ot b e com e e x ces s i v e n or t h e volt a ge

be twee n commuta tor se gme n ts too gre a t to p e rm i t of good
commut a ti o n U n d e r o r d i n a
. ry co n di t i o n s t hi s co n si d e r a ti on
li mi ts t h e w a ve wi n di n g to four or s i x pole m a -
ch i n e s Wh ere .

t h e n umb e r of pole s i s g re a ter t h e l a p w i n d i n g s e e m s to s u i t

t h e co n di t i o ns of go od Op e r a t i o n b e s t Wi th thi s wi n di n g
.

t he volt a ge be twee n se gme n ts i s ke pt dow n a n d h i gh co n du e

t i vi t y t h r ough t h e a rm a ture i s ma de possi ble wi thout u si n g

co i ls of l a rg e cr o s s s e ct i o n s
- For both l a.
p an d w a v e w i n d i n g s ,

on e pi ece coi l s ca
- n be u s e d but atwo pi e ce or h a
, lf coi l h a s

s ome a dva n ta ge s i n th a t le ss s ki ll i s n ee de d t o wi n d t h e
a rm a ture a n d t h e co i l s a re e a s i ly r e p a ir e d i f t h e d a ma ge i s onl y
to t h e top h a lf Th e ha
. lf coi l howe ver ca lls for as oldere d
joi n t a t t h e re a r of t h e a r ma tur e whi ch mus t be ma de wi th
gr e a t ca re .

I n s ul at i n g t h e C or e B e fore s t a
.
—
r t i n g t h e w i n d i n g Op e r a t ion
t h e core s hould be tho r oughly cle a n e d wi th a n a i r bl a s t thu s ,

re mov i n g a n y i r o n fili n g s or oth e r fo re i g n m a tte r from t h e

slot s . Th e commut a tor n e ck s must the n be ca re fully e x
 80 A RM A TUR E WI N DI N G A N D M OTOR R E P A I R

a
m i n ed tha t a
t o see ll a re s t rai ght a n d tha t t h e ope n i n gs a t
t h e top a re w i d e e n ough to a dm i t t h e co i l le a ds ea s i ly Te s t .

t h e commut a tor for b re a kdown to groun d a n d for s ho r t ,

ci rcu i t be t wee n s e gm e n t s w i t h t h e s t a n da r d tes t volt a ge for

‘

t h e ma chi n e ( S ee
. C h a
pt e r V al s o p ag e ,
A ll p a
r t s of
t h e s p i d e r wh i ch com e i n co n t a ct w i th t h e co i l s s u ch a s co il ,

s uppo rts e t c ,s hould be ca

.
,
re fully i n s ul a t e d wi th e i ther t a pe ,

FI G . 75 —
. M e di u m d h ea
-s i z e v y du t y a rm a t u re s h ow i n g u se of s t r a
p coil s
f or aw a
ve wi n di n g ( Wes ti n g h ous e E l e ctri c cf: M fg . C om p an y) .

fulle rboa r d ch an n e l s or two or thr e e th i ckn ess es of fis h pa

,
pe r
s tr i p s Whe n ta
. p e i s u s e d i t i s w rappe d i n ove rla pp i n g la yers
ove r t h e e n tire s upport A t t h e poi n t whe re t h e s pu rs whi ch
.

hold t h e coi l s uppor t i n pos i t i o n pre ve n t wi n di n g on t h e t a pe ,

t h e ir o n s houl d be cove r e d w i th i n s ul a ti n g cloth a n d he ld i n ,

pla ce by t h e t ape on e a ch s i d e E ach l aye r of t h e t a

. pe sh ould
be s h el l a ce d a s i t i s wou n d Whe n fulle r boa .r d s t r i ps are

u sed t h e firs t la
,
yer i s fre quen tly s cre we d to t h e i ron to pre
ve n t la te ral moti o n Othe r l a ye rs a
. re sh e ll a ce d over th i s ,
82 A R M A T UR E WI N DI NG A N D M OTOR R E P A I R

a
ll t he o ils h a
c ve on e s i d e i n pl a ce i n t h e s lot s Th e uppe r .

s i d e s ca n the n be d r i ve n i n to pl a ce i n r e gul a r o r de r A s in .

t h e s ma l l e r w i n d i n g s t h e upp er a
,
n d low e r co i l e n d s or te rm i

na l s s hould be se pa ra te d w ith b a n d s of o i l e d du ck or d r i ll i n g .

Wi th on e p i e ce co i l s th i s s hould be th re a
,
de d i n to pl a ce as t he

co i ls a re i n se rt e d i n t h e upp e r p a rt of t h e s lot s Wi th two .

p i e ce co i ls i t i s s i mply woun d over t h e lower se t of co i l s b efore

t h e othe rs a r e pl a ce d i n t h e s lot s .

FI G . 77
. C or e o f al a rm a
rg e a t u re s h ow i n g co n s t ru ct i on for g ood vent il a
t i on
(Ge n er al E l e ctri c C om p an y ) .

Th e oil s mu s t be aclos e fit i n t h e s lot s i n or de r to p re ve n t

c ,

a n y po s s i b il i ty of ch a fi n g I f n e ce s s ar y s tr i p s of full e r bo a
.
,
rd

or t r e ate d wood s hould be i n se r te d a t t h e s i d e s or bottom of t h e

s lot to m a
, ke t h e coil s ati ght fit A s e a ch top co i l i s put i n
.

pla ce i t s hould be d r i v e n i n to t h e s lot t h e p r ot e ct i n g ce ll s the n

,

cu t off a n d fold e d ove r i t

, an d fib er w e dg e s d r i v e n i n to t h e
,

w e dge gr oove s Th e s lots on ala . r ge s i z e d m a ch i n e a r e too

-

lo n g to a llow on e we dge to be u s e d s o tha t on e or more mus t

,

be d ri ve n i n from e a ch s i d e of t h e s lot t o fu r n i s h compl e t e

p rot e ct io n for t h e fa ce of t h e co i l Th e a rm a tur e s hould the n

.

be te s t e d for gr oun d s b e fo re t h e co n n e ct i o n s a
,
r e s old e r e d .

A fte r t h e w i n d i n g i s compl e t e d t h e a rm a ture m a, y b e b a n d e d

tem pora ri ly a t both en d s Th e n dr i ve wood e n w e d g es loo sely
.
 RE WI N DI N G DI R E C T-C UR R E N T A R M A T U R E S 83

i n b e twe e n t h e commut a t or n e ck s , a ll arou n d t h e a rm a ture t o

i ns ur e e ve n s p a ci n g A fte r th i s dr ive th e m i n ti ghtly, t o
.

fo rce t h e n e ck s a n d co i l e n d s i n to t i ght co n t act a n d hold the m

r i gi dly i n pl a ce Wi th two pi ece co i ls , co nn ecti n g cli ps a

- . re .

pla ce d ov e r t h e l e ads a t t h e re a r e n d, a n d w e dg e s dri ve n i n

be twee n the se i n t h e sa m e ma n n er Th e co n n e ct i o ns to t h e
.

nec ks a n d t h e re ar e n d co nn e ct i o n s if a re us e d ca
ny a n be, ,

s old ere d Th i s s olde ri n g s hould be do n e on t h e si d e of t h e

.

FI G . 78 .
—
L a
rg e di re ct -cu rr e n t e n g i n e t yp e a
rm at ure s h ow i n g m e t h od of
v en t il at i on ( Wes ti ng h ous e E lectri c d: M fg C om pa
. n y) .

ma ch i n e in s t e ad of t h e top a s ab e tte r jo i n t ca
,
n be m a de i n
th i s ma n n er an d th e re i s l e s s l i a
,
b ili ty of t h e m elte d solder
ru n n i n g a lon g t h e n e ck s a n d s ho rt ci r cu i t i n g t h e commuta
— tor
se gm e n t s .

B e fo re re mov i n g t h e we dg es t h e a rm a ture s houl d be m oun te d

i n al a th e or if n o s u i ta
,
ble l a the is a va ble in i t s b e a
il a ri n g s
,

wi th t h e fie ld fra m e r e move d a n d t h e s old e r e d co n n e ct i on s

,

turn e d down I f t h e a rm a
. tu re i s moun te d i n i t s be a r i n gs a ,

s ui t a ble tool hold e r mu s t be fa s te n e d to t h e fra me or some ,

ri gi d s uppo r t Th e commut a . tor m a y th e n be tu r n e d dow n an d .

g i v e n i t s fi n al pol i s hi n g at t h e s am e t i m e N e w k n o.ck o u t t h e
84 A RM A TUR E WI N DI N G A N D M OTOR R E P A I R

w e dge s from b e twee n t h e le a ds a n d rou n d off t h e s h a

,
rp cor

n ers w i th afil e Whe n t h e b a

. r e copp e r i s n ot covere d w i th

i n s ul a ti n g m a
t i on i n s ula , te ri al ca n be i n serte d b e twee n t h e

a dj a ce n t l e a
d s to pre ve n t a cci d e n t al con ta ct A t t h e rea r .

e n d th i s u s u a
, lly ta ke s t h e form of a s b e s tos t ape whi ch ca n be

i n t e rw ove n b e tw e e n t h e l e a ds or of ca n va s h oo d s se we d i n ,

pl a ce A t t h e fro n t e n d t h e n e ck s m a
.
,y b e se p a
r at e d at
t h e top s by s tr i p s of he a vy fish p a pe r b e n t ove r t h e tops of t h e ,

l ea ds so a s to be h e ld i n pl a ce by t h e b a n d wi re s Where t h e .

FI G . 7
9 .
—
La
r g e di re c t -c urr e n t e ng ine t y pe rm a
a t u re pa rt l y w ou n d wi t h
str a
p coi l s ( Wes ti ng hou s e E l ectr i c dc M fg . C om pa n y) .

nec ks a re qu i t e lo n g add i t i o n al s e pa
, ra to r s m a y b e i n se rt e d
ha lf wa y up f r om t h e commut a to r T h e s e m a
y b e .i n t h e fo r m
of fib e r butto n s or m a y m e r e ly c o n s i s t of h e a
vy tw i n e i n te r ,

wove n b e twe e n t h e lon g commuta tor n e ck s .

Ba n di ng Wi r e Ba n d s of s t ee l w i re a
.
—
re o r d i n a r i ly pl a ce d

over both e n d s of t h e a rm a ture a n d fre qu e n tly a ,

n oth e r ove r

t h e conn e ct i o n s to t h e commut a tor n e ck s N o b a n d s n ee d be .

u se d over t h e s urfa ce of t h e co r e a s t h e w e dge s a r e s u ffi ci e n t to

,

re t ai n t h e body of t h e co i l s i n pl a ce Th e co i ls ca n be pro
.
;
 RE WI N DI N G DI RE C T-e UR R E N T A R M A T U R E S 87

p loop a
O en n d th e n a ppli e d t o t h e a rm a ture I n ma kin g t h e
.

fin al con n e cti on t h e s pe ci a l cl a mp s hown i n Fi g 82 is n ee de d . .

Th e two j a w s of th i s cl a mp gri p t h e e n ds of t h e b a nd a n d by

me a n s of t h e ha n dl e who s e low e r e n d i s fo r m e d i n to a ca m th e ,

jaws ca n be fo r ce d tog e th e r s o a s to i n te r w e a
ve t h e loops of t h e
ban d w ire a n d pe rm i t t h e s te e l k e y B to be i n se r te d I n thi s .

ope ra ti o n t h e cl amp ca n be h e ld i n a n y po s i t i o n by i n s e rt i n g

FI G. 83 . L
—
ar g e d i r e ct - rm a
cu r r e n t a t u re p a r t l y w ou n d wi t h s t r a p coil s .

N ot e t h e i n s u l a
t i n g s t ri p s be t w e e n e n d con n e ct i on s a n d d ou bl e i n s u l at i on i n
sl ot s ( C r a
cker-Whe eler C om p a n y)
.

t h e pi n A th rough t h e mova ble ja w a n d bea m For other .

de t a i ls of b a n di n g s e e C h a pte r V I p a g e 1 46‘

.
,

Ba la n ci n g La r g e A rma t ur e s A fte r t h e a
.
—
rm a ture i s ba n de d

i t i s re a dy for b a la n ci n g S ui t a
. ble b a la n ci n g w a ys m a y co n

sis t of h e a vy s te e l b e a m s wi th poli sh e d s te el pla te s moun te d

on th e i r upp er e dge s Th e s ur f a
. ce of t h e po l i s h e d pl a te s
mus t be a ccu r a te ly leve le d Th e s h a . ft s hould re s t on t h e
i n n e r s u rf a ce of apoli s h e d s t e e l r i n g wh i ch i n tu r n res t s on
,

t h e po li sh ed pl a te s I n thi s wa
.
y a n a lm o s,t f ri ct i onl e ss
88 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

bea ri n g s u rf ace i s obt a in e d a nd the a rma , ture ten d s to roll

un til t h e h ea v i es t part i s a t t h e bottom M e lte d le a d ca
. n be

poure d i n to re ce s se s i n t h e s pi der or ca s t i r o n w e i ghts bolte d

,
-

to t h e S pi de r a rm s t o co rre ct a ny un ba la n ce d co n d i t i o n u n ti l ,

t he a rm a ture wi ll l i e wi th a n y pa rt uppe r mo s t Th e a rm a tur e .

should th e n be tho r oughly cle a n e d w i th a n a i r bl a st a nd

FI G . 84 .
—
M e t h od of cr os s con n e ct i n g al a rm a
r g e di r e ct -c u rr e n t a t ure h a
vi ng
al ap w i n di n g ( We s ti ng h ou s e E l ect ri c M f g C om pa
. n y)
.

sp ra ye d i n s i de a n d out w i t h bl a ck fi n i s h i n g v a r n i sh S pe ci a l .

car e s hould be t a ke n to re a ch a l l ex po se d p a r t s of t h e co re ,

to p reve n t rus tin g .

R ota r y C on ve rt er s Th e r e i s n o e s s e n t i a
.
—
l diff eren ce i n t h e
wi n d i n g ope r a t i on s as d e s cr i b e d b e tw e e n r o t a ry co n ve rt e rs ,

an d oth e r d i r e ct cu rr e n t m a
- ch i n e s A t t h e re a. r of t h e a rm a

ture howe ve r ta a e b r ou g ht out from t h e co i l s a t re g u l a

r
, p s r ,
 A R M A TU R E WI N DI N G A N D M OTOR R E P A I R

IV . W I N DI N G RA I L W A Y , M IL L A N D C R A N E TYP E S OF
A R M A TU R E S

Th e method s of wi n di n g a n d i n s ul a ti n g a rm a tures for ra il

wa y ,
m i ll m i n i n g a
,
n d c r an e typ e s of a r m atu r e s a r e pr a ct i
ca lly t h e sa m e s i n ce t h e se rvi ce i s s om e wha
,
t s imila r a nd the

w i n d i n g s m us t s t a n d up a ga i n s t mu ch h a r d u sa ge a nd a bu se
of t h e moto r Tho rough i n s ul a . ti on a n d pr ot e ct i on a ga in st
vi b r a t i on a n d ch a fin g of t h e i n sul a t i on a r e e s s en t i a l po i n ts
i n t h e wi n d i n g of th e s e a rm a tures a n d mu s t be gi ve n mo re

a tte n ti o n th a n in a n y oth e r .

Ra i l wa y Type Arma t ur e C o il s Th i s type of a rm a tu re co i l

.
—

i s compl e te ly fo rm e d a n d i mp re gn a t e d w i th i n s ul a t in g com
poun d s I t n e e d s n o s ha
. pi n g wh en pla ce d on t h e a rm a ture .

Fu l l erbou d M
' eg a
-i p
l

Od l on h pc

FI G 8 6. .
—
Wi re w ou n d c oil s s h ow FI G 8 7 W i r e w ou n d c oi l s
. .
—

i n g si n g l e coi l s arr an g e d i n ve r t i c a
l s h o w i n g s i n g l e c oi l s a
r ra
n g ed in

la y e rs . h ori z on t a l la y e rs .

I t is usua lly a dvi s a bl e for t h e re p a i rm an to pu rch a s e th e s e

co i l s f rom t h e m a n ufa ctu r e r of t h e moto r wh i ch i s to be r e

pa i re d U sua
. l ly t h e co i l s a re m a de up of two or more s i n gl e
co i l s wou n d wi th r ou n d w i r e or copp e r s t ra p The se s i n gl e coi ls .

are s e p a ra t ely woun d but gr oupe d toge th er for m e ch a n i ca l

rea son s i n h a n dl i n g a n d i n s ul a ti on Th e wi n di n gs of th e se .

motor s a r e of t h e w a ve or t wo ci r cui t type e x ce pt for t h e -

,

lar g e s t s i z es of m il l or lo como t i v e m e t e r s Th e i n s ul a t i on .

for co i l s a n d co r e a n d t h e d e ta i l s of t h e w i n d in g of r a i lw a y
arma tur e s a s gi v e n h e r e a r e t h e r e comm e n d a , t i on s outli ne d by a
W r i te r i n t h e E l ectr i c J ou r n a l V ol V I I N o 1 0 ,
.
,
. .

Wi r e C oi l s T h e co i ls for s m a
—
lle r m a ch i n e s are m a d e of
doubl e cotton covere d wi re Th e sin g le coi ls whi ch form a
-
.
 RE WI N DI N G DI R E C T-C U R R E N T A R M A T U R E S

complete coi l a r e i ns ul ate d from e a ch oth e r by fis h p a per or

fulle rboa r d se p a rators a nd m a y b e a rr a n g e d r ad i ally o r c i r

cu m f e re n t i a l l y in t h e s lot a s s hown i n Fi g s 86 a n d 87 Th e. .

le ad s from wi re wou n d coi ls a r e s e cu re d a lon g t h e d i a mon d e n d

a n d le a ve t h e coi l on e a fte r t h e othe r e a ch b e i n fi r mly t i e d
g,

an d ta pe d i n pos i ti o n s o tha t th e r e i s n o pos s i b i li ty for the m

to cha fe a ga i n s t on e a n oth e r Th e y a . re re in fo r ce d wi th

cotto n s l e e ve s .

S tr a p C o i l s M—
o s t of t h e l ar g e r r ai lw a y moto rs h a v e t h e

a rm a ture co i ls ma de from re cta n gula r con du cto r s i n s te a d

of roun d w i re a s w i th th i s fo r m of co n du cto r ag r e a
,
t e r pro
p o rt i o n of t h e s lot s p a ce m a y b e fill e d w i t h c opp e r w i t ho u t ,

of S l ot Onl y

u d 'l 'l pc

FI G . 88 —
. S ect i on of s l ot s h ow i n g FI G . S e ct i on of s l ot s h owi n g
89 .
—

st r a
p w ou n d coil of t w o t u rn s . s t ra
p w ou n d coi l of o n e t u r n .

a fi ci n g
s cr i t he i n s ul a
t i on
qui re me n ts Th e pre ssu re on
re .

t h e i n s ula ti n g s urfa ce s i s a l s o mo r e ev e n ly d i s t ri but e d a s ,

wi th t h e r oun d wi re t h e p re ss ure b e ar s on al i n e whi l e wi th ,

t h e re ct a n gul a r co n du cto rs i t i s d i s t r i but e d ov e r a fla t s ur fa ce

a n d i s m u ch l e s s l i a bl e to i nj u r e t h e i n s ula ti on Fi gs 88 . .

a n d 89 s how acr o s s s e ct i o n t h r ough two tur n a

- n d on e tu r n - -

co il s r e s p e ct i ve ly
,
.

Th e on e turn co i l re a d i ly l en d s i t s e lf to b ri n gin g out t h e

lea d s i n pos i ti on to e n t er t h e top a n d bottom of t h e com

mut a tor n e ck s r e s p e cti v e ly by t h e u se of t h e s ta

,
n da r d fo r m

of di a mon d en d A two turn co i l re qu i r e s aS pe ci a

. l t u rn a t
t h e re a r e n d of t h e co i l i n or d e r to b r i n g t h e l e a
,
d s out i n
t h e p rop e r po si t i o n B y t h e u s e of th i s fo r m of co i l a
. ll the ,
 92 A R M A TU RE WI N DI N G A N D M OTOR RE P A I R

a dva n ta ges of t h e s tri p wi n di ng ca n be s e cu re d f or t h e sm a ller

ma ch i n e s on wh i ch m o re th a n on e tu rn pe r s lot i s u s u a lly
re qu i re d .

I n s om e la rge moto rs co i l s of t h e rect a

,
n g ul a r typ e s a re

ma de i n two pi e ces a ,
nd a re kn own a s two pi e ce co i l s -
The i r
.

a dva n ta ge l i e s i n t h e f a ct th a t i f aco i l b e comes d a ma ge d on ly ,

on e h a
- lf of t h e compl e t e coi l n ee d be remove d to ove rcom e
t h e d e fe ct . A s da ma ge to t h e co i ls n e a rly a lwa y s o ccurs on
t h e ou t s i de of t h e a rm a ture thi s t ype of co i l i s pe culi a
,
r ly

a da pt e d t o ra i lwa y type a rm a ture s I t requ ire s howeve r

.
, ,

asold e re d con n e ct i on a t t h e ba ck in a ,
ddi t i on to t h e us ua l
sold e re d co n n e ct i on a t t h e commuta to r a n d h e n ce i s u s e d
,

only on t h e l a rge moto rs wh e r e t h e s a vi n g of copp er for re pa ir

pa rt s would be gr e a t .

C oil I n s ul a ti on .
—
Th e i n s ul a t i on us e d on m e t e rs of t h e type
un d er con si d e ra t i o n d e p en d s l a rge ly on t h e typ e of co i l u s e d .

Wh e re doubl e cotton cov e re d coi ls a

- - r e u s e d th e r e i s l i ttl e

a dva n ta ge i n u s i n g m a t e ri a ls for t h e rem a i n d e r of t h e s lot

i n sul a t i o n wh i ch h a ve h i gh er he a t r es i s t i n g a b i li ty th a n the

cotto n s t r a n d s wh i ch a re i n i mm e d i a t e co n t a ct w i th t h e con

du ct ors s i n ce i t i s n e ce s s a
,
ry u n d e r t h e ci r cum s t a n ces to l i m i t

t h e te mpe ra ture to va lues con s i s ten t wi th t h e cotton i n s ula t i on .

For th i s re a s on on ce rt a i n t ypes of m i ll moto r s wh e re t h e ,

t emp e ra ture con di t i on s a re ex ce pt i o n a lly s evere a sbest os

,

cov e ri n g i s u s e d i n s t e a d of t h e cotton wi th mi cai n sul a ,

t i on
a r oun d t h e compl e t e co i l cotto n b e i n g u s e d on ly i n t h e prot e o
,

ti ve ta pi n g ove r t h e out s i d e .

Wi th s tra p woun d co i ls i t i s pos s i bl e to us e bui lt up mi ca

i n i mm e di a te con ta ct w i th t h e co n du cto r s a n d co t ton o n ly

on t h e outs i d e p rot e ct i v e cov e r i n gs wh e r e i t i s i n co n ta

,
ct w i th

the a i r or t h e r e l a t i ve ly coole r i ron H en ce t h e coppe r ca

. n

be s a fe ly wor ke d to ah i gh e r va lue a n d co n t i n u e d ov e rlo a ds

a nd a bus e wi ll n ot be so l i a ble to ca u s e b re a kdown Th e coi ls
.

sh ould be v a cuum i mp r e gn a t e d b e for e i n se rt i on i n t h e a rm a

tu re Th i s pro ce s s ren d e rs them thor oughly mo i s tu re a

. nd

oi l p r oof a n d p rolo n g s t h e l i fe of t h e co i l s ov e r th a t of u n
i mpre gn a te d on e s e s pe ci a
,
lly wh e re the y a re s ubj e ct to mo i s

tu re a, ci d fum e s a n d d e l e t er i ou s g a s es I t is a
. ppli ed to a ll
ra i lwa y yp t e c o i l s e x ce pt tho s e f or m i n e l oc omot i v e s who se
,
94 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

On t h e o
c re s for s tra p woun d coi ls t h e co i l s upport s a , re

u su a lly st ra i ght a n d i n s ul a te d w i th bu i l t u p m i cabus hi n gs or -

wi th h ea vy b a n d s of t re a te d ce me n t pa pe r N o t a pe i s u se d
.

i n th i s ca se but t h e bu s h i n g s a
,
re a rra n ge d to com e up le v el

wi th t h e bottom of t h e s lot s .

On both w i re a n d s tr a p wou n d a rma ture s t h e s lot s for ,

a bout a n i n ch a t t h e en ds m a y b e s l i ghtly w i d e r th a n t h e c o i l s .

I n s u ch ca ses n a r r ow s tr i p s of h e a vy fish pa pe r p roj e cti n g ,

s l i ghtly f r om t h e s lot s s hould be i n se r t e d f or a

,
dd i ti on a l pro
t e ct i on to t h e coi l s a t thi s poi n t Th e s lot s s hould be furth e r
.

i n s ul a te d wi th re gul a r fis h p a p e r ce lls for t h e me cha

-
n i ca l
p rote cti on of t h e coi ls .

I n s e rt i ng th e C oi l s —
B e fo re s t a r t i n g to w i n d t h e a rm a tur e ,

t h e commut a tor should be te s te d for b re a kdown wi th 5000

volt s t o grou n d a n d 20 0 volts b e tw e en s e gm e n t s Ma r k two.

s lot s s e p a
,
ra te d by t h e proper throw w i th ch a ,
l k for t h e fir s t
co i l . The n coun t off fr om t h e ba r oppo s i t e t h e ce n t e r of t h e

firs t s lot t h e commuta

,
tor b a r s i n to wh i ch t h e l e a d s from th es e
s lot s mu s t fit I n al a
.
p w i n d i n g th e s e b a r s s hould l i e a dj a c e n t .

I n aw a ve wi n d i n g t h e n umbe r of b a
,
r s b e tw ee n th e m mus t be

d e term i ne d ( S e e pa
. ge 1 05 C h a ,
pter I V ) Th e fi rs t coi l i s .

the n pl a ce d i n th e se two s lot s t h e bottom h a ,

lf b e i n g dr i ve n
in to t h e low e r h a lf of t h e s lot a n d t h e top h a
,
lf b e i n g m erely
ca ught i n i t s p rop e r slot a s i t w i ll h a
,
ve to be re move d la te r ,

to a llow aco i l to be i n se rte d be n e a th i t .

Wi r e C oi l s I n wi re woun d a
—
rma tures t h e lower le a ds
s hould be t a p e d w i th fr i ct i o n t a p e whe n n e ce ss a ry to m a ke
t h e i n s ul a ti on con ti n uous fr om t h e co il to t h e commut a tor .

Th e s e l e a d s s hould the n be la id a lon g t h e coi l s upport s of t h e

a rm a ture cor e i n s moothly fitti n g row s a n d t h e ba re e n d s

d r ive n i n to t h e p rop e r commut a tor n e ck s H e a vy in s ula

. t i on
i s n e e d e d b e tw ee n t h e co i l e n d s a n d t h e upp e r a n d low e r

le a ds a n d b etw e en t h e uppe r a n d low e r co i l e n d s Thi s m a .

y
be of d iff e re n t for m i n d i ff e r e n t typ e s of a rma tu res I n on e .

typ e t re a te d ca n va s s t ri ps m a y be i n se r t e d s o a s to fu rn i s h
e x t r ai n s ul a ti o n b e twe e n t h e e n d s of a dj a ce n t co i l s a n d be

twe e n t h e co i l e n d s a n d t h e low e r l e a ds I n a dd it i on afri cti on

cloth s tr i p doubl e d ov e r ap i e ce of r op e m a
, y b e ,
i n se rt e d a t
ea ch e n d b e tw e e n t h e upp e r a n d low e r co i l a s t h e co i l s a re
 RE WI N DI N G DI R E C T- C U R R E N T A R M A T UR E S

ope fit ti n g in t h e poi n t of t h e di a
i n s e rt e d , t h e r mon d Th e .

pe d wi th afib re dr ift a
coi l s s hould be s h a n d ra whi de m a lle t
so a s to fit sn ugly a ga i n s t on e a
n othe r a t both e n d s I t is .

FI G 9 1
. .
—
I nse rt i n g t h e t op s i de s of coi l s i n a n rm a
a t u re . Th e l e a
d s of
t h e bot t om coi l si de s a re s h ow n con n e c t e d t o t h e com m u t at or. N ot e t h e
ba n d of i n s u l a t i on be t w e e n e n d con n e ct i o s
n .

esse n l th a
ti a t they be m a de to fit clos ely togethe r wh en firs t
,
rm a
i n se rte d oth er w i s e t h e a ture wi ll bulge at t h e en ds A ny .

a t t e mpt to s h a pe t h e coil s in acomple te d a rma ture i s li a

ble
t o inj ure t h e in sula ti on .
 A R M A TU R E WI N DI N G A N D M OTOR RE P A I R

A ft er a ve be e n in serte d a
ll t h e co i ls h a n d t h e top p a rt s of

the thr ow coi l s ha ve be e n re place d t h e e n d s of t h e ca

, n va s

t ps whi ch pr oj e ct up be twee n t h e coi l e n d s s hould be tri m

s ri

m e d off l e v e l w i th t h e top of t h e co i l s a t both e n d s of t h e a rma

ture Tho se s tr i p s whi ch proj e ct out fr om be n e a

. th t h e
coi l s,
s hould be tur n e d up ov e r t h e co i l e n d s a n d bou n d i n

pl a ce w i th fri ct i o n t a p e Th i s t a
. pe whe n woun d comple te ly
a cr o s s t h e uppe r s u rf a ce of t h e co i l e n d s se rve s a s a prot e cti n g
n d t h e uppe r l e a
,

a n d i n s ul a ti n g la ye r b etwe e n t h e co i ls a ds .

A n other m e thod of pr ov i d i n g ext rain s ula ti on on s ome

a rma ture s i s to s li t two strip s of tre a te d ca n va s a n d i n s er t

them b e twee n t h e lower lea ds a n d t h e co i l e n d s w i th t h e s li t s

sta gge re d N o stri ps a

. r e i n s e rt e d a t t h e re a r en d a nd no

in s ul a ti o n i s re qui red b etwe e n t h e e n d s of a dj a ce n t co il s ,

b e yon d t ha t on t h e coi ls th e ms e lves S tr i ps of fri cti on cloth

.

a n d r ope m a y b e i n s er t e d b e tw e e n t h e upp er a n d t h e low e r

co i l e n d s a
,
n d t h e ca n va s s tr i p s fold e d ov e r t h e e n d s of t h e

co i l s a n d cov e re d w i th fr i ct i o n t a pe a s ju s t d escr i b e d . In
thi s ca s e how ev e r s t r i p s of fis h p a
, ,
p er s hould be sli pp e d over
ea ch co i l a n d w e dg e d be t we e n t h e co i l e n d s clo s e to t h e co r e ,

for furthe r pr o t e ct i o n to t h e upper l e a ds .

B e fo re co n n e ct i n g t h e uppe r l e a ds t o t h e a rm a ture they

s hould a l l be ti e d toge th er wi t h b a r e copp e r w i r e a
‘

n d t h e co i l s

s ubj e ct e d to a bre a k down te s t of 3 600 volt s A n y d efe ct ive

-
.

co i l mu s t be re pl a ce d Th e a rma ture ca n the n be t ru e d up

'

. .

Thi s ca n be do n e by t a ppi n g down wi th am a lle t a l l t h e hi gh

co i l s a s lo ca te d by holdi n g api e ce of ch a l k s o t ha t i t wi ll ru b
a ga i n s t t h e h i gh p a r t s wh e n t h e a rm a tu re i s revolve d A s om e
.

wh a t b e tt e r m e t hod i s to s qu e e z e t h e co i l s i n to pla ce by m e a ns

of a fl ex i ble m e t a lli c st r a p a n d tu rn bu ckl e

-
. Th e l a t t er
m e thod i s le ss li a ble to d a ma ge t h e i n s ula ti o n a nd a ll t h e co i l s
re ce i v e u n i form t r e a t m e n t s o th a t abe tter b a la n ce of t h e

a rma tur e re sult s B oth en d s mu s t for m acomp a

. ct m a ss.

Wh ere en d r oom i s e sp eci a lly s hort a ,

s i n m i n e motor s a ,
s p e ci a l
form ca n be u s e d on t h e r e a r e n d of t h e a rma ture s o a s to

p re ss a l l co i l s a ga i n s t thi s wh en b ei n g i n s e r t e d to gi ve u n i
form i ty to t h e a rr a n ge m e n t .

Wh e re t h e top of t h e co i l i s a bove t h e top of t h e commut a t or ,

t h ere i s someti m es d i ffi cul t y i n k e e p i n g t h e l e a d s prop e rly

 A R M A T U RE WI N DI N G A N D M OTOR R E P A I R

of t h e coi ls by two thi ckne sse s of tre a te d ca n va s th re a de d i n

,

pla ce a s t h e co i l s a re i n se rte d .

T h e co i l s uppo rt s for two p ie ce co i ls m a -

y b e i n s ula te d i n t h e
sa me m a n ner a s t h e on e pi e ce co i ls - Th e e n d be lls for th i s
.

type of a rma ture howe ve r a,

re u s u a lly se pa
,
ra te from t h e core
a nd a re n ot put in pl a ce u n t i l t h e w i n d i n g i s comple te s o th a t ,

t h e w i n de r h a s ple n ty of r oom to work on t h e re a r e n d of t h e

co i l s . Th e w i n d i n g opera ti on ca n be gre a tly fa ci l i t ate d by

t h e u se of as tee l w i n d i n g ji g co n s i s ti n g of aslotte d d i s k w i th
,

ahub bore d to fit t h e a ‘

r ma ture s ha ft Th e n umbe r of s lots .

s hould be e qu a l to t h e n umbe r of si n gle coi ls i n t h e a r ma ture ,

a n d t h e t hi ck n es s of t h e d i s k e qu a l to t h e wi dth of t h e con n e ct
i n g cli p s .A s ea ch co i l i s pl a ce d i n t h e a r ma tu re slot t h e ,

s t ra ps compos i n g i t s hould be pla ce d i n t h e pr ope r s lot s in t h e

jgi a n d i n t h e c ommut a to r n e c k s u n t i l all t h e low e r h a lf of t h e

w i n d i n g i s i n pl a ce Th e l e a .d s on t h e uppe r a n d t h e lower

ha lf should be se pa ra te d by acouple of thi ckn e sse s of t re a te d

ce me n t pa pe r or by ala
,
ye r of fish pa pe r a n d m i ca A ft e r a ll
.

t h e co i l s a r e i n pl a ce t h e s tr a p s whi ch a
,
re to be co n n e cte d

toge ther a t t h e re a r e n d li e on e a bove t h e other i n t h e slots

of t h e jig The se ca . n be cu t off e ve n w i th t h e s u rf a ce of t h e

jgi ,
a t e mpo r ar y b a n d w r app e d a r ou n d t h e c o i l e n d s a n d t h e ,

jgi r e mov e d C .opp e r c o n n e c to r s l ee v e s s hould th e n b e s li pp e d

ove r t h e coi l e n d s a n d wood e n w e dge s d r i ve n i n be tw ee n th e m .

Th e con n e cto r s m a y th e n be s old e r e d an d t h e c o i l e n d s tu rn e d

down a t t h e top a n d s i de N e xt k n o ck out t h e we dge s a
. nd

i n ter we a ve a sbe s t o s bra i d be twee n t h e co n n e ctors to p re ve n t

a cci d e n t a l con ta ct Th e e n d be ll pr oper ly i n s ul a
.
, te d wi th
moulde d mi caor moulde d p a per ca n the n be bolt e d i n to
,

posi ti on .

C onn e cti on s wi t h De a d C oil s I f i n afour pole motor wi th

.
— -

atwo cir cui t win di n g there i s a

-
n e ve n n umbe r of si n gle co i l s

i n acomple te co i l on e s i n gle co i l i n t h e a
,
rm a ture mu s t be cu t
out i n or d er th a t t h e w in di n g m a y b e m a d e c o n t i n uou s T h i s .

co i l i s ca l le d ade a d coi l be ca u se i t i s n ot con n e cte d to t h e

,

ci r cu i t . I t i s n e ce s s a ry firs t to de te rm i n e t h e n umbe r Of s i n gle

co i ls i n acompl e t e co i l by d i v i d i n g t h e n umb e r of comple t e

,

coi ls or s lot s by t h e n umb er of commut a to r b a rs I f th ere a. re

more le a ds from e a ch s i d e of t h e co i l th a n the re a r e s i n gle

 RE WI N DI N G DI R E C T-C UR RE N T A R M A T UR E S

c oi ls e a
,
ch s i n gle co i l is compo s e d of two or mo re w i r e s i n

pa ra lle l an d the s e mu s t be t re a te d a s as i n gle l e a d I n s tr a

. p
co i l s e a ch s t ra p corre s po n d s to asi n gle coi l Th e coi l i s cu t
.

out by cutti n g off t h e le a d s on both s i de s of asi n gle co i l a bout

a n i n ch fr om w h er e t h e y s e p a ra te fr om t h e co i l The n ca
. re

fully ta pe them u p Th e body of t h e coi l of course must be

.
,

le ft i n t h e s lot for u n if ormi ty of t h e wi n di n g .

H oodi ng a nd B a n di n g A s afin a
—
l pr ote ct i on to t h e a rm a

ture coi ls he a ,
vy hood s m a y b e put on ov e r t h e e n d s of t h e

co i l s cove r i n g t h e a
,
r ma ture from t h e commut a to r to t h e co re
a n d f rom t h e co re to t h e e n d b e ll A t t h e commut a
. tor e n d
t h e hood m a y b e of w ov e n as b es t o s se w e d to a co n i ca l s h ape,

a n d i mp r e g n a te d i n amo i s ture a n d Oi l re p e ll i n g compou n d .

I t s hould be put i n pl a
d ra wn up ove r t h e commut a
ce wh i l e w e t Th e s m a
. ll en d s hould be
to r turne d i n s i de out a
, ,
n d fi rmly

ti e d ove r t h e le a ds a n d commut a tor n e cks wi th he a vy twi n e .

Th e body of t h e hood mu st the n be tur n e d b a ck ov e r t h e a r ma

ture I f t h e commut a
. to r n e ck s a r e low e r th a n t h e le v e l of t h e

core a ,
n othe r l a ye r of twi n e s hould be woun d ove r t h e hood
ne a r t h e commut a tor a n d ab a n d of ca n va s se w e d ov e r t h e

whole The n stre tch t h e hood ti ghtly b a

. ck ove r t h e a r ma ture
a n d t i e w i th tw i n e .

A rou n d t h e re a r en d of t h e a rma tu re ab a,
n d of ca n va s m a y
be wr a pp e d so th a t t h e gre a te r p a rt of t h e s t r i p e x te n d s out

ove r t h e sha ft on ly e n ough b e i n g woun d ove r t h e a

,
r ma tu re t o
pe rm i t ase cu re fa st e n i n g Th i s m a
.
y b e bou n d i n pl a ce w i th
ab an d of twi n e woun d ti ghtly i n t h e gr oove b etwee n t h e coi l
en d s a n d t h e e n d b e ll Th e ca
. n va s s hould th e n be tu r n e d

ba ck ove r t h e a r ma tu re a n d bou n d s moothly i n pl a ce .

Th e n umb e r a n d s i z e of b a n d s de pe n d s upo n t h e s i z e a nd

s pe e d of t h e a r ma ture A ll a
. rm a tu re s should h a ve b a n d s on

ea ch e n d pla
,
ce d a s fa r out a s po s s i bl e so a
,
s t o cov e r t h e

g re a ter p a r t of t h e co i l e n d s Whe n s u ch ab a
. n d would be

qu i t e wi de two se p a
,
ra te n a rr owe r b a n ds m a y b e wou n d o n

ea ch e n d .Th e se b a n d s s hould be i n s ul a te d fro m t h e co i ls

by t hree turn s of ca n va s ta pe se pa ra te d by tre a te d pa pe r
whi ch ex ten d s a t le a s t on e e i ghth i n ch b e yo n d t h e b a
- n d on

ea ch s i d e . Th e b a n ds a r ou n d t h e body of t h e co r e i n t h e b a nd

oov e s s hould b e i n s ul a t e d fr om t h e core a n d co i l s by s t ri p s

g r
1 00 A R M A TU R E WI N DI N G A N D M OTOR R E P A I R

of fish pa per They s hould a

. ls o be put on wi th ate n si on
Of a bout 3 50poun d s su ffi ci e n t t o ma ke agood fir m b a nd a n d to

b ri n g t h e coi ls dow n so tha t the y wi ll n ot proj e ct a bove t h e

s urf a ce of t h e core a t an y po i n t Th e i n d i v i du a
. l tu rn s of t h e
ba n d i n g s hould be w e ll s olde re d toge th er a n d he ld a t se ve r a
l
pla ce s by th i n coppe r cli p s pla ce d b e fo re t h e b a n di n g w a s

sta rt e d . i ls of b a
For oth e r d e t a n di n g s ee C ha pte r V p a , ge
1 46 .

A fte r t h e ba n d i n g i s comple t e d t h e m i ca
,
i n s ul a
ti o n be twee n
t h e commut a tor b a r s s hould be u n d er cut to ad e pth of a bou t
on e s ix tee n th i n ch w i th as p e ci a
-
,
l m i lli n g cutte r Th e e n ti r e
.

a rm a ture ex ce p t t h e commuta tor ca,

n n ow be s pr a ye d w i t h an

a i r d ry i n g fi n i s h i n g v a
- rn i sh
.
 A R M A T U RE WI N DI N G A N D M OTOR R E P A I R

cu i t e d by t he bru she s whi le t h e coi l si de s a re i n an eutra l

pos i ti o n or out si de t h e pole flux .

Th e s p a ci n g of t h e b ru sh e s fr om t h e h ee l of on e b ru s h to h e
t
hee l of t h e n e xt for al a p w i n di n g w i ll b e e qu a l to t h e n u m
ber of commut a tor b a rs d i vi d e d by t h e n umb e r of pol e s .

Te st in g Ou t C oil Term i n a ls A ft e r t h e commut a

—
tor pi tch
ha s b e en d e t er m i n e d ta k e t h e bott om le a
,
d of on e coil a nd

co n n e ct i t to acommut a tor r i se r u si n g t h e sa
,
me throw a s

e mploy e d on t h e old w i n d i n g i n ca se i t i s b e i n g dupli ca te d .

A fter t h e po s i ti o n of t h e firs t le a d ha s b e e n d e te r m i n e d t he ,

re m a i n d er of t h e bottom l e a ds ca n be co n n e ct e d i n r ot a ti on .

Whe n a ll t h e bo t tom l e a ds a re i n pl a ali ghti n g ou t te st ‘

ce ,

s hould be m a de to see if t h e le a ds a re con n e ct e d to t h e p r ope r

ba A s hor t ci r cu i t a n d g r ou n d t e s t mu s t a ls o be m a de a t
‘

rs.

thi s t i m e .

For ali ght i n g-out te s t pla , ce on e t e r m i n a l of t h e la mp te s ter

on acommut a t or ba r a n d w i th t h e oth e r t ou ch t h e top le a
, ds
of s e ve r a l co il s un til t h e l amp l i ght s Thi s w i ll lo ca . te t h e t op
s i d e of t h e co i l co rr e s po n d i n g t o t h e bottom s i d e co n n e cte d

to t h e te s t l a mp I f t h e la
. mp li ghts on more t ha n on e l e a d ,

i t i n d i ca te s as hor t ci rcu i t be twe e n coi ls I n a n arma

. ture
co n t a i n i n g tw i ce t h e n umb er of commut a tor s b a rs a s th e re

a re a rma tur e s lot s t h e s a

, me pro ce dure i s followe d i n loca ti n g
t h e two l e a ds of t h e s a me coi l .

C om m ut a t or C onn e ct i on s for a L a p W i n di n g A ft e r a l l —

t h e b e gi n n i n g e n d s of t h e co i l s or t h e e n d s for t h e coi l s i d e s i n
t h e bot t om of t h e s lot h a ve b e en con n e cte d to t h e commut a tor
a nd a ll t h e co i l s t e s te d out for ope n ci r cu i t s hor t ci r cu i t ,

a n d grou n d s t h e fin i s h e n d s or t h e e n d s of t h e co i l s i de s i n
,
'

t h e top of t h e s lot ca n be co n n e cte d to t h e commu t a

, tor I n
t h e ca s e of a co i l woun d w i th on e wi r e or two w i r e s i n p a ra lle l ,

t h e fin i s h e n d of co i l N o 1 i s co n n e ct e d to t h e commut a
. to r
ba r n e x t to th a t to whi ch t h e s t a r t e n d i s co n n e cte d Thu s .
,

if for coi l N o 1 t h e b e gi n n i n g e n d i s co n n e ct e d to ba
. r No 1 .

t h e fin i s h e n d w i ll be co n n e cte d to ba r No 2 Th e b e gi n n i n g
. .

e n d of co i l N o 2 w i ll a
. l s o be con n e ct e d to ba r No 2 .

a n d i t s fin i s h en d to ba r No 3 a .n d s o on u n t i l for t h e l a st

co i l t h e fi n i s h e n d w i ll co n n e ct t o ba r No 1 a n d clo se t h e w i n d
.

i n g ( se e Fi g .
 M A KI N G C ON N E C TI ON S TO THE C OM M U TA TOR 1 03

On t h e arm a ture of some l a r ge d i r e ct cur re n t m a ch i n e s -

acommut a tor i s pr ovi de d wh i ch h a s tw i ce or th ree t i me s a s

m a n y commut a tor ba rs as s lot s or w i n d i n g co i ls Th e obj ect .

of thi s is t o im prove commuta ti on a n d p re ve n t s p a r k i n g by

commut a ti n g on ly apa rt of t h e cu rr e n t a t at i m e I n aca se .

whe re t h e commut a tor h a s tw i ce a s ma ny ba rs a s s lot s t h e

‘

coi l s a re m a de up wi th two wi re s i n ha n d whe n wi n d i n g- -

.

For t h e ca se wh e r e th e re are th re e t i m e s a s ma ny ba rs a s slot s ,

co i l s m a
de u p wi th three wire s i n ha n d whe n w i n d i n g a
- -
r e u se d .

Th e coi s l i n e i ther ca se a re pl a ce d i n t h e s lot s t h e s a me a s

those woun d wi th one w i re but con n e cte d to t h e commut a tor

di ff e re n tl y .

I n t h e ca se wh ere t h e n umb e r of b a r s i s doubl e t h e n umb e r of

slot s a n d co i l s t h e s t a, rt a n d fin i s h e n d s of t h e co i l s wi ll h a ve
t wp wi r es . For coi l N o I con n e ct t h e st a
. rt e n d s a s follow s :

One w i re to ba r No 1 a n d t h e oth er e n d to ba
. r N O 2 ; for .

co il N o 2 on e e n d to ba r No 3 a n d t h e oth er to ba r N o 4;
'

. . .
, ,

a n d so on When conn ecti n g t h e fin i s h e n d s pro cee d a

. s

follows : For coi l N o 1 con n e ct on e en d to ba

.
,
r No 3 a nd t he .

other to ba r N o 4 ; for co i l N o 2 on e e n d to ba
. .
,
r No 5 a nd t he .

othe r e n d to ba r No 6 a n d s o on un t i l for t h e l a
. s t co i l on e of

t h e fi ni s h e n d s wi ll con n e ct to ba r No 1 a n d t h e oth e r to ba
. r

No 2 . . I n thi s ca se e a ch b ru s h w i ll cove r two b a

,
rs .

Wh en there a re three s t a rt a n d thr ee fin i s h e n d s to e a ch

coi l a n d t h re e t i m e s a s ma n y commut a tor b a rs a s s lot s ,

proce e d i n t h e s a me w a y by c o n n e c t i n g t h e s t a r t e n d s to
a dj a ce n t b a rs a n d t h e e n d of on e co i l to t h e s t a r t of t h e n ex t .

I n thi s ca se e a ch b ru s h w i ll cove r thre e b a rs .

R e qui r e m e nt s of aL a p W i n d i n g A l a p
—
w i n d i n g c a n b e

w oun d on a n a r ma ture h a vi n g a n y n umb e r of s lot s p r ov i d e d

ea ch s lot w ill a ccommod a te two coi l si d e s for e a ch commut a tor

ba r a n d t h e n umb e r of b a rs i s a n e ve n mult i pl e of t h e n umb e r

of slot s . When t h e tot a l n umbe r Of co i ls i s n ot exa ctly di

v i s i bl e by t h e n umbe r Of p a ir s of pole s t h e w i n d i n g p i t ch
ca n n ot be e qu a l to apole pi t ch Thi s however i s n ot a
.
,
n ,

O bsta cl e e x ce pt wh ere i t i s d e s i r a ble to u se e qu i pote n ti a l

c o n n e ctor s When t h e wi n di n g p i t ch ca
. n n ot be e qu a l to a
p o l e p i t ch i t i s m a d e s o as n e ar ly a s po ss i bl e W h e n t.h e f r o n t
a n d ba ck pi t ches a re speci fied t o be odd for al a p w i n di n g ,
1 04 AR M A TU R E WI N DI N G A N D M OTOR R E P A I R

t he oi l p i t ch i n win d i n g s p a
c ce s i s m e a nt a n d n ot t h e s lot

p i t ch I t wi ll be fou n d th a
. t w ith t h e usu a l type e f form ‘

w ou n d coi l s t h e p i t ch e s for b a
,
ck a n d f ro n t a re n e ce ss a ri ly

odd b e ca
,
us e on e s i d e of t h e co i l i s i n t h e bot t om of as lot
a n d t h e oth er s i d e i n t h e t op of t h e slot Th e te r m i n a ls of t h e
.

co i l s i d e i n t h e bottom of t h e s lot a r e us u a lly con si d e re d t h e

s ta rt e n d s a n d t h e te r m i n a ls of t h e si d e i n t h e top of t h e slot
t h e fin i s h e n d s .

C o m m u ta t or C onn e cti on s f or a W a ve W i n di ng
- For a .
—

wa ve w i n d i n g t h e st a rt a n d fi n i s h e n d s of co i l s a
,
r e co n n e ct e d

to t h e commut a t o r d iff e re n tly th a n for al a p w i n d i n g I n .

t h e ca s e of aco i l wou n d w i th on e w i re h a vi n g on e st a rt a nd,

on e fin i s h e n d th e s e a r e n ot co n n e ct e d to a
,
dj a ce n t commut a to r
ba rs a s in a lap w i n d i n g but a n umb e r
,
of b a r s a p a r t W h e n .

t h e co i l s a r e i n se r te d i n t h e s lot s t h e s t a r t e n d s of t h e cp i l

s i d e s i n t h e botto m of t h e

s lot s s hould be co n n e ct e d

to t h e commut a to r a s in

t he l a p w i n d i n g wh e n e a c h
co i l i s pl a ce d Whe n re a dy .

to co n n e ct t h e e n d s t h e ,

commut a tor pi t ch mu st be
d eter m i n e d Th e for mul a .

for commut a ti on pi tch i n

n umb e r s of b a r s i s (y) .

yl ya
) 2
Wh e re y. i s t h e fron t
FI G 92 A 4-p ol e , w a v e w i n di n g f or p i t ch a n d yz i s t h e b a ck
—
. .

h ” m g I 3 8 I Ot S a
t
$3 8
n d 1 3 c° m
p 1 t ch of t h e c o d e a
c h ,

coun t e d i n w i n d i n g s pa
,

ce s .

Wi th adoubl e la ye r wi n di n g or t w o co i ls per slot t h ere wi ll ,

be t wo w i n di n g s p a ce s pe r s lot .

I n t h e ca se of a4 pol e double la ye r wi th 1 3 slots a

-
,
nd 1 3

commut a tor b ars y z e qu a

l s 7 an d y . e
, qu al s 5 T h e n y) . .

(5 7 ) 2 or si x b a rs Wi th ab a ck p i t ch of 7 w i n di n g
.

spa ce s a nd a fron t pi t ch of 5 wi n di n g s p a ce s co i l N O 1 would .

li e i n slot N O 1 a n d slot N o 4 . I t s st a r t en d would be con

. .

n e ct e d to commut a t o r ba r No 1 a n d i t s fin i s h e n d to ba r .

N o 7 C oil N o 2 w ould li e i n s lot s N o 2 a I t s sta

'

. . . nd 5 rt . .
1 06 A R M A T UR E WI N DI A G A N D M OTOR R E P A I R
'

con n e c tio n to t h e commut a tor L o ca

. te t h e cen te r l i n e be
twe e n t h e s lot s of t h e co i l t hrow I f t h e throw of t h e l e a
. d s of
t h e co i l s i s an odd n umb e r of b a r s th i s ce n t e r l i n e w ill f a
,
ll on
acommut a tor ba r .I f it i s a n ev e n n umb e r t h e ce n t e r l i n e
,

wi ll fa ll on t h e mi cab etwe e n b a rs I n e i th e r ca
. se t h e ba r or

m i cas o lo ca t e d i s t h e st a r t i n g po i n t for l a yi n g off t h e con n e c

ti o n s to t h e commut a tor .

I f the re a re a n odd n umb e r of b a r s i n t h e th r ow of t h e le a ds ,

ta ke on e le ss tha n t h e n umb er of b a rs a n d coun t ofl h a lf of thi s

FI G . 94
.
—
Wa
ve wi n di n g wi t h a
n e v e n coil t h row a
nd a
n e ve n t h r ow of coi l
l ea ds .

n umb er i n e a ch di r e ct i o n from t h e s t a r t i n g ba r a n d th i s w i ll
,

give t h e fir st a n d la s t ba r of t h e commut a t or thr ow If .

th e re i s a n e v e n n umb e r of b a r s i n t h e th r ow coun t off h a ,

lf
t h e n umb er i n e a ch di r e ct i o n from t h e s t a rt i n g m i ca A .

ch e ck i s to cou n t fr om t h e fir s t t o t h e l a s t ba r a n d see if i t ,

a gre e s wi th t h e i nform a ti on gi ve n A s t h e firs t co i l put down

.

w i ll h ave a n odd n umb e r of l e a d s t h e ce n ter on e of t h e top a

,
nd

bottom le a d s s hould be pl a ce d i n t h e fir s t a n d la s t ba r of t h e

th row a s d et e r m i n e d .
 M A KI N G C ON NE C TI ON S TO THE C OM M U TA TOR 1 07

Wh en th ere a re a n odd n umbe r of coi l s pe r s lot a nd a n ev e n

n umb e r Of slot s asome wh a t di ff eren t method i s re qui re d

,
.

T h i s how e v er se ldo
,
m o ccurs I n su ch aca
,
se if t h e le a d .
,

t h r ow i s a n odd n umb er of b a r s t h e cen te r a s i n di ca te d by t h e , ,

co i l t h row wi ll li n e up on t h e m i caa
,
n d if a n e ve n n umb er of ,

ba rs i t w i ll l in e up on aba
,
r I f there i s a n odd n um b e r of .

ba r s i n t h e thr ow t a ke on e less th a n t h e n umbe r of b a

,
rs a nd

coun t ofl h a lf th i s n umb e r to t h e l e ft a n d on e mo re th a n ha lf
to t h e ri gh t a n d t h i s w i ll gi v e fir s t a
,
n d la s t ba
r of t h e commut a

t or thr ow I f t he re i s a
. n e v e n n umb er of b a r s i n t h e th row

cou n t off h a lf t h e throw t o t h e r i ght a n d on e le ss th a n ha lf t o

t h e le ft I f th e re a
. re two l e a ds i n t h e firs t coi l N o 1 l e a d ,
.

s hould l i e i n N O 1 ba r a n d i f th e r e a re four l e a
. ds in t h e firs t
,

coi l N o 2 l ea
, d s hould li e i n N o 1 ba
. r . .

of com m u t a
t or ba
rs

C oi l t h row an d l ea d t h row ev en
C oil t h row odd l e a d t h row odd
,

C oi l t h row ev e n l e ad t h row od d
,

C oi l t h r ow odd l e a d t h row ev e n
,

R e qui re m e n t s for aWa ve Wi n di ng For t h e w a ve or two —

ci rcui t w i n d i n g ther e s houl d a lwa ys be a n odd n umb e r of

commut a tor b a rs Wi th a n odd n umb er of slot s on t h e a

. rma

ture cor e a nd a n odd n umb e r of co i l si des pe r s lot a

, ba lan ce d ,

wa ve w i ndi n g w i th no de a d coi l s i s po ssi ble Th e a ctu a l .

n umb e r of co i l si d e s per slot ca n be de te r mi n e d by cou n t i n g

t h e te r m i n al s of e a ch t a pe d up co i l in t h e slot The r e m a y b e .

onl y two ta pe d u p coi l si de s i n t h e slot but e a

- ch co i l m a y b e

wou n d w i th three wire s i n ha n d wh i le w i n d i n g I n su ch a

- .

ca se the r e w il l be si x co i l si d e s pe r s lot for a two la yer wi n din g - .

P rog r e ssi ve a n d R et rog re s s i ve Wa ve Wi n di ng s Whe n a .

—

wa v e w i n di n g p a sse s o n ce a roun d t h e comple te a rm a tu re a nd

ha s i t s st art a n d fini s h e n d s con n e cte d to t h e commut a tor a

.

shown i n Fi g 95 (a t l eft ) i t i s s a
. i d to be aprogre ss i ve wi n di n g
,
.

Whe n a fter p a ss i n g o n ce a roun d t h e a rm a ture t h e s ta rt a nd

fin i s h e n ds a r e co n n e cte d a s show n in Fi g 95 (a t ri ght ) i t i s .

sa i d t o be re trog ressi ve .
1 08 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

Th e c n o di ti ons un de r whi ch awa

ve or seri es wi n di n g ca
n be
It 12
use d a
re s how n by the for mul a: K i 1
3
.

Wh e re K is t h e n umbe r of commut a t or b a rs p t h e n umb e r of ,

pole s a n d k awhole n umb e r Whe n t h e m in u s s i gn is u se d

.

t h e w i n d i n g w i ll be p r ogre ss i ve a n d wh e n t h e plu s s i g n i s u s e d

i t will be re tr ogr es s i ve i n aca s e whe r e t h e n umbe r of com

muta t or b a r s i s odd .

FI G 95
. .
—
t i on a
T h e i ll u s t r a t t h e l e ft s h ow s on e t u rn ap r og re s s i v e
of w a
ve
wi n di n g ; t h e on e a t t h e ri g h t are t rog re s s i v e wav e w i n di n g .

Wa
ve Wi n di ng wi t h De d C oil sa .
—
awave w i n d i n g a
For s ,

a l re a dy m e n t i on e d t h e n umbe r
,
tor b a
of commut a rs mu s t

n ot be a mult i ple of t h e n umb er of pole s ot he rwi s e t h e wi n d ,

i n g would clo se a ft e r i t h a s pa s s e d o n ce a r ou n d t h e a rma ture ,

i n s te a d of a dva n ci n g or fa lli n g b e hi n d on e commuta tor ba r

a s re qu i r e d by t h e w a ve wi n di n g I n othe r wor d s the r e mu s t

.
,

be a s ma n y co i l s i n s er i e s b e tw e e n a dj a ce n t comm u ta tor b a rs

a s th e re a re pa i r s of pol e s .A l s o w i th two or mo r e co i l s i d e s
p e r s lot t h,
e tot a l w i n d i n g p i t c h of t h e e n d c o n n e ct i o n s ( f r o n t
pi t ch ba ck pi t ch ) s hould be a
’
whole n umbe r I t fre que n tly .

ha ppe n s th a t i s fou n d to be afra ct i o n B y d ropp i n g t h e

.

fr a ct i o n wh e n t h e n um be r i s odd a wa ,
ve wi n di n g ca n us u a lly
be con ne cte d w i th ad e a d coi l A rule wh i ch i s ofte n u se d by
.

e n gi n e e r s to d e t e r m i n e wh e n aw a ve wi n d i n g i s po s si ble wi th
out adea d coi l i s th a t gi ve n i n a n oth e r p a ra gr a ph n a me ly : ,

N umb e r commut a tor b a rs

132 i 1 whe re p i s t h e n u m
2
n d It mu s t be awhol e n umb e r en a
be rof pole s a Wh n e y en .

r e u se d a
n umb e r of co i l si des per slot a nd an odd n umb e r of
1 10 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

a
n d di s co n n e ct oi l be t wee n b ars 5 1 a
t he nd 3 a
c t a a nd b

For de fini ti on of re t r ogress i ve a n d p rogre ss i ve w ave w i n d i n g ,

ge 1 07 C ha
s ee p a pte r I V ,
.

96 0 .
—
M e t h od cu t t i n g ou t ad a
mag ed coil in are t r og re ssi v e wa
ve
wi n d i n g .

FI G . 96 b — . M e t h od of cu t t i n g ou t adam a
g ed coil in ap rog re ss i ve w a
ve
w i n di n g .

FI G . 97 .
—
Dou bl e l a
y e r wi n di n g f or a4-pu l e a rm a t u re h a
vi n g 2 4 sl ot s and

24 com m u t at or bars . Th e con n e ct i on s f or t hi s di ag ra m a re g i v e n i n t a

bu
la
t e d for m on p age 1 1 1 .

Ta
bl e s for P l a
ci n g C oil s a
nd C onn e cti ng Th e m i n aD .
-
C .

A rm a
t ure voi d mi s ta
a
Wi n di ng k e s i n r ea
.
—
di n g acomple te
To
gra
w i n d i n g d ia ma n d to avoi d t h e n e ce s s i t y of ma ki n g su ch a
d ia gra m Fi g 9 7 i t i s a
,
dvi s a
. ble t o furn i s h a
, n i n e x pe r i e n ce d

arma ture wi n de r w i th at able for l a yi n g t h e coi ls i n t h e slot s

and a ls o atable for con n e cti n g t h e proper lea ds to t h e com
muta tor These t a. ble s can be m a de up a s follows :
 M A KI N G C ON N E C TI ON S TO TH E C OM M U TA TOR 111

TA B L E FO B PL AC I N G C OI L s I N A R M A TU RE S L o rs
' —
LAP WI N D I N G
Pi a
‘

ce s i d es of coi l in

Thi s ta ble i s for afou pole double lar- ye r l a

,p w i n d i n g on an ,

a rm a ture ha vi n g 24 s lots a n d 24 commu t a tor ba rs B y gi v i n g .

t h e thr ow of t h e coi l s both i n w i n di n g s p ace s an d i n n umb e r of

s lots t h e w i n de r wi ll n ot b e co m e co n fu se d whe n e i the r i s u s ed

i n re fe rr i n g to t h e wi n d i n g A table of co n n ecti on s to t h e
.

commut a t o r for thi s w i n d i n g i s m a

d e up a s follow s

TA B L E F OB C ON N E C TI N G C OI L L E A DS TO T H E C OM M UTA TOR —
LAP
WI N DI N G

C o n n e ct a
t er m i n l s of coi l
1 12 A R M A T U RE WI N DI N G A N D M OTOR R E P A I R

S uch ta ble s are p a rt i cu l a

rly u s e ful i n t h e ca se of adouble

layer wa ve wi n di n g whe re e a ch co i l i s woun d w i th two or mo re

wi re s i n h a nd
-
Th e follow i n g t a
. ble s for afou r pole double -
,

laye r w a , ve wi n di n g w i th two te rmi n a l s pe r coi l 1 5 s lot s a

nd ,

30 commut a tor ba r s w il l i llu s t ra

, te the i r u se fuln e s s i n such a
w i n di n g :

TA B L E FO R PL AC I N G C oI L s I N A R M A TU R E S L O rs —
'
D OU B L E WA V E
WI N DI N G
Pl a
ce s i des of coi l in

TA B L E FO R C ON N E C TI N G C OI L LE A Ds TO TH E C OM M U T A T OR —
DO UB L E
WA V E WI N DI N G
C on n e c t a
t e r m i n l s of coil

Wa
ve vs . La
p Wi n di ng swa ve w i n d i n g i s mos tly
.
—
Th e
u se d on t h e s m a lle r type s of di re ct curre n t m a ch i n e s of multi

pol a r co n s t ru ct i o n Th i s w i n di n g h a
. s but two p a ths through
the a rm a ture re ga r dl es s of t h e n umb er of pole s a
,
n d half t h e ,

co i l s i n t h e a rm a ture a re co n n e cte d i n seri e s i n e a ch p a th ,

1 14 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

is p re fera ble in ca se s Of l a rge or sm a ll ma chi ne s for hi gh vol

ta g e a s w e ll as f o r s m a l l m ach i n e s fo r low volt ag e .

E x ce pt u n de r t h e s pe ci a l con di ti on s n a me d a bove su ch a , s

hea v y curre n t t o be h a n dl e d by t h e a r ma ture ma , ch i n e s Of

hi gh volta g e a
,
n d s m all m a c h i n e s O f low vol t a g e wh e re t h e l a p
w i n di n g h a s a dva n ta ge s ove r t h e wa ve wi n di n g t he re i s li ttle
,

choi ce b e twee n t h e w a ve or l a p w i n d i n g f o r tho se m a c h in e s

whe re t h e n umbe r Of pole s m a y e qu a l t h e n umb e r of c i r c u i t s

Of wh i ch t h e win d i n g m a y b e m a d e up . I t m a y b e sa i d th a t
i n thi s ca se A m e ri ca
,
n pr a cti ce fa vors t h e l a p w i n d i n g a n d
E u r op e a n p ra cti ce t h e w a ve wi n di n g .

I t mi ght be po i n te d out furt he r th a t i n awa ve or two ci rcui t -

w i n di n g a l l of t h e coi l s b e tw ee n two d i a me tri ca ll y oppo si t e

po in ts on t h e wi n di n g a re i n s eri e s wi th e a ch othe r whi le i n a

la p w i n d i n g o n ly t h e c o i l s b e tw e e n a dj a ce n t p o l e ce n t e r s a re

i n se ri e s .T h e re fore un d e r s im i l a
,
r co n d i t i o n s t h e volt a
,
ge
i n aw a ve wi n di n g wi ll e qua l t h e volta ge of al a p w i n d i n g
multi pli e d by t h e n umbe r of pa ir s Of pole s . Th e volt a ge
b etwe e n t h e commut a tor se g me n t s w ill a l s o va ry i n t h e s a me
ra ti o I n orde r to Obta
. i n t h e sa me volta ge of t h e m a ch i n e

t h e re l a ti ve n umbe r Of coi l s i n t h e t wo type s must v a ry i n

v e r se l y w i th t h e n umbe r Of pol e s a n d t h e s i z e of t h e co i l s

i n th e wa ve wi n di n g must i n cre a se i n p r opo r t i o n . Whe re t h e ,

s i z e of a rm a ture coi l doe s n ot be come ex ce ss i ve n or t h e volta ge

be twe e n se gme n t s t oo gre a t to pe rm i t good commut a tion ,

t h e wa ve wi n di n g ca n be u se d . Th e se co n di t i on s h owe ve r , ,

li mi t thi s type of wi n di n g un der or di n a ry co n d i t i o n s to four

or si x pole m a chi n e s . I n ca se s wh e re t h e n umb e r of pole s

i s la r ge r t h e l a p w i n d i n g h a s a w i d e r appl i ca t i o n f o r d i r e c t
cu rre n t a rm a ture s .

I n re ga r d to t h e s e le cti o n of t h e prop e r typ e Of w i n di n g for

d i re ct curren t a
- nd a
lte rn a tin g curre n t m a
-
chi n e s He n ry S ch e ril
, ,

forme rly ame mbe r of t h e e n gi n e e ri n g de p a r tm e n t of t h e

C r o cke r Whee le r C ompa

- ny h a ,
s ma de t h e followin g comme n t
( le ctri ca
E l R ecor d J a ,
n ua ry 1 9 1 9)
,

Th e se le cti o n of t h e prope r ki n d of w in d i n g de pe n d s upo n

t h e ca pa a
ci ty of t h e m ch i n e t h e volt a ge a Wa
a ,
n d s pee d . ve
w i n d i n g s re u se d on m a ch i n e s of s m a ll ca pa ci ty T he y a
. re

a lso be i n g u se d for low s pee d a n d m e d i um r a tin gs On s ma . ll

 M A KI N G C ON N E C TI ON S TO TH E C OM M U TA TOR 1 15

hi gh volta ge m a ch i n e s li k e t h e ra
,
i lw a y moto r t h e w a ,
ve w i n d
i n g i s b e i n g u se d to a dva n ta ge be ca u se i t h a s o n ly two se t s Of

b ru s h e s a n d i t ca n be i n s p e cte d ve ry e a s i ly Wa
. v e w in d i n g s
a re a lso u se d for t h e rotors e mploye d i n i n du cti on motors I n .

a l l oth e r ca s es l a
, p w i n d i n g s ar e to b e p re f e r re d .

Lap W i n d i n g s f or D i r e c t c-urre n t Ar m a t u r e s I n ge
. n —
er al ,

t he e n d s of aco i l of l a p w i n d i n g i n a d i r e c t c u -
rre n t m ac h i n e

a re co n n e cte d to t h e a dj a ce n t co m mut a tor b a rs Th e s i de s

.

of t h e co il a r e s p re a d over a n d pl a ce d i n t h e s lot s of t h e a rma

ture corre s pon di n g to t h e di s ta n ce e qui va le n t to 1 80 e lectri ca l

98 —
. La
p or pa
ral l el wi n di n g for a6 p Ol e m
- a
ch i n e .

d egree s Tha t i s to s a
,

y i f on e
,
s i d e of t h e c o i l i s u nd e r t h e

ce n t e r Of an or th pole the n t h e othe r s i de Of t h e co i l w i ll be

,

pla ce d i n as lot h a vi n g as i mi la r po s i t i o n un d e r t h e a dj a ce n t

s out h pole T h i s b r i n gs on e to acon s i d e ra

. ti on of t h e wi n d
i n g p i tch Th e p i t ch i s t h e n umb e r of s lot s s p re a
. d over t h e
per i phe ry of t h e a r ma ture corr e s pon d i n g to t h e a r ce qu a l to t he
di s t an ce b e tw e e n two s i m i la r po i n t s of two co n se cut i ve pole s .
1 16 A R M A T URE WI N DI N G A N D M OTOR R E P A I R

For i n s t a
n ce , if am a ch i n e h a s 7 2 s lot s a n d e i ght poles t h e ,

full p i t ch w i ll be 72 8 9 a n d t h e co i l w i l l li e i n s lot s Of
,

on e a nd t en .

I n adi re ct cu rre n t ma
p ch i n e t h e l a p o r mult i pl e w i n d i n g h as a
n umbe r of p a ths for t h e curren t to t ra ve l through t h e w in di n g
from posi t i ve to n e ga t i ve e qu a l to t h e n umbe r Of pole s I t
,
.

b ecom e s n e ce ss a ry s om e t i m e s to win d am a
, ,
ch i n e w i th wh a t
i s k n ow n a s the s hort cho r d or fr a ct i o n a l pi t ch w i n d in g
“
.

I n th i s k i n d of wi n d i n g u s i n g af ra ,
ct i o n a l pi tch t h e coi l i s
,

s pr e a d ove r t h e di s t a n ce wh i ch t a ke s i n le ss tha n t h e n umb e r

Of s lot s b e tw e e n two s i m i l a r po i n t s on two co n se cut i v e pole s .

Th e u s e of th i s ki n d of wi n d i n g on adi re ct cu rre n t m a -
chi n e

i s ma de whe n there i s adesi re to i mp rove t h e commut a ti on .

Th a t i s be ca
,
use w i th afra ct i o n a l pi t ch w i n d i n g t h e e m f .
,

du e to i n du ct a n ce of t h e a rm a ture i s le s se n e d a t t h e t i me of
'

commut a ti on I n d i re ct curr e n t m a
.
- ch i n e s i t i s n ot a dvi sa ble
to u se ashorter p i t ch tha n a bout 90 per ce n t of t h e full pi t ch
. .

I f thi s figu re i s ex cee d e d th e n t h e a dva nta ge s wh i ch th i s wi n d

i n g would g i v e a re p r a ct i ca lly e li m in a te d a n d li a ble to bri n g
a bout worse re sult s .

A l l i n t e r pol e m a ch i n e s a re bu i lt w i t h l a p w i n d i n g s an d
e qu a li z e r b a rs a re u s e d Th e s e tt i n g of t h e b ru she s on i n te r
.

pol e m a ch i n e s mu s t be do n e ve ry a ccu r a te ly b e ca u se the i r

po s i ti o n i s fixe d on ce a n d for a ll but due to i rre gul a
,
ri t i e s i n

ma n uf a ctu re i n or d e r to e li m i n a
,
te a n y po ss i b i l i t y Of poor com

muta ti on e qu a l i z e r con n e cto rs a re b e i n g u se d .

La p W i n d i n g s f or Al t e r n a t i n g c urre n t- M a c hi n e s F r—
a c t i
ca lly a ll a lte rn a ti n g cur re n t m a
-
ch i n e s u se w i n d i n g s h a vi n g a
s hor t p i t ch . Th e r e a s o n s for u s i n g t h e s ho rt p i t ch w i n d i n g ,

e s p e ci a lly on a lte r n a t i n g curre n t m a -

ch i n e ry a,
re m a ny TO
.

b e gi n wi th mo st ma
,
n uf a ctu re rs s t a nda r d i z e th e i r fr a me s ,

st a n da r d i z e th e i r s h i e ld s st a n da ,
r d i z e t h e cle a ra n ce s b e tw e e n

t h e rot a ry e l e m e n t s a n d t h e s ta ti on a r y e le m e n t s I n some
.

ma ch i n e s t h e cl e a
,
ra n ce s b e tw e e n t h e w i n d i n gs a n d t h e s h i e ld s ,

e s pe ci a lly i n m a ch i n e s ca rry i n g h e a vy cu rre n t s a ,

nd a lso i n
hi gh volta ge m a ch i n e s b e com e v e r y s m a
,
ll du e to t h e form of
e n d co n n e ct i o n s wh i ch a re b e i n g use d i n l a p w i n d i n g s I t
.

ha s be e n fou n d th a t by usi n g t h e shor t pi t ch w in d i n g t h e ,

e n d co n n e ct i o n s ca n be s ho r t e n e d co n s i d e r a bly a n d thu s Ob
1 18 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

po si ti ve to n e ga ti ve b rus h in de pe n de n t Of t h e n umb er Of poles .

N ow s i n ce t h e w i n di n g goe s a r ou n d t h e a rm a ture severa l

ti m e s d epen di n g upon t h e n umb e r Of slot s i n or der t ha
, ,
t the
win di n g m a y n o t clo s e upo n i t se lf t h
, e n umb er of c o i l s i n

s e r i e s mu s t be on e mo re th a n or on e le s s th a
,
n t h e n umb e r of

pole s S i n ce thi s wi n di n g h a
. s o n ly two ci r cu i t s re ga ,
r dle ss of

t h e n umb e r of pole s o n ly two se t s of b ru sh e s a

, re n ee de d .

H ow e ver wh e n th i s w i n d i n g i s b e i n g u se d on m a
, ch i n e s of

la rge ca pa ci ty th e re w i ll us u a
,
lly be a s ma n y s e t s Of b ru s h e s

a s th e re a re poles Th e pu r po se of th i s i s twofold
. . On e i s
to re du ce t h e si z e of t h e commut a tor a n d t h e othe r i s to re du ce

t h e b ru s h d e n s i ty .

Wa ve W d g si n i n f o r Al t rn a
e t g curre n t M a
i n - chi ne s In
—

a lte rn a ti n g curr en t m a
- ch in e s w a v e w i n d in g s a re mos tly us e d

i n roto rs of s li p r i n g i n du ct i o n moto rs . T he y a re e i th e r

s i n gle or double ci r cui t a n d the i r use for tha t pu r pose i s two

fold On e re a s o n i s b e ca use t h e e n d con n e cti on s a
.

. re mu ch

ea s i e r to m a k e th a n i n t h e ca s e of t h e l a p w i n d i n g a n d t h e

s e co n d re a s o n i s b e ca use of cert a i n d efi n i te ra t i o s to be ob
ta in ed . Double or tri ple w a ve w i n di n g s a re a ls o u se d on
a lte rn a tin g curre n t m a
-
ch i n e s of very low volta ge a n d hi gh

curr e n t s wh e r e l a p w i n d i n g s a re fou n d to b e n o t p r ac t i c al
be ca u se Of t h e for m of en d conn e ct i on s A ll w a ‘
. ve w i n d i n gs
s hould be s ymm e t r i ca l .

For aw a ve wi n d i n g i n a n a lte rn a ti n g curre n t motor t h e

-

n umb e r of s lot s (plu s or m i n u s on e ) i s cho se n s o a s to be d i v is

i ble by t h e n umb e r of pole s I f t h e n umb e r of s lots i s plu s

.

on e t h e w i n d i n g i s ca
,
lle d progre ss ive sin ce a ,
ft e r tr a veli n g on ce
a roun d t h e s t a to r i t retu rn s to t h e sta rt i n g slot plu s on e If
.

it i s mi n u s on e i t i s ca ,
lle d re trogre ss ive si n ce t h e ci r cui t
re turn s t h e w i n d i n g to t h e s t a r t i n g s lot m i n u s on e . I n th i s
w i n di n g t h e corres pon di n gly pla ce d co n du cto r s u n de r a dja
ce n t pole s a r e co n n e ct e d i n se ri e s w i th t h e ci rcui t p r o ce e d i n g

from pole to pole sever a l ti m e s a r ou n d t h e s t a tor Th e ci rcui t s

.

a re th e n i n t e rco n n e ct e d to g i v e t h e re qu i re d ph a se re l a ti on s .

S i ng l e vs aN u m ber of I n d e pe n de n t Wi n di n g s M o st
.
—

ma ch i n e s a re bui lt w i th a s i n gle w i n d i n g w i th t h e e x ce pti o n of

s om e th ree w ir e ge n e r a
- tors ha , vi n g double wi n di n gs t h e two ,

wi n di n g s b ein g i n de pe n d en t of e a ch oth e r .A ll a ltern a tin g

 M A KI N G C ON N E C TI ON S TO TH E C OM M U TA TOR 119

curre n t ma chi n e s a re bui lt wi th w i n di n g s so th a t th ey ca n be

ea s i ly ch a n ge d from multi ple ci r cu i t t o s i ng le ci r cu i t Th a t is

.

to sa y ,t h e d e s i gn of a w i n d i n g f o r a n alt e rn a t i n g c u rr e n t
-
m a
chi n e i s m a de s u ch th a t if i t is buil t i n two circui t s for sa y
,

2 20 volt s th a , t sa me m a ch in e ca n ha ve t h e win di ng s reco n

ne ct e d for 440 volt s .

D oubl e or t ri ple wi n di n gs e i th e r l a , p o r w a v e h av e ,
b ee n

foun d to gi ve mu ch trouble i n di rect curre n t m a - ch i n e s e s pe ,

ci c ll y i n commut a t i o n S pa . r ki n g a t t h e commut a tor be

come s v e ry p r o n oun ce d a n d t h e commut a tor we a rs down v e ry

ra pi dly For thi s re a

. son th i s ki n d of w i n d i n g i s n ot w i d e ly

use d on di re ct curre n t m a - ch i nes .

La p W i n d i n g s vs M u l t i p l e W a v e W i n d i n g s A l.t hough
—
t h e y
ha ve n ot bee n mu ch use d in t h e p a st mult i ple w a
, v e wi n di n g s ,

s om e ti me s ca lle d se ri e s pa ra
-
lle l win di n gs si n ce the y a re w a ve

wi n di n gs wi th more tha n two ci r cui ts h a v e som e a

,
dv a n ta ge s .

Th e po i n t s i n fa vor of the ir u se a re outli n e d a s follow s by

A lb e rt A N i m s of t h e e n g i ne e r i n g d e p a
. r tm e n t of t h e C r o cke r

Wh ee le r C omp a n y ( E lectri ca l R ecord Fe b rua ry

s o n for a
, ,

Th e re se e ms to be n o re a voi d i n g w a v e w i n d in gs
wi th mo re tha n two ci r cui t s on ra ti n gs whe re they would be
de s i r able p rovi de d the y be ma
, d e pe rfe ctly symme tri ca l .

Th i s co n d i t i o n would ba r ou t afour ci rcu i t w i n d i n g on a s ix

pole m a ch i n e A rn old who i s ge n e ra

.
,
lly re ga rd e d a s t h e o ri g i

na tor of thi s type of wi n d in g di d n ot a ,

lwa y s i n sis t on comple te
symm e t ry but t h e wri te r be li e ve s tha
, t t h e un su cce ssful
ex pe ri e n ce s w i th s e ri e s-p a ra l le l w i n d i n g s i n t h e p a st ha s b ee n

la rge ly due to a n i n comple te un d ers t a n di n g or Ob se rv a n ce of

t h e la w s of symm e try of a rm a tu re wi n di n g s .

I n w in d i n gs w i th ci r cui t s e qua l i n n umber to t h e pole s mul

ti ple or l a p w i n d i n g s a r e o r d i n a r i ly use d They posse ss t h e
.

a dva n tage Of h a vi n g e a ch co i l commut a te d a t o n ly on e b ru sh ,

a nd a lso t h e di s a dva n ta ge Of ha vi n g e a ch ci r cu i t u n d e r adif

fe re n t pole or p a i r Of pol e s
, I f t h e fi e ld s tre n gth s un d er t h e
.

va ri ou s pole s a re n ot i d en t i ca l t h e in du ce d e mfs i n t h e va
, ri ou s

ci r cui t s a re n ot t h e s a me U n des ir a . ble curre n ts wh i ch m a , y

be of con s i d er a ble ma gn i tude b e ca use Of t h e low re s i s ta n ce of

t h e w i n d in g th e n ci r cul a
,
te be twee n t h e d iffe ren t cir cui t s ,

overlo a di n g som e b ru shes a n d ca usin g the m to s p a rk a nd ,

1 20 A RM A TUR E WI N DI N G A N D M OTOR R E P A I R

u se les sly he a tin g t h e arma ture Th e b rus hes m a

.
y b e p r o

t e ct e d by d i v e rti n g the s e curre n t s thr ough i n tern a l e qui

poten ti a l con n e cti on s but t h e u s eless he a
,
tin g of t h e a rm a t u re
s t i ll re m a in s . T hi s how e ve r i s u s u a
, ,
lly n ot ex cess i ve com
pa re d w i th t h e he a ti n g Of othe r losse s so tha ,t thi s wi n di n g m a y
be ca lle d s t a n da r d tod a y .

S er i e s pa
- ra lle l w a ve w i n di n gs wi th ci r cui t s e qu a l i n n umb er
to t h e poles po sse ss t h e d i sa dva n ta ge commo n to a,
ll se ri e s
wa ve wi n di ng s tha ,
t t h e te r m i n a l s of e a ch coi l l i e u n d e r two

d iff e re n t b rus he s wh i ch a
,
re Of t h e s a me pola r i ty a n d th e refor e
, ,

co n n ect e d by alow re si s ta n ce co n du cto r Th a . t i s acoi l i s ,

commut a te d by two b ru sh e s a n d t h e con n e cto r b e tw e e n th e m

a n d th e r e i s ate n d e n cy for se l e ct i ve commut a ti on or un e qu a l

di vi si on of t h e curre n t a mon g t h e b ru sh e s to o ccur e s peci a ,
lly
i n la rge n on i n te r pol e m a
-
ch i n e s T h i s ge n e r a
. lly re s ults i n
sp a rk i n g a t som e Of t h e b ru s h es Th e y a
. re e a te n a wa y so
th a t t h e eff e cti ve po si ti on of the ir con ta ct s u rf a ces a re cha n ge d .

Othe r brush e s th e n g e t mor e curre n t th a n th e y s hould a nd

ev e n tu a lly a ll t h e b rush e s a re da ma ge d S e r i e s p a . ra lle l

-

wa ve win di n gs do ha ve t h e a dv a nt a ge tha t ea ch ci rcui t i s

i n flue n ce d by a ll t h e pole s s o th a,
t t h e i n duce d e mfs i n a ll
ci r cui t s a re e qu a l a n d th e re i s li ttle te n de n cy for ci r cul a ti n g
curre n t s to o ccur due to un b a la n ce d i n du ce d e mf s To .

e li m i n a te t h e d i s a dva n ta ge s a n d comb i n e t h e a dva n ta ge s of

the se two cla s s e s of w i n d i n gs multi ple w a
,
ve wi n di n gs h a ve
b ee n u se d p a ,
r t i cul a rly on fou r pole m a -
ch i n e s A lthough t h ey
.

a re
“
s p e ci a l a
”
n d th e re fo re co s t mor e th a
, ,
n sta n da r d w i n d i n gs ,

they a ccompli s h th e i r pur po se a dmi r a bly There se e m s to be

.

n o re a s on why th e y would n ot be e qu a lly s u cces s ful on m a

ch i n e s w i th s ix Or mo r e pole s .

U s e of E qua li z er R i ng s —
E qu a li z er ri n gs a re b e i n g use d on

la p w i n d i n g s o n ly on l ar g e mult i pol a r m a c h i n e s wh ,
e re u n

ba la n ce d co n d i t i o n s i n t h e m a gn e ti c circui t a re l i a ble to ca u se
ci r cul a ti n g cu rre n t s b e twe e n t h e seve ra l pa th s through t h e
a rma ture Thi s con di t i on w i l l o ccur for i n st a
. n ce in t he
cour se Of ope ra ti on whe re t h e a ir g a p w i ll n o t b e u n i fo r m
s o th a t t h e e m f i n du ce d i n acoi l oppo si te asm a ll g a p w i ll
be la rge r th a n th a t i n duce d i n t h e coil whi ch i s oppo si te t h e
la rg e g a p an d t h i s d i ff er e n ce i n t h e e mf s w i ll b r i n g a bout
 TE S TI N G D C .
-
. A R M A TU R E WI N DI N G S

Th e c ommon ca use s of trouble in a rm a ture s a re pra cti ca lly

t h e sa me a s in a n y e le ct ri ca l cir cui t n a me ly as hort cir cui t
, ,

i n or b e tween co i l s a n Ope n ci r cu i t re verse d co i l s a

, ,
n d grou n d s .

Of a ll t h e fa ults in heren t to a r ma ture s pr oba bly t h e mo s t

,

da n ger ou s i s t h e s hor t ci r cui t b e tw e e n co i ls I f i t i s n ot .

de te cte d a n d re m e di e d a s s pe e di ly a s po ss i bl e t h e re s ult i n ,

most ca s e s i s t h e bu rni n g out of t h e co i l s a fi e ct e d a n d poss i bly ,

t h e wh ol e a rm a ture .

Ca u s e s Of S h ort C i r cui t i n a n A rm a t ur e T here a re n um e r

.
—

ou s w a y s i n whi ch as hor t cir cui t of coi ls m a y o c cur I n t h e .

ca se of w i r e woun d coi l s i t s om e t i m e s h a
-
,
ppe ns th a t one Of t h e
tu rn s form i n g t h e coi l become s twi s te d dur i n g t h e p rocess .

Of i n se rt i n g t h e co i l i n t h e s lot a n d i n o r d e r to fo r ce t h e wi n d
,

i n g dow n to a n e ve n d e pth t h e tu rn of w i re w a
, s d ri v e n dow n

upon othe r turn s cutti n g through t h e i n s ul a

,
ti o n a n d ca usi n g
ashor t ci rcui t be twe e n turn s of t h e s a me coi l Wh e n thi s .

o ccurs t h e re sis t a
,
n ce of t h e co i l i s re du ce d a llowi n g more ,

cur re n t to flow i n cre a

,
s i n g t h e te mpe r a ture of t h e co i l a nd

e v e n tu a lly ca u sin g ade teri ora ti on Of i n s ul a ti on on other w ir es

a t th a t poin t I n t h e m a
. jori ty of ca se s thi s r e s u lt s i n s ho rt

ci r cui t i n g t h e en t i re co i l upo n i t s e lf .

A l so afr e qu e n t ca use of trouble i s t h e shor t ci r cui t b e twe en

co i l s T hi s i s Ofte n ca u se d on t h e b a ck e n d Of t h e a rm a ture
by oil s o a ki n g i n to t h e coi ls by le a ka ge from t h e ou t boa rd -

bea ri n g , whi ch toge ther w i th t h e du st th a

,
t wi l l i n v a ri ably
wor k in be twe e n t h e w in d in gs b re a k down t h e i n s ula
,
t i on a nd

ca u se a n e l e ctr i ca l le ak b e twe e n coi ls A s hort ci rcu i t m a .

y
a ls o result from t h e t op a n d bottom a rm a ture le a d s comi n g
i n con t a ct w i th e a ch othe r A s hort cir cu i t b e twe en commuta
.

t or b a r s i s Ofte n t h e ca use of burn e d out coils I n solde ri n g .

le a d s to t h e commuta to r g re a t ca re m u s t be exe r ci s e d n ot t o
,

1 22
 TE S TI N G D -C . . A R M A TU R E WI N DI N GS

a llow a n y of t h e molte n sold e r t o ru n dow n b eh i n d t h e b a rs ,

a s thi s ve ry fre que n tly s hor t ci r cui t s t h e b a rs A good w a

.
y
to a voi d thi s i s to ra i se t h e b a ck e n d of t h e a rm a ture atri fl e
so a s to a llow t h e solder to ru n to t h e fron t where i t ca n be

ea si ly re mov e d .

Te st s for aS h ort C i rcui t in a n A rm a t ure P rob a

. bly t h e
—

be st w a y of d e te ct i n g t h e p r e se n ce of a s ho r t c i r cu i t i n t h e

a rm a tu re of amotor i n ope ra ti o n i s to ca
,
re fu l ly w a t ch i t
whe n s t a r t in g a s s oo n a s fa ulty ope ra ti o n i s n oti ce d S om e .

tim e s t h e a rm a ture w il l n ot st a r t upo n t h e fir s t fe w po i n t s

of t h e r heos ta t a n d w i ll the n t a
, ke a n e x ce ss i v e cu rr e n t Th i s .

wi ll ca u se i t to ru n w i th as low a n d u n s te a dy mot i o n ( es pe ci a l ly
a t l ow s pee d s ) du e to t h e fa
, ct th a t eve ry ti me t h e short ci r -

cu i t e d co i l com e s u n de r t h e i nflue n ce Of a pole i t wi ll h a , ve a

te n de n cy t o re ta r d t h e mot i o n of t h e a r ma ture B y r un n i n g .

t h e mo tor for as ho rt t im e t h e ba ,
d co i l w i l l h e a t mu ch more
tha n t h e othe rs a n d i t s lo ca
,
ti o n ca n usua lly be de te cte d by
pa ss i n g t h e h a n d ov e r t h e e n d w i n d i n gs .

Wh e n ashort cir cui t i s sus pe cte d in a n a r ma ture t h e m a ,

ch in e s hould be s hut dow n a t o n ce a n d t h e n e ce ss a ry r e p a irs

ma de On e s ure me thod of loca
. tin g as hort-ci rcui te d coil
i s to d i s co n n e ct a ll t h e le a d s fr om t h e commuta tor a n d te s t

out t h e coi ls w i th ate st la mp A te st la . mp con s i s ts of two

w ir e s a bout 1 0 feet lon g con n ecte d to a1 1 0 volt ci r cui t wi th
,
-

a n i n ca n d e s ce n t l a mp con ne cte d i n se ri es i n t h e ci r cui t Thi s .

me thod re qui re s agre a t de a l of wo rk i n un s olde ri n g a ll t he

le a ds wh i ch m a
, y n o t b e n e ce ss a r y s i n ce i n t h e m aj o r i ty of
ca se s t h e se a
, t of t h e trouble wi ll be foun d i n t h e commuta tor
i ts e lf du e to short ci r cui t s b e tw e e n b a
,
rs .

A ra p i d t e s t ofte n u s e d to loca te t h e trouble wi thout dis

conn e ct i n g a n y Of t h e w i r es on t h e commuta to r duri n g t h e
te s t i s t h e ba
, r to ba r te s t Thi s tes t ca
. n be a ppli e d to a r ma

ture s wi th a n y s ty l e of w i n di n g co nn ecti o n s for ther e w i ll be

,

e xa ctly t h e s a me d rop of pote n ti a l b e twee n a n y two a dj a ce n t

commuta tor se gme n ts n o ma tter whi ch s che me of con n e cti o n

i s u se d Fi g 1 00 s how s t h e co n n e cti o ns n e ce s s a
. . ry for a te st of
thi s k in d A s te a . dy cu rre n t ta k e n from a1 1 0 volt ci rcu i t
,
-

s hould be s e n t th r ough t h e a rm a ture a t Oppo s i te s i d e s of t h e

commut a tor Th e b rus he s B s hould o n ly be w i de e n ough to
.
1 24 A R M A T UR E WI N DI N G A N D M OTOR RE P A I R

c over on e ba r C i s afib er blo ck hold i n g t h e copp e r co n t a

. ct

po i n ts so s p a
,
ce d a s to re s t on a dj oi n i n g se gme n t s a s s how n .

A dju st t h e la mp b a n k u n t i l t h e voltm e te r g i ve s are a da ble

de flecti on whe n G i s i n con ta ct w i th wh a ta re s uppose d to be

g ood co i l s T.h e d e fl e ct i o n of t h e voltm e t e r w i l l d e p e n d upo n

t h e d iff e r e n ce of pote n t i a l b e twee n t h e b a rs I f e ve ryth i n g .

is a ll ri ght p ra ct i ca
,
lly t h e s a m e d e fle cti on w ill be obt a in e d
a ll a r ou n d t h e commut a tor r ega r dl e s s Of wh a t pa i r of b a rs C

FI G . 1 00 —
C on n e ct i on s for t e s t i n g ou t a
rm a
t u re coi l s wi t h am i l l i v ol t m e t e r .

m a y re s t upo n P a s s t
. h e c o n t a
c t po i n t s ov er e a c h p a
i r Of

ba rs a n d n ote t h e d e fle ct i o n on t h e voltm e t e r Whe n t h e .

s hor t ci r cui te d co i l to wh i ch t h e b a
-
,
rs a r e co nn e ct e d com e s ,

un d er t h e con ta ct s th e re w i ll be v e ry li ttle if a n y mov e m e n t of

t h e n e e dle b e ca use there wi ll be li ttle or n o drop thr ough t h e

,

co i l A more s a ti sf a cto ry te s t for u s e on a re move d a r ma ture

'

i s t h e tr a n sfor m e r t e s t di s cr i be d on p a ge 1 25 .

Whe n t h e coil a t fa ult h a s b e e n foun d i n thi s m a

'

n ner it s ,

le a ds s hould be di s con n e cte d from t h e commut a tor toge ther ,

wi th t h e le a ds a dj oin i n g i t on e i the r si de Th e commut a tor

.

should n ow be t e s te d by u s e of t h e t e s t l a mp to dete rmi n e if

t h e ba rs to whi ch t h e co i l w a s co n n e cte d a re short cir cui te d -
.
 A R M A TU R E WI N DI N G A N D M OTOR R E P A I R

t he oil s I f t h e w in di n g i s co rre ct n o curre n t wil l flow a

c . s

t h e volt a ge s wi ll b a la n ce e a ch othe r I f howe ver acoi l i s

.
, ,

s ho rt ci r cui t e d a
-
cu r re n t w i ll fl ow i n t h e tu rn s th a
, ta re s ho r t

cir cui te d To lo ca
. te t h e defe ct i ve coil s t a ke ash a r p p i e ce Of

s t ee l or a k n if e bla de a n d pa ss i t a
rou n d t h e commut a t or so a s

to short cir cui t i n su cce s s i on t h e coi l s whi ch ha ,

ve on e si de
u n de r t h e t ra n sfor m e r A de ci de d s p a
. rk i n g i n di ca ti n g a,

pote n t i a l d iff e re n ce b e twe e n t h e b a rs s how s th a t t h e coil i s

,

i n good co n di ti o n A b se n ce of s p a
. r ki n g i n d i ca te s ei the r

FI G . l Ol .
—
M e t h od of t e s t i n g a
n a
rm a t u re f or s h or t ci rcu i t s a
nd Op e n ci r cui t s
i n coil s by us e of t h e s p e ci al t ran s f orm e r s h ow n
.

a n ope n ci r cui t or as hort ci r cu i t Th e l a tte r ca

. n be re a di ly
de t e rmi n e d by run ni n g ali ght pi e ce of sh e e t i r on over t h e
s urf a ce of t h e a rma ture core so a s to b ri dg e t h e slot s i n su c

ce s s i o n I f the re i s asho rt cir cui t i n on e of t h e coi l s whi ch

.

ha s on e si d e un d e r t h e t ra n sfor m e r alo ca l curren t wi ll fl ow

,

thr ough thi s coi l ge n e ra ti n g am a gn e ti c flux w hi ch wi ll a t t ra ct

t h e pi e ce of s hee t ir o n I f i t i s h e ld a
. wa y sli ghtly it wi ll be
ma d e t o vi b r ate ve ry ra pi dly Th e coi l w i ll a . lso h e a t ve ry
ra pi dly a n d if t h e t r an sf o r m e r i s l arg e e n ough for t h e a r ma tu re
b e i n g te ste d t h e coi l w i ll be bu rn e d out comple t e ly
,
.

I n ca se the re i s n o s p a r ki n g a t th e commut a tor wh en t h e

coi l s a re s hor t ci r cui t e d a
- s d es cri b e d a bove a n d th e r e i s n o
 TE S TI N G D -C . . A R M A T U RE WI N DI N GS

lo ca l ma gn e ti c flu x whe n movin g t h e pie ce of sheet i ron ove r

t h e s lot s Of t h e co re a n Op e n ci r cui t i s i n di ca
, t ed .

A t ra n s fo r m er cf t h e di me n s i o n s s how n i n t h e a ccomp a n yi n g

ill us trati on ca n be ope ra te d on a1 1 0 volt 60 cycle cir cui t a —

nd ,
—

will se r ve for te sti n g ma n y s iz es of a rma tures Th e on e .

i llus trate d w a s ma de up by E W C ope la n d ( E le ctr i ca

. l Wor ld)
.

usi n g 60 tur n s of N O 6 ma gn et wi re Whe n u si n g s u ch a

. .

t ra n sfor m e r i t s hould be f a s te n e d un d e r t h e a rm a ture so t h a t

the re i s ju s t e n ough cle a ra n ce be tw ee n t h e t ra n sfo r m e r a nd

a rm a ture core th a t n ei the r wi ll tou ch C urren t should a lw a ys

.

be off whi l e pla ci n g t h e tra nsfo rm e r a nd a lso when i t i s n ot

in use .

Wh e n te s ti n g a n a rm a ture wi th asm a
. ll explori n g tra ns

for mer t h e n umbe r of pole s i n t h e m a

, ch i n e mus t be t a ke n
i n to con s i de ra ti on I n at wo pole a
. rm a ture asi n gle s hor t
-
,

ci r cui t m a y h e at up two co i l s i n a fou r pol, e a r m a tu -r e fou r ,

co i l s a n d so on A good w a
.
y to lo ca t e t h e d e f e c t i v e co i l i s

s ugges te d by M a u ri ce S C le m en t (E l ectri ca
. l R ecor d N ove m ,

be r 1 9 1 8) by a
,
pplyi n g t h e te le phon e re ce i ve r te st I n a pply .

i n g th i s te s t t h e te rm in a l s Of at e le pho n e re cei ve r a re pl a ce d

on a dj a ce n t commut a tor b a r s wh i ch a re co n n e cte d to on e of

the a ff e cte d coi l s a n d t h e volum e Of sou n d t ra

,
n s m i tt e d to t h e

re ce i ve r n ote d .Th e sa me s hould be do ne to a ll t h e othe r

a ff e cte d coi ls . A s ho rt ci rcui t w i ll ha ve agrea ter volume of
s oun d th a n a pe rfect coi l .

Ca u s e s of Open C i r cui t s i n a n A rm a t ur e A n ope n cir cui t .

—

ma y res ult f r om a n umb e r of c a u se s I n t h e fi r.s t pl a c e wh e n ,

the a rma ture wa s wou n d t h e co i l m a ,y h av e b ee n d r i v e n i n to

pos i ti on i n su ch ama n n er th a t on e of t h e w i res wa s s t ra i ne d

or p a rtly cu t i n two Th e mom e n tum of t h e a
. rm a ture a nd ,

con s t a n t vi b r a ti on of t h e m a ch i n e w i ll fin a ll y b re a k t h e w ir e ,

a n d i n th i s w a y fo r m a n op e n ci r cu i t S om e t i m e.s a n op e n

ci r cui t Of th i s k i n d w i ll o n ly s how up wh e n t h e a rm a tur e i s up

to s pe e d t h e cen tri fuga
, l force ca u si n g t h e wi re s t o se pa ra te ,

thus Ope n in g t h e cir cui t Wh e n t h e moto r i s a. t re s t t h e w i r e s ,

will come togethe r a ga in a nd a te st w i ll re ve a

,
l n oth in g T h i s .

co n d i ti on i s k n ow n a s a fly in g a
”
Op en ci r cui t n d o ccurs ,

qui te fre que n tly Th e sa . me st a te of a ffa ir s m a y r es ult w i th

ashor t cir cui t be tween overla pp i n g coil s A n open ci r cui t .
1 28 A R M A T UR E WI N DI N G A N D M OTOR RE P A I R

m a y al s o b e c au s e d by t h e a r m a tu r e le a d s b e i n g d ra wn too
ti ghtly whe n the y a re s ol de re d to t h e commut a tor T hi s wi ll .

ca u se abre a k due to ex p a n si on a n d co n t ra cti o n Of t h e w i re

from t h e con s ta n t he a ti n g a n d cool i n g .

A n othe r commo n ca us e of ope n ci r cu i ts is poor workma n

s hi p whe n t h e l e a ds a re s olde re d to t h e commut a tor I f t h e .

lugs or ri se rs a re n ot pe rf e ctly t i n n e d b e fo re a tte mptin g to

s olde r t h e l e a ds i n to the m t h e s older wi ll n ot ta
,
ke hold ove r
t h e e n t i re a re a a n d al e a
,
d ma y b e h e ld i n pl a c e o n ly by a
thi n fil m Of solder on t h e out si de surf a ce When t h e curren t
.

through t h e a r ma ture i s he a vy t h e con t a

, ct a re a be twee n t h e
ri s e r a n d t h e le a ds m a y n o t b e s u ffi c i e n t to ca r r y t h e n e c e s s a r y
cu rre n t w i thout e x cessi ve he a ti n g Thi s wi ll m e lt out wha
. t
li ttle s older the re i s a nd a ,
n op e n ci rcui t wi ll re s ult S ome ti mes
.

acommut a tor wi ll be come so hot from ex ce ss i ve brus h fri ct io n ,

re si s t a n ce d rop overlo a
,
ds or t h e li ke tha
, ,
t it m a y th r ow
s olde r a n d ca
, use a n ope n ci r cui t .

Te st s for a n Ope n C i rcui t i n a n A rm a ture Th e s ymptoms

.
—

of a n Op e n ci r cui t a re Oft e n ve ry pr omi ne n t A vi ci ous gre en

.

i s h pur ple s p a
- rk wil l us u a l ly a ppe a r a t ea ch br u s h a s t he

ope n ci rcui t e d coi l pa

-
ss es fr om on e pole to t h e n e x t T hi s .

s pa rk h a s at e n d en cy to l e a p out from t h e brus h a n d follow

a r oun d t h e commut a tor for qui t e adi sta n ce Th e b a

. rs to

whi ch thi s coi l i s con n e cte d wi ll be foun d to be bur n e d a nd

r ough e n e d a n d t h e m i cai n s ul a
,
ti o n betwee n e a te n out to a
co n s i de r a ble de pth .

I n al a p wou n d ar m a tu r e t h e po s i t i o n of a n O p e n c i r cu i t
- e d
co i l i s e a s i ly lo ca te d be ca u se e a
, ch e n d of t h e co i l i s co n n e ct e d

to a dj oi n i n g ba rs I n aw a
. ve wi n di n g thi s i s n ot t h e ca se .

E a ch e n d of acoi l i s co n n e cte d to aba r re move d ace rt a in

di st a n ce a r ou n d t h e commut a tor from t h e other de pe n di n g Of ,

cour se upon t h e n umbe r of pole s a

,
n d t h e wi n di n g pi t ch

e mploy e d .

If a n Ope n cir cui t e xi s t s i n a n a rm a ture for a n y le n gth of

ti me t h e b urn e d con di ti on of t h e commut a

,
tor b a r s w i ll u s u a lly
i n d i ca te whe re t h e trouble i s loca t e d B oth l a
.
p a n d w a v e

woun d a rma ture s m a y b e te s t e d f o r op e n c i r cu i t by a t e s t i ng

tra n s fo r me r by u se of t h e o r di n a ry t es t l a mp a nd a ,
ba r to ba r
,

te s t or by ri n g i n g out be twe e n a
,
dj a ce n t b a rs wi th a ma gn e to .
1 30 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

wa
ve wi n din g is s how Wh n . en one Ofcoi l s i s s ho rt
t he ir -c

cu i t e d a s s hown a t A t h e top s i de Of t h e coi l i s d is co n n ecte d

,

fr om ba r B
.

a
,
n d t h e bottom si d e from ba r B J umpe rs
'

s hould be s olde re d i n a s s hown by t h e do t te d li n e Th e en ds .

Of t h e co i l lea ds ca n the n be cu t off clo se to t h e a rm a ture core

a nd ta pe d T h e coi l s hould be cu t comple te ly i n two a
. t X
a nd X an d t h e en ds ta pe d Thi s wi ll pre ve n t se lf i n duce d
.
-

curre n t s from be i n g ge n e r a te d wi thi n t h e coi l wh i ch mi ght ,

ca u se he a tin g a n d i n jure t h e i n s u l a ti on on othe r good coil s I n .

Fi g 1 02 (a
. t ri ght ) t h e m ethod of cutti n g out acoi l i n al a p
wi n di n g is s hown Th e coi l is op en ci rcui t e d a
.
- t A Th e top .

s i d e Of thi s co i l s hould be di s co n n ect ed f r om ba r 3 a nd t he ,

bottom si d e from ba r 4 I n thi s ca

. s e t h e j ump e r mus t be ru n

from ba r 3 to ba r 4 Th e d ea
. d coil ca n be t a p ed u p t h e sa me
wa y a s t h e s er i es or w a v e co il m en t i o n e d a bov e .

On e coi l cu t ou t of a n a rm a t ure w i ll n ot pe rce pti bly a ffe ct

t h e run n i n g of amoto r a n d se vera, l Of the m ca n usua lly be
cu t out w i th s a fe ty provi di n g the y a
, re n ot bu n ch e d toge th e r .

I t i s n ot w i se to cu t out too m a n y co i l s a s thi s i n cre a, se s t h e

he a ti n g a n d s pe e d of t h e a rm a ture a n d low ers t h e e ffi ci e n cy of

t h e ma ch i n e .

Ca u s e s of Grou n ds i n a n Arm a tur e A g r oun d o ccurs whe n

.
—

curre n t le a k s from t h e curren t ca rry i n g p a r t s of t h e a rm a ture

i n to tho se p a rts th a t a r e n ot i n t e n de d to ca r ry curr e n t A .

s i n gle grou n d w i ll h a ve li ttle eff e ct on t h e op e r a t i on of amoto r ,

bu t i t s hould be re move d a s s oo n a s po ss i ble a s th e re i s a lw a

,
ys
da n ge r of ase co n d groun d com i n g on a t s om e oth e r po i n t ,

w hi ch would produ ce t h e s a me eff e ct a s a s hor t ci r cu i t When .

agr oun d o ccurs asma , ll hole w il l be foun d bu rn e d through t h e

i n sula ti on a n d i n to t h e i r o n p a rt s of t h e a rm a ture A cro ss .

this ca rbo n iz e d i n s ul a ti on curren t w i ll p a

,
ss Gr ou n d s o ccur .

ve ry fre que n tly on t h e e n d s of t h e a rm a ture core a t t h e poi n t s

where t h e co i l s le a ve t h e co re I f t h e be n d h a . s b e e n too

sha r ply m a de or h a, s b ee n h a mm ere d too h a rd t h e sha rp ,

e dge of t h e core w i ll cu t th rough t h e i n s ul a t i on To a voi d .

thi s t h e slot i n sul a

, ti on s hould exte n d a t le a s t on e qu a r te r -

to on e h a -
lf i n ch p a s t t h e e n d of t h e co re on e a ch e n d .

G roun ds a ls o fr equ en tly o ccur i n t h e commuta tor ca us e d ,

by Oil cree ping up on t h e mi cari n g C omb i n ed w i th t h e .

 TE S TI N G D -C . . A R M A TUR E WI N DI N GS

opper a n d ca rbo n dus t fr om t h e commut a tor thi s forms a

“

c ,

good p a th for le a ka ge Of curre n t .

Te st s f or Groun ds i n a n Ar m a t ur e A g roun d ca n u su a lly

.
-

be lo ca te d by us i n g t h e te st la mp Di s con n e ct t h e le a . ds fr om
four of t h e commuta tor b a r s on on e qu a rt e r Of t h e ci r cumfe r
-

e n ce . Thi s w i ll de te rmi n e t h e se ct i o n Of t h e w i n di n g i n
whi ch t h e groun d i s loca te d R a i se t h e le a
. ds Of t h e defe cti ve
s ect i o n out of t h e commut a tor P l a ce on e wi re Of t h e te s t
.

la mp on t h e sh a ft a n d wi th t h e othe r t es t e a
, ch co i l se pa ra t e ly
,

to lo ca te t h e groun d S ome ti me s t h e trouble m a

.
y n o t b e i n

t he a rm a ture but m a , y b e ca u s e d by a g r ou n d e d c ommut a to r .

I f t h e coi l i s a t fa ult i t s hould be re move d a

,
n d r e i n s ul a te d .

R e ver se d C oil s A r e ve rs e d co il th a
.
-
t is on e wi th t h e lea
,
ds ,

to t h e commut a tor re verse d fre quen tly o ccur s A pr a ,

ct i ca l .

wa y Of lo ca t i n g a re v e rse d co i l i s t o p a ss a c u rre n t t h r ough

t he a rm a ture a t Oppo s i te po i n t s Th e la mp b a nk a
. n d con

n e ct i on s Of Fi g 1 00 ca
. n be use d for thi s te s t T he n wi th a .

comp a s s or s m a ll ba r of m a gn e ti ze d s te e l ex plore a r oun d t h e

a rm a ture to de t ermi ne t h e dire ct i on Of ma gn e ti s m from slot

to slot When t h e comp a
. s s i s ov er t h e r e ve rs e d coi l t h e n ee dle ,

wi ll re ve rse g i vi n g ave ry de fin i te i n di ca
,
ti on Of t h e coi l whi ch
i s co n n e cte d wr on g Th e le a
. ds of thi s coi l s hould si mply be
re ve r se d .

U s e of aB a r Ma g n e t an d M ill i vo l t m e t er t o L o c a t e a
R e ve r s e d Ar m a t ure C oi l In a rm a ture s whe re both le a
.
—
ds Of a
co i l a re t a pe d togethe r a n d l e d out fr om a
,
n i de nt i ca l poi n t ,

there i s con si de ra ble d a n ge r of ge tti n g t h e le a ds cr oss e d whi le

co nn e ct i n g thu s re ve rs i n g t h e di re cti o n of fl ow of t h e curr e n t
,

i n th a t coil S u ch are ver s a l wi ll i n a ll ca

”
. s es li ght out “

a s though pe rfe ct whe n te s te d wi th al a mp but wi ll ca u se ,

bucki n g whe n t h e m a ch i n e i s run A re verse d co i l of thi s

.
,

sort i s un u s u a lly di fficult to lo ca te a n d in ma n y ca se s a whole

ma chi n e h a s b e e n s t ri ppe d be ca u s e o r di n a ry m e thod s of t e s ti n g

fa i le d to lo ca te t h e trouble .

A n e ffici e n t te s t whi ch h a s bee n u s e d by J G Yoe rn s . .

( l ectri ca
E l R ecord S e pt e mb e r 1 9 1 8) i s i llus tr a
, ,
te d i n Fi g 1 03 . .

I t wi ll be n ot i ce d th a t ami lli voltmete r i s u se d ra the r th a n a

voltme te r be ca u se of t h e gre a ter se n si ti ve n ess Of t h e former .

B oth te rm i n a ls Of t h e me ter a re con n ecte d to a dj a ce n t

1 32 A R M A T UR E WI N DI N G A N D M OTOR RE PAIR

c ommuta tor b a rs N e xt t a. ke api e ce of me ta

,
l whi ch h a s

be e n m a gn e ti ze d a n d move i t i n ad i r e ct i on co rr e s po n d i n g

to t h e re volvi n g of t h e a rm a t u re di re ctly a bove t h e co i l

,

to whi ch t h e me te r i s con n e cte d I t i s we ll to ke e p i n mi n d

.

t h e fa ct th a t if aclo ckwi se moti o n i s u s e d on t h e firs t coi l t h e ,

sa me di re cti on must be re t a i n e d on a l l re m a i n i n g coi ls ,

othe rwi se t h e meter re a di n g w i ll be b a ckw a rd On t h e .

dow n w a r d s t r ok e of t h e m a gn e ti z e d ba r a nd a s it a pproa che s

t h e coi l to be tes t e d ma gn e ti c li n es of force w il l t ra

,
vel from
t h e ba r to t h e co i l the n ce to t h e mete r ca
,
us i n g t h e n e e dl e
,

to flu ctu a te sli ghtly I f t h e n ee dle jump s a

. he a d on t h e
down wa r d s t r oke i t wi ll j ump b a
,
ckw a r d on t h e upw a rd

s tr ok e a n d vi ce ve r s a Th e re ve r s e d co i l w i ll re a
,
. d Opposi te
from t h e othe rs TO cha . n ge t h e d i r e ct i on of t h e flu ctu a t i on s
of t h e n ee dle e i ther re verse t h e me te r te rmi n a
,
l s or reverse
t h e moti o n Of t h e m a g n e t .

C om p s s a

FI G .1 03 M e t h od of u si n g a
.
—
FI G . 1 04 .
—
A con v e n i e n t m e t h od
m a g ne tiz e d b r a a
n d m il l i v ol t m e t e r f or us i n g acom p as s w h e n t es t i n g
t o l oca t e are v e rs e d arm a t u re coi l . f or are v e rse d coi l .

U se of aC om pa
ssLoca t e aR e ver s e d A rm a
to t ur e C oil .

I n co nn e cti n g up s m a ll arm a tures wi th l a p wi n d i n g s wou n d on

by ha nd wi th fou r or mo re l ea ds comi n g out Of ea ch s lot ,

t h e l ea
ds m a y be ea s i ly co n fu s e d as al r eady m e n t i o n e d s o th at
s om e of t h e i n di vi du a larma ture coil s wi ll be r ev ers ed E C . . .

Pa rh am (E l ectri ca l R ecor d A ugus t 1 9 1 8 ) h a ,

s th e refor e
, , ,

s ugg es t e d t h e u s e of t h e t es ti n g d e vi ce s how n i n Fi g 1 04 . .

Whil e s evera l revers ed coi l s dis tri but ed a rou n d t h e a rm a ture

1 34 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

th is coi l B y a. pplyi ng as ma l l pi e ce of ir on t o t h e surfa ce of

the a rm a ture core a n d g ra du a lly movi n g i t a r ou n d t he ,

g rou n d e d co i l ca n be lo cat e d by m e a n s of i t s fi e ld w hi ch w i ll ,

a ttr act t h e ir o n .

Th e sa me m e thod ca n a lso be a ppli e d to a lt ern a ti n g curre n t

wi n di n gs a lthough n ot qui te so re a di ly For ex a mple i n .
,

t e ca
h s e of a t hr ee ph a s e s i n gl e c cu t
- i r i Y-co nn e ct e d a
, rm a
-
ture , ,

firs t di s con n e ct t h e Y s pli tti n g t h e wi n di n g up i n to three

,

se p ara te ci rcui ts The n t es t out e a

. ch ci r cui t w i th a ma g n e to

G roun d to A rm a
t u re S h f t a
FI G . 1 05 —
. M e t h od of l oca
t i n g g rou n ds i n a
n a
rm a
t u re w i n di n g .

or te s t l amp N ext a
. pply acur re n t to on e en d of t h e gr oun de d
ci r cui t a n d to t h e s h a ft A ss ume tha t there a. re 1 2 co i ls a s

s hown i n Fi g 1 05 coi l N O 7be i n g t h e g roun d e d coi l wh i l e

.
,
.

coi l N o 1 i s co nn e cte d t o t h e li n e a
. s s how n Th ere wi ll the n .

be aci r cui t thr ough co i l s N os 1 2 3 4 5 6 a n d 7w hi ch ca

. n
, , , , , ,

be re a di ly de te cte d wi th api e ce of i r on a s a lr e ady expla in e d ,

whi le coi ls N os 8 9 1 0 1 1 a .
,
nd 1 2 a
,
re d e ad I t is the n of
, ,
.
,

cour s e Obvi ou s th a t if coi ls N os 1 2 3 4 5 6 a n d 7ca rr y a , ,

,
.
, , , ,

cur re n t whi l e co i l s N os 8 9 1 0 1 1 a n d 1 2 ca
. rry n o cur re n t
, , , , ,

t h e groun d mus t be i n s ome s e cti o n Of coi l N O 7 t h e cir cui t .

,

bei ng complete d a t th a t po i n t .
 TE S TI N G D -C . . A R M A T UR E WI N DI N GS

Us e of 8 Te l e ph on e R e cei ver in Testi ng for S h ort C ircui t s ,

‘

Ope n C i r cui t s and Groun d s i n a n A rm t ur e —

Th e t ele phon e a
re ce i ve r on a ccou n t of b e in g ve ry sens i t i ve to sou n d m a kes ,

acon veni e n t t es tin g ins trume n t i n are pa i r s hop Th e wa y s .

i t ca n be e mploye d t o di s cove r as hort ci r cui t open circui t , ,

or gro un d a r e gi ven h ere a s u se d by M a uri ce S C le me n t .

( E le ct r i ca l R e c o r d, D e ce mb e r ,

Th is te s t i n g de vi ce ca n be u s e d e i the r w i t h a lt ern a ti n g cu r
ren t Or di re ct curre n t . If a lterna tin g curre n t is t o be use d a ,

tes t la mp a n d a pa i r Of
l a
e ds from a 1 1 0 ~volt cir
01 1 15 a re co nn e cte d 130 t h e S o ec l/ r

commut a tor a s i n Fi g 1 06
.
,

from on e four th t o on e h a
- - lf C O W "

Of t h e ci r cumfe r e n ce a pa rt .

N e xt , ta ke t h e re ce i ver
whi ch h a s a bout t wo fee t
Of t w o w i r e t e l e pho n e co r d
-

a tt a che d a n d h e ld i t to t h e
F 1 06 C o I G. ti o fo u i g a
—
nn e c ns r s n

ea a
.

r. W i th t h e oth e r h n d t l p
h d e ei f
on e
r l o a ti g
r ece v er h t o c n s or
m m a a m a
pre ss t h e recei ve r lea ds flfi fig
p ”m ‘n ° °° ( tmu n "

firm ly to t h e commut a tor ,

ta ki n g ca re to tou ch a dj acen t se gm e n t s M ove fr om on e le a

. d
of t h e test la mp to t h e other se gme n t by se gme n t a n d re pe a t
t h e ope r a ti on un ti l t h e commuta tor h a s b e e n cir cl e d

I f t h e wire i n t h e coi l s i s of too low a

.

re sis t a n ce to m a ke a
buzz i n t h e rece i ver put ar ose tte fuse in pla
, ce of t h e t e s t

la mp a n d cut arh e o s t a t in seri es wi th t h e fuse T hi s wi ll .

brin g t h e re sis ta n ce up s uffici e n tly to m a ke abuzz i n t h e

r e ce i ver . A low buzz in di ca te s agood flow Of curren t ; i f
n o soun d wh a te ver ca n be h e a r d f r om two commut a tor b a rs ,

the re is ade a d s hort cir cui t A n Ope n ci rcui t i s i n di ca

. te d by a
very loud buzz A cross conn e cti on wi ll p ro du ce adefe cti ve
.

soun d on three s e gmen t s The se thr ee lea

. ds s hould be ta ke n
Off a n d re co nn e cte d i mme di a te ly a n d t h e rece i ver te st o n ce

more a ppli e d .

For ade a d g r oun d whi ch pe rsi s ts in re ma i n i n g in vi s i bl e ,

pla ce on e si d e of t h e re ce i ve r li n e to t h e s h a ft a s i n Fi g 1 07 ,
.
,

a n d t h e oth e r si d e of t h e t e s t l i ne t dd h e commut a to r the n , ,

1 36 A RM A TUR E WI N DI N G A N D M OTOR R E P A I R

wi th t h e rece i ver t o t h e ea
'
r buzz e a ch se gme n t
, Th e .

groun de d coi l wi ll buzz loude r tha n t h e re s t .

I f di re ct curren t i s to be use d t h e s ource Of e n e rgy s hould be

,

aba ttery A buzz er con n e cte d i n seri e s on on e si de Of t h e

.

ba ttery completes a rr a
n ge m e n t s .

S ome ti me s whe n t est in g a

,
n a rma ture wi th atra n sfo rm e r ,

asin gle s hort ci rcui t wi ll he a t up coi l s i n two four si x or e i ght , ,

pla ce s a cco r di n g to t h e ,
T s t Lamp e
p ol a r i ty of t h e w i n di n g .

By a pply i n g t h e re ce i ver
lea ds to t h e b a r s con

n e ct e d to e a ch co i l thus

a ff e ct e d asho rt ci r cui t ,

ca n be lo ca te d qui ckl y .

Te st in g for R e vers e d
a
nd De ad Fi e l d C oil s .

multi polar ma chi n e s

a
In

W
m

i a a a
n n rmi d
a
st f zzrizi zs ét m
t u re w
‘

n ing .
2s; A
ca
n
w e r.e of fie s w e
be te s te d W i th a
abon fila
c r me n t l a
mp .

By pl a ci n g t h e l a mp whi le lig hte d betwee n t h e pole ti p s t h e ,

loop s of t h e fil a me n ts will dra w clos e together or se pa ra te fa r

a pa rt d e pe n di n g upo n t h e d i r e ct i o n Of t h e ma gn eti c flux A .

dea d pole ca n be qui ckly fou n d i n th i s w a y:

A n oth er v ery s i mpl e a n d po s i t i v e m ethod for t e s ti n g t h e

pol a ri ty Of fi e ld coi l s i s by m ea n s Of two o r d i n a ry i r on n a i ls .

To do thi s p a ,ss acurr en t thr ough t h e fi eld coi l wi n d i n g a nd

pla ce t h e n a i l s on two a dj a cen t pol es I f t h e pol a . ri ty i s ri ght ,

th ey wi ll a ttra ct ea ch oth er a n d if wro n g th e y wi ll r e p e l ea ch

‘

oth er This m ethod ca

. n be us e d a l s o for d e t ect i n g ad ea d coi l .

Th e C om m u ta t or Tr oubl e i n a
.
—
commut a tor m a y be t r a ce d
to ei the r as hor t cir cui t or agroun d I n acommut a . tor a
s hort ci r cui t m a y be ca u se d by a n y of t h e fol l ow i n g : P a r t i cl es

of me t a l tou chi n g two a dj a ce n t b a r s or m i caburn e d a ,

wa y
a llowi n g curren t to a re a cr o ss In a n un de r cut commut a
. tor
be s ur e t h e slot s b e tween b a rs a re thor oughly fr ee fr om a ll
di rt b e fo re t e st i n g A grou n de d commut a
. tor mu st i n va ri a bly
be re move d from t h e s h a ft a n d t he da ,
ma ge d p a rt w e ll cle a ned

a n d rei ns ul a te d I n au se wh ere amotor h a

. s b ee n thr oug h a
1 38 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

fire , t h e gme n t s wi ll i n n ea
se r ly a l l ca s es be u n d a ma ge d but ,

t h e m i cawi ll be bu rn e d be yo n d futur e use a n d i n s u ch a

, ca se

re filli n g w i ll be n ece ss a ry .

Te st ing E qui pm en t f or aR e pa i r S h op In a . ddi ti on t o t h e

—

fa cili t i e s ne ce s s ary for te s t in g out a rma tures a n d ma chi ne s

for s hort ci r cui ts Ope n ci r cui t s g rou n ds a

, ,
n d t h e lik e , e ve ry

re pa i r s hop must be e qu ipp e d t o tes t a n d lo a d motors of difier

e n t s i z e s re qui ri n g volt a ge s from 1 1 0 to 2300 A volta g
. e of
from 1 200 to 1 500 volts i s n ee de d for te s ti n g a n a rm a ture for
groun ds A tra . n s form er i s th e re fo re re qu i re d w i th t a ps a nd
co n n e ct i o n s s o th a t t h e volt a g e c a n b e v a r i e d f r om a bo u t 50 0
volt s up to 2500 volts .

For te s t i n g for s hort ci rcui t s a n d ope n ci r cui t s as m a ll

tra n s fo rm e r w i th s pe ci a lly s ha pe d la mi n a ti ons a bout whi ch a
coi l of wi re i s wou n d s h ould be a va ila ble (see Fi g 1 01 on pa .ge
x
Wh e n a ppl i e d to a n a rm a ture wi th ashort cir cui te d -

co i l t h e d e fe ct i ve co i l w i ll s how up by ge tt i n g hot
,
.

For te st i n g out ci r cui ts for ope n s a n d t o ma

,
tch up en ds Of
coi l s whe n i ns e rt i n g th e m i n t h e a rma ture core at es t la mp a
,
nd

ter mi n a ls is co n ve ni e n t A m a .
g n e to i s a l s o u se d f or t h i s

purpo s e I n t h e ca
. s e Of t e s ti n g for Ope n ci r cu i t s two le a ds ,

co n n e cte d to a 1 1 0 volt ci rcui t wi th ala

- mp co n n e cte d i n se ri e s
i n on e of t h e le a ds i s s uffi ci e n t For se l ecti n g co i l te rmi na ls
'

or li ghti n g out a
- n a rma ture w i n di n g wh il e i n t h e m a chi ne

to di s cover trouble a6 Or 1 2 volt a

,
- uto mob i le s tora ge b a tte ry
provi de d wi th two le a ds ha vi n g sn a p te stin g cli ps a nd a la mp
i n s e ri e s wi t h on e le a d i s acon ve ni en t outfit tha
,
t ca n be ta ke n
a bout th g sh Op a nd to a
‘

n y job .

A t lea s t on e po rt a ble a mme te r a n d on e voltme t e r a re n ee d e d

a n d on e ri n gi n g out m a gn e to a n d ap a i r of he a d tele phon e

r e ce i ve r s .

For t e s ti n g motors asm a ll s wi t chboa r d w i re d so th a t con

n e ct i on s ca n be m a de on t h e fron t by plug s a n d t h e volt a

a
g e

i n cre a se d by u s i n g jumpe rs i s aco n ve n i e n t ou t fit th a

,
t s ve s
mu ch ti me i n m a ki n g ates t T hi s s w i t chbo a
. r d sh ould h a ve
moun te d on i t avoltme te r a
,
mme te r fre que n cy me ter a
, ,
nd

t h e n ecess a ry s wi t ch es to co n n ect a n d op er a t e both m ot ors a nd

g en era tors on ei th er di rect or a lt ern a ti n g curr en t .

 C H A P TE R V I

OP E R ATI ON S B E FOR E A N D AFTE R WI N DI N G

D C AR M A TUR E S
- . .

a
B e foren a rm at ure go es to a n e x p e ri en ce d a rm ature wi n de r
and a ve s h i s h a
fte r i t le a n ds the re a re ce rt a i n s t e ps i n t h e
,

proces s whi ch ca n be p rop e r ly te r m e d be fo re a nd a fte r “ ” “ ”

ti ons I n aca
Ope ra . se wh ere ad a ma ge d a rma ture must be
comple te ly re w oun d these Ope ra t i on s m a
, y b e outl i n e d a s

follows :

S t ri ppi n g 03 Ol d w i n di n g . Tes t i n g ou t wi n din g .

C l ea
ni n g s l ot s a
nd e n ds of cor e . S ol d er in g l e a
ds t o com m u t a
t or .

Fili n g bu rr s Ofi s l ot s . Hood in g arm a t ur e .

Tes t i n g com m u t at or . Ba n di n g a rm a t ure .

Re pa
i rin g com m u t a
t or . Tu rn i n g com m u t a t or .

Ma
ki n g n ew coil s . U n de r cu t t i n g m i caOf com m u t a
t or .

I ns u l a
t in g e n ds of core a
n d s l ot s . Ba la n ci n g a rm a t u re .

Pa i n t in g a rm a t u re .

R e l i n in g be a ri n g s.

R e fe re n ce h a
s a lre a dy be e n ma de t o an umbe r of the se
ope ra ti on s i n co nn e cti on wi th t h e pro ce dure i n re wi n di n g
ma ch i n e s a s outli n e d i n C h a pte r s I I I a nd VI I I Th e d e t a il s .

tha ta r e g i ve n h e r e r e f e r t o t h e r e q u i r e m e n t s i n a l l ca s e s w i th ,

refere n ce s to oth e r C h a pte rs where t h e opera ti o n h a s be e n

ta ken up a s as peci a l subj e ct .

S t ri ppi n g 03 a n Ol d Wi n di ng I n t hi s Ope ra ti on whe n

.
—

ba n d wi r es mus t be remov ed th ey s hould be cut or fil ed i n ,

s ev era l pl a ces Wh en achi s el a

. n d ha mm er a r e us ed ca r e mus t

be exerci s e d n ot to ma s h down t h e a rm a tur e t eeth Th e n ext .

s te p i s to un s old er t h e l e a ds to t h e commut a to r a n d cle a n out

t h e sli t s i n t h e commuta tor ne cks ca refully B y pulli n g out .

1 39
1 40 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

t he top si de s of t h e proper n um ber of coil s a cco rdi n g t o t h e

thr ow t h e bottom s i de s ca
, n be rea ch e d th a t wi ll a l low t h e
coil s to be re move d e a si ly ( S ee C ha pter I I I ) . .

C lea n i ng a n d Fil i n g S l ot s A ft e r t h e coil s ha —

ve bee n re
move d a ll Ol d i n s u l a
, ti on must be thoroughl y ta ken Ofi t h e
co re a n d t h e s lot s A solut i o n compo s e d of 2 5 pe r ce n t a
. l co .

hol a nd 7 5 pe r ce n t be n zole is good for loo s e n i n g t h e v a

. rn i s h

Of Ol d i n s u l a ti on so tha t i t ca n be s cr a pe d from t h e s lots i n

t he a rma ture Thi s wil l produ ce n o ba
. d e ff e cts on t h e la mi
na t i on s or on t h e win din g whe n t h e a rm a ture i s re woun d .

A lk a li soluti on s su ch a s ca us ti c sodawi ll a lso loos e n t h e in s ula

ti on wi thout i n j ury to t h e l a mi n a t i on s but wil l cre e p be ,

twe e n t h e la mi n ati o n s a nd a fte r t h e a rm a tur e i s re wo u n d t h e

a lka li fume s a re l i a ble to d a ma ge t h e i n s u l a tion A tool .

ma de from ba r s te e l on e by on e s ixt e e n th i n ch Of s ui t a
- ble ,

le n gth a n d dr a wn down to alo n g thin poin t lik e ach is e l

a n s we r s ve ry w e ll to r e move Ol d in s ul a ti o n a fte r i t h a s be e n

s oft en e d a n d w il l a
,
l s o g i v e ve r y s a ti sfa ctory r e s u lts wi th

out t h e u s e of a n y ch e mi ca l s wh a te ver A fter re movin g .

t h e i n s ul a ti o n in this wa y a fil e d r a w n th r ough t h e s lot s w i ll

re move s m a ll p i e ce s of i n su l a ti on
a n d s mooth Ofl a l l r oughn ess Th e .

e dge s of t h e s lot s s houl d be fil e d t o

i - r e move s h a r p e dges a n d b ur r s th a t
sxm “
m m we would i n jure t h e n e w coi ls whi le
.

W “
b e i n g pl a ce d i n t h e s lot s Th e .

e n t i re co r e s hould the n be tho r

oughly cle a n ed W i th a bl a s t Of
F IG l o9 Sh ttl f m f
—
u e or
comp re s s e d a
. . or
il t h at a b p ll d
w i di g lr

ag
n n s co c n e u e .

m C om e t s -fl ee ts
of thi s Ope r a ti o n a re gi ve n In
C ha pte r X I I a s w e ll a s t h e s t e p s in r e p a i r in g acommut a tor ,

tes ti n g it out a fte r re a sse mbly ba k i n g t h e i n s ul at i on a

,
nd

t i ght e n in g e n d ri n gs .

Ma kin g N e w C oi l s Thi s op e r a ti on ca .ll s for a

—
n i ns pe ct i o n

of t h e old coi ls a n d w i n di n g d a t aa s outli n e d on p a ge 5 7 ,

C ha pt e r I I I I n ca se Of ch a
. n ge s i n s pe e d or volt a ge i t re quire s
ce rt a i n ca l culat i o n s whi ch i n volve t h e si ze Of wir e to u se The se .

ca lcula t i on s a re gi ve n i n C h a pte r X p a ge 240 Whe n t h e ,

.
1 42 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

e a
t in g ha
thep e of coil s pre vi ously use d i n a
s n a rma ture tha t
i s be i n g re woun d i s s hown i n Fi g 1 1 1 Th e di me n s i o n s a
. . nd

ge ne r a l s ha pe ca n be s e cu r e d fr om as a mple coi l p rese r ve d

from t h e Ol d win din g I n t h e i llus t ra . ti on A i s as ma ll hole
for moun t in g on as pi n dl e S ma ll pin s B a
. re dri ve n i n to t h e

form t o hold t h e coil i n pla ce wh i l e wi n di n g C a a '

nd C re .

s lot s cu t i n to t h e s i de s s o th a t t h e se ve ra l turn s of t h e coi l

m a y b e t i e d tog e th e r w i th th r e ad T hi s k e e p s
. t h e w i r es

toget he r a f te r t h e co i l i s r e move d from t h e fo rm A t t h e e n ds .

D a n d D two p i n s a r e u se d i n o r de r to m a ke t h e turn s hown

'

On t h e e n d s e ct i o n a t t h e ri ght i n Fi g 1 1 1 . .

FI G 111 p i n g di a
For m f or s h a m on d a
rm a
t u re coil s to m a
t ch Ol d on e s u se d
—
. .
.

N ow moun t t h e form on aspi n dle so th a t i t ca n be re volve d

a n d wi n d on t h e r e qui re d n umb e r of t u rn s u s in g t h e pi n s a s a
,

a
.

g u i d e I f
. t h e c ompl e t e d co il i s to c o n s i s t O f two co i l s t k e ,

two wi re s a n d w i n d the m t oge the r Whe n t h e p rope r n umber

.

Of turn s h a v e b e e n ma de cu t off t h e wi r e a
,
n d t i e t h e co il wi th

thre a da t C a R e move t h e co il fr om t h e fo r m a
'
nd C . n d com

pa r e i t wi th a sa mple i f su ch as a mple w a s p re s e rv e d fr om t h e

Ol d wi n di n g s I t is a .ls o we ll to t ry thi s firs t coi l in t h e a r ma

ture a n d s e e th a
, t it h a s t h e p r op e r s p a n a n d th a t t h e le a
,
ds to
t he a r ma ture a r e lo n g e n ough .

Th e follow i n g me thod for w i n d i n g coi l s for s ma ll motors

ha s b e e n foun d co n ve ni e n t by M a uri ce S C le men t (E l ectri ca . l
R ecord N ove mb e r 1 9 1 8) i n tho s e ca
, ,
s e s wh e r e are p a i r must
 OP E R A TI ON S B E FOR E A N D A F TE R WI N DI N G 1 43

be ma de on t h e j ob or coi ls m a de up whe re acoil win din g

ma chi n e i s n ot a va il a ble Th e fo rm i s ma de up a
. s follow s :

Fi r s t take afla t p i e ce of wood a bout thr e e four ths of a n i n ch -

thi ck a n d plot out t h e s h a p e of t h e coi l Th en pl a ce ri gh t .

a n gl e scr e w hooks a t a ll a n gl e po i n t s
, Th e scr ew hooks .

s hould po i n t a wa y from t h e cen t er of t h e form M a r k out t h e .

Cen t e r a n d ru n a br ea s t d ri ll thr ough a s fa r as i t wi ll go P la ce .

t h e b r eas t d ri ll i n avi s e i n aho ri zo n t a l pos i ti on wi th t h e coi l

form towa rd t h e l eft ta ki ng ca r e to pl a,ce i t so a s to a l low fr ee

FI G . 1 12 . FI G . 113 .

FI G . 1 12 .
—
A si x g a
ng form for wi n di n g coi l s in se ri es .

S ix a be w oun d i n s e ries a
coil s c n n d r e m ov e d i n a g r ou p s o t h ey ca n be i s e rt ed i n t h e
s l ot s of
an a
con n e ct i ons
l t e rna
Th i
t i n g curr en t m ot or s t a
s f orm ca n al s o be u se d
t
t
o
o
r
w
w
i
i t
nd a
h ou
s
t
i n
t h
l
e n e cess i t y of m a
s o r d ou bl e c orl
k
I
n
t
i h
i
g
s b
t
u
h
i
e
l t
s
u
e
p
ri es
i n
s e ct i on s wh i ch a
,
.

r e h e l d t og e t h e r by t h e bol t s a h e sl ot s I n t h e dw i s w ns be t w e e n
o

t A
se ct i ons e n a bl e t h e wi n di n g a n d r em ov a
.

l of t h e coil s I n s e r i es .

FI G l l 3
. C on t i n u ous joi n t l e s s p h a
.
—
s e -g r ou p coil s used on r ot ors of
Fa i r ban k s -M orse p h a s e w ou n d m ot ors T h e se coil s a re w ou n d
. on aform
si m i l a
r t o th a t s h ow n i n Fi g 1 1 2 . .

move me n t of t h e ha n dle T urn t h e wi re of whi ch t h e co il is

.

to be ma de on ce or twi ce a
, r oun d an a i l on t h e b a ck of co i l

form a n d le a
,
d t h e wi re ove r t h e e dge to t h e fa ce of t h e form

a n d tur n t h e h a n dle Th e fo rm ca n be r e volv e d a

. t a n y de

s i re d r a
te of s pee d a n d t h e wi re ru n ove r a ll t h e s cre w hook s .

Kee p s u ffi ci e n t t e n s i o n on t h e wi re to pe r mi t e a ch tur n t o li e

sn ugly b e s i de i t s pr e de ce ss o r .

This is aco n ve n i e n t w a y to w i n d co i l s f or t h e r e as o n th a
t ,

unn e ce s sa ry cr o ss i n g Of w i re s ca n be p re ve n t e d Wh e n t h e .

s pe ci fie d n umb e r Of tur n s h a ve be e n wou n d twis t as hort ,

pi ece of wi re a r ou n d e a ch e n d of co i l to hold i t i n p rope r s h a pe .

1 44 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

To fin i s h t h e ope ra ti on turn a ll s cre w hook s towa

, r d t h e ce n te r

of t h e form a n d s li p t h e co i l ofi .

A n othe r ha n d ma de form a
- l so re comme n de d by M r C l e .

me n t for u se i n wi n din g l a rge r coi ls th a n t h e on e d e scr i b e d

a bove i s s hown i n Fi g 1 1 4 . .

I n s ul a ti on of C or e a n d S l ot s Th e i n sul a ti on n ee de d wi th
.
—

co i l s u s e d i n p a lly clos e d s lot s a

rt i a n d i n op e n s lots of a lte rn a t
i n g curre n t m a chi n e s i s gi ve n i n C h a pt er V I I I a n d i n co n n e ct i o n

wi th t h e wi n di n g of di r e ct cu rre n t ma ch i n e s i n C h a
-
pte r I I I .

S l l t t h rou g h wh i ch
Fi r s t L oa
d of C ol l

( h w h i ch

B i n d C ol l

B enc

oor a
P l te

FI G . 1 14 —
. C on s t ru ct i on Of aco n v e n i e n t be n ch wi n de r fo r form i n g a
rm at u re
coil s .

Te s t in g Ou t th e Wi n din g .
—
De t a
of thi s ope ra il s t i on both
b efore t h e le a ds to t h e commut a tor a r e co n n e ct e d a n d w he n

try i n g to lo ca t e tr ouble s i n t h e w in di n g a r e g i v e n in C h a pt er V .

S ol deri n g C oil Le a ds t o th e C om m ut a t or A ft e r t h e w in d .
—

i n g of a n a rma tur e h a s be e n tho r oughly te s te d out t h e co il ,

te rmin a ls ca n be s old er e d to t h e commut a tor I n t h e s older .

i n g Ope r a t i o n g re a t care s hould be t a ke n tha t p i e ce s Of s older

.

do n ot fa ll or ru n down b a ck of t h e commut a tor to la ter pro

du ce as hort cir cui t a - n d ca use t h e a rma ture t o be return ed
for fu rth e r re p a irs TO p re ve n t d a
. ma ge to win di n gs a ci d ,

fluxe s s hould n eve r be u s e d i n s olde ri n g acommutat or A .

s olut i o n of r os i n i n a l cohol i s re comme n de d i n ste a d A t in .

a n d le a d s olde r i s con s i de re d b e s t i n s olde ri n g le a ds to t h e

commut a tor but apure t i n solde r i s u se d i n ma ki n g a ll other
 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

B a
n di n g a
A rm t ur e s .
—
pa
In i r s hop s where b a
re n din g

ma chi n es a r e n ot a va il a ble t h e ba ,
n d i n g of a rm a ture s i s don e
i n amo re or less i n di ff e ren t wa y w i th t h e r es ult th a t t h e

ba n din g m a y o n ly p e r fo r m a p a rt of i t s fu n c t i o n n a m ,
e ly ,

to pre ven t t h e coil s from b ein g thrown ofi t h e a rma ture core .

U n le ss t h e b a n d i n g i s pl a ce d on t h e a rm a tur e wi th gre a t ca re ,

there m a y b e s u ffi ci e n t mov e m e n t of t h e co i l s i n t h e s lot s t o

we a r t h e i n su l a t i on a n d ca us e g roun d s S u ch move men t is

.

a ls o li a ble to ca use bre a k s in t h e coppe r le a d s where the y a re

s old er e d ri g i dly i n to t h e commut a to r Th e d eta . i l s for ba n di n g

a n a rm a ture given in wh a t follows a re ta

,
ken fr om a n a r ti cl e

i n t h e E l ect ri c J ourn a l a n d r e p re se n t good s h Op p ra ct i ce tha t

ca n be follow e d i n both l a r ge a n d s ma ll re pa i r s hop s .

S hri n ki n g C oi l I nsu la t i on S i n ce t h e co il in s ul a
.
—
ti on s hri n ks
upo n be i n g he a te d i t i s n e ce s sa
,
ry to s hr i n k i t a s mu ch a s

po s si ble b efo re t h e fin a l ba n d i n g w i re i s a ppli e d T hi s i s .

do n e by he a ti n g t h e whole a rm a ture t o a bout 75 C ( 1 67 °

.

when t h e i n sula t i o n b e come s pli a ble a n d ca n be press e d down

in to pe rm a n e n t sh a pe .

Tem pora ry B a n ds Th e hot a

—
rm a tu re s hould then be
moun te d in ala the a nd a prote cti n g stri p of cloth pl a ce d over

t h e e n d w ind i n g s . Win d at e mpora ry b a n d i n g wir e over t h e

coil s w i th e n ough t e n s i o n to dr a w them down i n to pla ce a nd ,

fa st e n t h e en d s by s olde r i n g t i n cl i p s over t h e w i re Th e.

a rm a ture should then be a llowe d to cool A fte r t h e t e m .

p o r ar y w i re s a r e r e mov e d t h e a r m a tu re i s r e a dy f or t h e

pe rm a n ent ba n di n g .

Ba n di n g M w hi n e —
Whe n ab a n di n g m a ch in e is u se d t h e ,

t en s i on in t h e wi re i s re gula te d by p a ss in g i t over atr a in of

fri cti o n pu l le ys moun t e d on t h e ca r ri a ge Th e fri cti on of t h e
a
.
,

pulle ys ca n be dj us te d to a n y d e s i r e d va lue by t h e re gu la ti n g
s cre w s . I n t he a bse n ce of s u ch ad evi ce fa i r re s ult s ca
,
n be

obta i n e d by p a s s i n g t h e w i r e t wo or t h re e t i me s a roun d a

r oun d woode n b a n d i n g s ti ck a ppr ox i ma tely two i n che s i n

di a me te r a nd a djusti n g t h e te n s i on by ha nd .

C ore B a n ds .
—
Whe n co re ba n ds a re u s e d t h e grooves sho u ld
,

be fit t e d w i th th in s tri ps of t in wh i ch prot e ct t h e co i l s from

,

t h e cutt i n g a ct i o n of t h e b a n ds I n s ta
. rt i n g t h e p e r m a n en t

ba n di n g w i n d a
, fe w turn s a t on e e n d to se cure t h e n e ce s sa ry
 OP E R A TI ON S B E FOR E A N D A F TE R WI N DI N G 1 47

t en si on Then wi n d a
. ll t h e b a n di n g gr oups co n t inuous ly t o ,

e li m i n a te t h e n e ce ssi ty Of fa s t e ni n g t h e en ds of e a ch g roup a s

the y a r e wou n d .Th e b a n d s s ho u ld be h e ld toge the r a nd the

e n ds fa s t en e d by m ea n s of n a rr ow t i n s t r i p s ( a bout to
i n ch thi ck a nd i n ch wi de ) pl a ce d un d e r t h e wi re s

a n d be n t ba ck ove r t h e t op a n d h e ld by pu re t i n s old er T he se
.

s t r i ps s hould be i n s e rt e d whi l e t h e w i r e i s be i n g fe d on a nd

lo ca te d a bout e very three i n che s a r ou n d t h e a rm a ture wi th ,

close r S p a cin g a t t h e be gi n n i n g a n d e n d Of e a ch b a nd For .

t h e co re b a n d s the se s tri p s s hould be pl a

, ce d i n t h e s lot s a nd ,

be in g wi de r tha n t h e g roove th e y p re ve n t a
, n y te n d e n cy for

t h e ba n ds to sl i d e a r ou n d t h e a rm a ture Th e e n ds of t h e
.

g r oup s s hou l d th e n b e cu t an d s e cu r e d by b e i n g b e n t b ac k
out s i de on e cli p a n d i n s i d e t h e n e xt one P ur e t i n s olde r
.

s hou ld be a ppli e d to t h e whole surfa ce of t h e b a n d s to for m

asoli d web .

E nd B a d a Th e e n d wi n di n gs s hould be se cure d by
ro —

groups of wi re woun d on i n s ula ti n g hoods to prote ct t h e coi ls .

On t h e commut a tor e n d s tr i ps of thin mi cawi th ove rla

,
ppi n g
en ds a re u s u a lly pl a ce d on t h e commut a to r n e ck a n d h e ld i n

pla ce wi th a fe w turn s of twi n e . I f ahood or h e a d of ca n va s

i s t o be u s e d it s hould be wr a ppe d a rou n d t h e n e ck e x t en di n g

,

a bout a n i n ch fr om t h e e dge a
.

n d tur n e d i n s i d e out A ft e r .

thi s e n d i s se cure d wi th twi n e t h e free e n d of t h e hood s hould

,

be pulle d b a ck ove r t h e w i n di n gs b r i n gi n g t h e out si d e Of t h e

,

hood a t t h e s urf a ce a n d ma ki n g an e a t fold e d u n de r e dge

- .

Thi s hood ca n be h e ld te mpo r a ri ly w i th tw in e un t i l t h e wi r e

is a ppli e d Th e othe r en d of t h e a
. rm a ture s hould be si mil a rly

cove r e d wi th ah ood a nd ba n de d .

Tens i on to be A ppl i ed to B a nd Wi r e —
Th e p r ope r te ns i on
for b a n d i n g w i r e wh e n b e i n g a ppli e d va r i e s w i th t h e s i z e Of

wi r e a nd t he co n s t r u ct i o n of t h e e n d win di n gs When .

t h e e n d co i ls h a ve n o ri gi d s upport a n d e xt e n d out acon

si dera bl e dis t a n ce fr om t h e co r e t h e t e n s i o n s hould be g r a

,
du
a lly re du ce d a ,
s s hown i n t h e a ccomp a n yi n g t a ble .

Wi re Th e be st m a
—
t e ri a l i s ahi gh gra -
de s te e l pi a n o w i re ,

ha vi n g a fin a l b re a ki n g st re n g th Of lb pe r s q i n For
. . .

te mpor a ry b a n d s ach e a p er g r a de ca n bet u se d .Th e b a nd

wir e s hould be ti n ne d .
1 48 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

P O U N Ds TE N s I O N FO R B A N DI N G WI B E s

E nd ba
n ds

S ol de r .
—
houl d be us e d a
P ure t i n s s t h i s gi v es a
, ba n d th a t
wil l hold toge ther for alo n ger ti me tha n ha lf a n d ha lf s older - - .

E la n —
A bout lb of powde re d ros i n di s s olve d i n one
.
,

qua r t of d e n a t ure d or wood a l cohol m a kes agood flu x .

Ti n C l i ps a n d S t r i ps s ho ul d be Of comm e r ci a l shee t t i n
a bout to i n ch thi ck .

P reca u ti on s U se ab a
—
n d wi re th a t is stron g e n oug h to
pre ven t move me n t du e t o hi gh s pe e d a n d vi b ra t i on .

S e cu re t h e e n d s of a ll h a n d w i r e s u n d er t h e cli ps .

S ee th a t t h e ba n ds a re b e low t h e s u rfa ce Of t h e core to

kee p the m from rubb in g on t h e pole s .

B e fo re a pplyi n g core b a n ds s e e th a
,
t t h e t ops of t h e co i l s
a re a bout l é g in ch a bove t h e b a n d g roov e so th a t t h e ba
,
n ds

pull t h e coi l s down e ve n wi t h t h e core I f t h e co i ls a . re too

hi gh a n d t h e ba n ds do n ot r e s t on t h e core s loo se b a n d s wi ll ,

re s ult wh e n t h e i n s u l a ti on dri e s out .

Wi n d a ll co re b a n d s i n on e Ope ra ti o n .

I n s olde r i n g u s e a4 l b cle a
,
-
n i ron we ll t in n e d
.
,
.

Ba n d s to be e fi e ct i ve s ho ul d be k e pt t i ght I f they a re .

a llowe d to be come loo se groun de d a ,

rma ture s a n d b r ok e n l e a ds
m a y r e s u lt I t .i s c o n s i de r e d good p r ac t i ce to r e b a n d n e w o r

n e wly re woun d r a i lw a y or hois t a r ma ture s a ft er a bout 1 2 to

1 8 mo nth s a s a sa fe ty firs t me a -
s ure ; a n d to m a ke ren e wa l s on
Ol d o n e s wh e n e v e r t h e b a n ds s ta rt to loo se n Th e se rvi ce .

co n d i ti o n s te mpe ra
—
ture a n d s pe e d la r ge ly de te r m i n e t h e
—

le n g th Of ti me tha t ba n d s w i ll hold t i ght On e l a rg e Ope ra

. ti n g
comp a n y r e ba n ds a ll a rm a ture s e ve ry two ye a rs .

S ea s o ni n g a n d Gri n di n g aC om m u t a t or A n e w or re a .
—
s

s e mbl e d Com m u b t or b e come s sea son e d th a t i s t he

“

i n s ul a ti on b a ke d out a nd a ll p a r t s i n th e i r fi n a l set posi ti on ,

1 50 A R M A TU R E WI N DI N G A N D M OTOR RE P A I R

brus h hold er a
- rms a n d s ho u ld e xt e n d fr om t h e commuta tor
s urf a ce to a n i n ch Or two a bove t h e s urfa ce of t h e a r ma ture .

It m a y a ls o b e d e s i r abl e to put a t e mpo r a r y c a n v a s hood

over t h e a rma ture wi n di n g This prote cti on ca
. n be bes t

provi de d by ca rryi n g t h e coppe r dus t a wa y by m ea ns of a

va cuum s ys te m . E ven whe n thi s is do n e t h e a rm a ture should

be pro t e cte d a s des cri be d . A fte r gri n di n g t h e comple t e
,

ma ch i n e s hould be thoroughly cl e a n e d by t h e m e thods a lre a dy

d es cri be d I t m a
.
y b e n e c e ss a r y to r e p e at t h e h e a t i n g,
t i ght g
-

e ni n g a n d g ri n di n g one or more t i m es b e fo re t h e commuta tor

i s i n firs t cl a
- ss co n di ti o n . E me ry cloth or p a pe r s hould n eve r
be us e d for thi s purpos e on a ccou n t Of t h e co n t i n ue d a b ra s i ve

a cti o n of t h e e m e ry whi ch b ecom es e mb e dd e d i n t h e C op pe r

ba rs a nd b rus h es . E ve n whe n s a n dpa pe r i s us e d t h e brushes

s hould be r a ise d a n d t h e commut a tor wi pe d clea n w i th a pi e ce
of ca n va s lub r i ca te d wi th avery s ma ll qua n ti ty of v a s eli n e or

Oil . C otto n w a s te s hould n e ver be us ed a nd a n e xce ss of

lub ri ca n t s houl d be a voi de d .

Th e gri n d i n g d ev i ce sh own i n Fi g 1 1 5 ca . n be moun ted i n on e

Of t h e b r u s h hold e r a
-
rm s or rac e s of al a
b k t rg e m a ch i n e .

Th e gr i n d i n g s to n e s should be a djus ted a ga i n s t t h e rota

“

tin g
commut a to r un ti l aclea n cutti n g eff e ct i s se cu re d but s hou ld
,

be ca re fully s h a pe d to t h e com muta tor surfa ce b e fo re b e i n g

pl a ce d i n t h e g r i n d i n g d e vi ce Th e s to n e s ca
. n be move d

a cro s s t h e s ur fa ce of t h e commut a tor whi le i t i s ru nni n g by ,

m ea n s of t h e h a n dl e sho wn a t t h e ri ght i n t h e i ll u s tra ti on .

U n de rcu t ti n g M i caof C o m m u ta t or S e ve ra
.
—
l d evi ces a nd

ha n d tool s a re u s e d for th i s op e r a t i on D e ta . i l s Of th ei r us e
a nd d e s cri pti on s of t h e d evi ce s a re gi v e n i n C ha pter XI I ,

pa ge 3 2 0 .

Ba la n ci n g a n A rm a t ure —
Af t e r ana rm a ture h a s b e e n woun d ,

ba n de d a n d i t s commut a tor true d it mus t be b a la n ce d . In

.

t h e ca se of s m a ll me di um s pe e d a rm a ture s thi s ope ra ti on ca n

be s u cce ss fully do n e on apa i r of s te e l kn i fe e dge s moun te d

pa ra lle l to e a ch othe r a n d p e rfe ctly l e ve l Th e en d s of t h e
.

a rm a ture s h a ft a re pl a ce d on th e se k nif e e dge s s o th a t th e

a rma ture i s free t o roll I t i s the n gi ve n as li ght r oll wi th
.

t h e ha nd a n d whe n i t com e s to r es t t h e bottom m a ,

r k e d w i th a

pi e ce of ch a lk Thi s rolli n g a
. n d ma r ki n g s hould be re pe a te d
 OPE R A TI ON S B E FOR E A N D A FTE R WI N DI N G 1 51

se ve ra l ti m e s I f t h e m a
. r k s fa ll wel l di s tri bute d a roun d t h e

a rm a ture core t h e a rm a tur e i s i n suffi ci en t b a la n ce for se r vi ce

a n d ca n be pl a ce d i n t h e motor .I n ca se t h e m a r ks f all close

toge th er or a ll on on e s i d e of t h e a rma ture i t mus t be b a
, la n ce d

by a d d i n g we i ght to t h e oppo si te si de or re movin g we i ght

from t h e he a vy si de Thi s i s don e i n di ff e r en t wa
. ys de pen d
i n g upo n how mu ch t h e a rm a ture i s out of ba la n ce B e fore .

t h e we i ght i s pe rm a n e n tly fix e d i t mu s t be d e t e rm i n e d e x a ctly .

Thi s ca n be do n e by t h e u se of s lug s of l e a d pr ope rly a tta ch e d

a n d sha ve d dow n wit h akn i fe un ti l t h e pr ope r b a la n ce i s

se cur e d . Freque n tly an ut or bolt h ea d ca n be file d on t h e

he a vy si de whe n t h e a moun t to be re move d i s s ma ll Other .

wi se s ome method of a tta ch in g a pi ece of me ta l or s olde r mus t

be de vi se d e qua l i n wei ght t o t h e le a d s lug determ in e d by
t h e tes t .

For h i gh - s pee d a rm a tures a n d those m a ch i n e s where a

perfe ct ba lan ce mus t be se cu re d t he a

, rm a ture shoul d be
tes t e d in as pe ci a l ba la n ci n g m a chi n e .

Pa i n t in g th e Wi n din g . Th e ki n ds Of in s ul a
—
ti n g v a rn i s h

a n d i m pre g n a ti n g compoun ds t h a t should be us e d on a n a r ma

ture wi n di n g a re g i v e n on pa ge 1 76 Of C h a pte r V I I On ly .

good g ra des of i n s ula t i o n pa i n ts s hould be us e d on wi n di n gs .

When t h e wi n di n g i s s ubj e ct e d to a ci d fum e s or t h e m a

,
ch in e

lo ca te d i n da mp pla ce s t h e m a nu

fa cture r sh ould be con s ulte d on t h e

tre a tm en t th a t sho ul d be gi ven t h e

wi n di n g .

R e l i ni n g S pli t B ea
ri ng s —
Th e
followi n g s ugge s t i on s (I ns tructi on
B ook We st i n ghouse E le ct ri c
,

M fg C O ) ca
. n be followe d i n r e
.

n e wi n g s pli t b e ari n g s of t h e oi l r i n g

type M e lt t h e Ol d be a
. ri n g out Fm 1 16 . M a d .l f—
n r e or
l i i g p li t b a
of i t s sh el l a n d pr e p a re a
Wh
n i ro n
en “ n n s e "

ifg:
ma n dre l s u ch a s s how n i n Fi g .

1 1 6 ha vi n g t h e s a me d i a me te r f a s t h e sh a ft an d di me n s i o n s

c d a
, n d e ta ke n from t h e h e a r i n g to be r e n e w e d I ro n p i e ce s
.

BB a n d C s hould be a tt ach e d by scre w s to t h e m a n d r e l to

form t h e Oil ri n g slots a n d t h e ho riz on t a l i nspe cti o n Ope n in g

1 52 A R M A TU R E WI N DI N G A N D M OTOR R E P A I R

i n t h e t op ha lf of t h e bea ri n g Th e pie ces B B s ho uld be

.

ta pe re d so tha t the y wi ll w i thdra w ea sil y fr om t h e ca s t meta .l

A shoulde r D so pla , ce d a s t o fit a g ain s t t h e e n d of t h e b ea r

i n g she ll serves a s agui de .

For the L ower H a lf Wa—

rm t h e m e dr e l a n d be a r in g s h e ll

a n d wh il e both a re s ti ll w a r m so a s n ot t o cool t h e m e ta l too

ra pi dl y when pour in g pla , ce t h e ma n dre l i n t h e lowe r h a lf of
t h e s h e ll wi th t h e s houlde r D t i ght a ga i n s t t h e e n d of t h e s h e ll
a n d t h e s tr a i ght bottom porti on s of t h e pi e ce s B B res tin g on
t h e S pl i t pl a n e of t h e b e a rin g C lo se t h e j o i n t s a
. : w i th putty

a n d fill t h e Op e n i n gs b e tw ee n t h e s h el l a n d t h e hou s i n g le a d
i n g t o t h e Oil we ll wi th we t w a s te P our t h e molte n me t a
. l
,

hea te d j us t e n ough to flow re a di ly in to t h e s pa

, ce b e twee n t h e

s he ll a n d t h e ma n d re l u n t i l t h e me t a l i s flus h wi th t h e s pli t
s urf a ce of t h e hou s i n g Th e me t a
. l wil l ha r de n very q ui ckly

a n d t h e ma n d re l ca n th e n be re move d .

For th e Upper H a lf Fil l t h e Ope n in gs i n t h e upper h a

—
lf
s h e ll w i th putty a nd l a y t h e m a n d r e l i n t h e s h e l l w i th t h e

s pli t s i d e u p . B lo ck t h e Ope n i n g s le a di n g to t h e Oil wel l wi th

wa ste a, n d pour a s d es cri be d for t h e lowe r h a lf R e move t h e
.

ma n dr e l s mooth a
,
ll r ough e dges i n t h e be a ri n g by ch i pp i n g

or fili n g a ,
n d chi p t h e Oil g r oove s i n t h e li n i n g of t h e upp er

ha lf. T h e be a ri n g s urfa ce of both h a lve s s hould be ea se d Ofi

by s cra pi n g a n d t h e e dge s a lon g t h e s pli t s urfa ce s ho uld be

file d flus h wi th t h e shell .

 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

For Hi g h Tem pera tu res and E l ectri ca l I nsu l a

ti on M i ca .
—
,

ni t e , m i cap a
m i ca pe r and m i cacloth .

For E l ectri cal I ns u la

ti on On l y — C otto n ta pe a
. n d Oi l e d or

te d cloth whi ch i n clude s cotto n or li n e n mus li n va

t re a rn i s h ed ,

ca mbri c va rni s h e d mus li n a

, n d e m pi re cloth
, .

FI G . l l T yp e of wi re w ou n d coils u se d i n s t a
7 .
—
t or of Fa i r ba
n k s -M ors e
al t e rn at ors ( Fi g Th e s e coil s a
. re t h orou g hl y i n s u l a
ted a n d re q u i r e

On l y an on -a br a si v e m a l i n t h e s l ot t o g i ve m e ch a
t e ri a ni cal p r ote ct i on t o t h e
coi l s
.

For M e ch a
ni ca l P r ot e ct i on a l I n sul a
n d E l e ct ri ca ti on .

rd or fu l l erboa
P res s boa rd i s am a te ri a
l rese mbli n g ca rdboa rd

an d ma de fr om cotton ra gs a n d pa pe r cli ppin gs I t va ri e s

a
.

from se ve n to 1 2 5 mi ls i n thi ck n e ss a n d wh e n p rope r ly tre te d

a n d va rn i s he d h a s a di e le ctri c s tre n g th of a bout 500 volts pe r

m i l i n th i ck n e s s up to 2 5 m i ls a n d th e n re du ci n g to a bout 200
volts pe r m il i n t h e thi cker s hee ts .

P res s pa hn i s t h e na m e g i ven to t h e p res s bo a r d whi ch i s m a de

i n Ge r m a ny .

V u lca n i z ed fib er a ls o kn own a s ha rd fibe r i s ade n s e h a rd

ma te r i al wi th adi el e ct i c s tre n g th of a bout 200 volts pe r m il

a t thi ck n e s s e s of fr om 50 to 1 50 m i l s .I t i s u se d wh e reve r
a n i n s ul a ti n g ma t e ri a l Of ex ce pt i on a l me cha n i ca l s tren g t h is
n e e d e d s u ch a s w e dg e s i n a r ma ture s lots a n d coil b ra ces .

H om fiber is ama t e r ial ma de i n di ff ere nt colors tha t ha s

a hi gh te ns i le s tre n gth a nd a ls o agood di ele ctri c s tre ng th

( 2 5 0 volt s p er m i l wh e n 1 0 m i ls th i c k ) w hi ch c a n be i n cr e as e d
by i mpre g n a ti o n wi th oil or v a r n is h.

Fi s h pa p er i s m a d e f r om r a g s to ck a n d th r ough a t re at i n g
pro ce ss be comes aha r d fibe r li ke p a
-
pe r whi ch is very s tro n g .

Th i s m a teri a l is not a fle ct e d by he a ta n d on a ccou nt of thi s

'
 I N S UL A TI N G C OI L S A N D S L OTS

a
n d i t s me ch a
ni ca
l stre ngth is mu ch use d a
s ce l l l i n i n g in
a
rm ature sl ots .

n i la
Ma a
p per i s ma de from li ne n or M ani l afibe r pr oduci n g a
t ou gh s tr o n g p a
pe r whi ch whe n dry h a s ad i e le ct ri c s t re n gth

va ryi n g from 1 00 to 2 30 volt s pe r m il i n th i ckn es ses Of fr om

to 2 8 mi ls .

For Hi g h Te m pera t ur e s a n d E l e ct ri ca l I n sul at i on —

M i ca
i s on e Of t h e ve ry fe w m a ls whi ch ma
te ri a i n tai n s ah i gh d i e le c
tri c s tre n gth a t hi gh t e mpe ra ture s I t i s n ot howe ve r m e .
, ,

ch a n i cal l y s tro n g Fle x i ble s hee ts of m i caa

. re m a de up by
s t i cki n g thi n s pli tt i n gs of m i ca on on e s i d e Of a s h e e t Of pa pe r
or cloth w i th a s ui t a
ble va rn i s h i n s u ch a wa y th a t t h e jo i n t s

FI G . 118 .
—
Di fi ere n t t yp e s of coi l s u se d I n re wi n di n g m o t ors .

l ). a
nd ( 3) a
rew i r e w ou n d d ir e c t - urr e n t c oi l s
c T w o s e ct i ons a r e s h ow n i n ( 1 )
a a
Th e coi l i n ( 3 ) i s r e d y t o be 3 r ea d i n to a
.
. o

ore sse m bl i n g t h e cp m p l e t e coi l m

di a m ond s h a p e i n pa u l h n g m c hi n a
e ( 4 ) I s a 3 0 — ca ll e d m us h or ba s e t c o il o rk p a rt i a
l l y
Th e C oIl a a a
.

s s h w n 1s re d y f or us e I n A C
.

cl ose d s l ot s p m ot o rs f r om b o u t 36 t o 1 5 h
a a a
.

r e am e n t
.

a s as h u t t e
.

( )
5 i s c o m p l e t e d s t r p c O I l r e dy f o r
fi n l t t or d i pp i n g ( 6 ) i .

w ou n d coil , t h r ee wi r es W i d e by e i t w i r es d ee I n s e r i es f or A C m ot ors w i t h ope n

T hi s coil i s sp r ea d i n t o aa ghe I n a i n ng a
.

ns u l a
.

s l ot s m ch i n e I t i i t d w i th
p p s e
a a Th e 001 1 a ) is t h e s a
.

va
.

t t h e e n d w h e re W i res cross I n w i nd i ng t (7
.

rn i s h ed c m bric m e
a aa
ft er bei ng s pre d n d Ins ul t e d t h t a a
.

a s ( 6) pe .

a r e s ta gge re d S uch . s he ets a bu lt u p

re kn own un d e r d i ff e ren t
i -

na me s s u ch a
,
s Japa n e se P a pe r a n d M i ca Fi s h P a pe r a nd

M i ca a
”
nd T re a
te d C loth a n d M i ca Th e s e a re a l so
“
.

refe rre d t o a s M i ca a
p p e r a n d M i ca cl oth .

M i ca n i te is a form Of re con s tructe d m i cam a de bo th i n pla te

a n d fl ex i bl e fo r m s Th e la t te r i s u s e d for a
. rm a ture s lots a nd

t h e for m e r for commut a tor s e gm e n t i n sula t i on I t s di e l e ct ri c .

s t ren gth i s ve ry h i gh r a n g i n g i n t h e fl e xi bl e fo r m fr om a bout

600 volts per m il for fiv e m il thi ckn e ss to 500 volt s pe r m il in
1 56 A R M A TU R E WI N DI N G A N D M OTOR REPA I R

1 25 -m il thi ckn e ss e s M i ca . n i te pa p e r a n d M i ca n i te cl oth i s

a ls o ma de wi th J a pa n e se p a pe r a n d w i th mu s l in .

For E l e ct ri ca l I n s ul a t i on 0nl y C otto n i s u se d i n t h e fo r m

.
—

of ta pe or cloth Whe n use d pri ma

. ri ly for i t s di e le ct ri c

s t re n gth ,
i t i s t re a te d wi th a n i n s ul a ti n g compoun d A f t e r .

s u ch t re a tm en t cotto n cloth will wi thst a nd a bou t 1 000 volts

p e r m i l th i ck n e ss B e
. c au se th i s i n s ul at i o n i s fl e x i bl e an d
t ough i t i s mu ch us e d a s a n i n s ul a t i on i n t h e in sula ti n g of co ils
a n d oth e r p a rt s of e le ct ri ca
'

l ma ch i n e ry S i n ce i t i s qu i te
.

s u s ce pt i ble to d a ma ge a nd a bra s i o n i t i s mo s tly u se d w i th a

prote cti ve cove ri n g s u ch a s u n t re a t e d cotton ta pe or fri cti on

ta pe or atough pa pe r s u ch a s fish p a pe r Diffe re n t w e i ghts
.

a n d th i ck n e s ses of cloth a re u s e d for i n s ul a t i n g pur po se s such

a s ca mb ri c fiv e mils thi ck ; mus li n e i ght m i ls thi ck ;h e a vy cotto n
1 1 m i l s th i ck ; dr i lli n g a bout 1 7m i l s th i ck ; a n d du ck a bout 30
m i ls thi ck Wh e n du ck is tre a
. te d wi th li n se e d oil or va rn i s h

i t i s fr e quen tly u se d a s a prote cti vecove ri n g ov e r co i l support s ,

b etwe e n co il en ds a n d ove r t h e e n d s of a rma tur e s C otton .

i n s ula ti n g ma t e ri al wh en t rea te d wi th a n i n s ul a ti n g compoun d ,

va rn i s h or l i n s ee d oi l i s k n own un d e r se ve r a
,
l na m e s s uch a s va r

n i s h ed ca m br i c va
,
r n i s he d m us l i n E m pi re cl oth K a
,
ba k cl oth et c
, ,
.

A n y of t h e cotto n m a te r i als ca n be cu t i n to n a rrow w i dth s

for u se a s ta pe whe n i n sula ti on i s more i mport a n t th a n m e

ch a n ca s t e n gth
i l r Ta
. p e cu t on t h e b i a s i s u se d t o ta pe u p
-

co i l s of i rr e gula r sha p es .

De s cri pt i on s a
nd Uses of I n sul a t e ri a
t in g M a ls —
In th e
followi n g p a ra g ra phs t h e composi ti on of t h e i n s ul a ti n g m a
t eri a ls a lrea dy m en ti on ed tog eth er wi th ma n y oth e rs th a ta re

a va i la bl e a r e gi v en wi th thei r va ri ou s u s es Thi s i nf orm a ti on .

is ta k en from acompr eh en si v e cl a ti on of tr ea
ss i fi ca t ed cloths ,

pr ess boa rd s ,
fib ers a nd pa p ers by Hugh E We i ghtm a n .
,

C hi ef E n gi n e er E n gi n eeri n g S ervi ce C ompa

, ny C h i ca go I ll , ,
.

( E l e ctr i c a l R ec o r d J ul y, ,

Tre a t e d C l ot h s Th e d i ff e re n t ki n d s of t r ea
.
—
t ed cloths
whi ch a re a va il a bl e a re a s follow s :

Bl a
ck a
v rni s h e d c m a bri c Ye l l ow a
v rn is h e d c m a bri c
Jaa d m us l in Oil e d m u s l in
‘

p n n e

Ja
p an n e d du ck Ye ll ow oi l e d c nva a
s

Varni s h e d s i l k Y el l ow oi l e d cot t on dril l

1 58 A R M A TUR E WI N DI N G A N D M OTOR REPA I R

thi ck Thi s m a
. teri a l i s us ed for m u ch t h e s a m e purpos es a s

bl a ck va rn i s h ed ca mbri c .

Oi l ed mus lin i s ali n en fini s h ed cloth coa t ed wi th oil a nd

ov en cu red to s et t h e film to aha r d s mooth s u rf a ce Th e .

p roduct i s afl exi bl e cloth h a vi n g hi gh i n sul a ti n g prop erti es

a n d g ood r es i s t a n ce to d et eri o r a ti on through vi bra ti on or
a gi n g I t i s us ed for ala
. r g e va ri ety of pu r pos es es p eci a ll y
,

f or wr a ppi n g a rm a tu re coi ls a n d i n ta ,
p e form for ta pi n g coi ls
,

a n d l ea ds I t i s suppli ed
. i n t hi ck i n 36 i n roll s or i n
.
- .

st a n da r d wi dth t a p es .

Y el low oi l ed ca n va s 1 8 ahi gh gra d e duck tr ea t ed wi th

oi l to p rodu ce a fl e x i bl e w a t erproof ma t eri a l I t is u s ed .

f or pa d s un d er ra i lwa y motor fi eld coi ls a n d i n s i mi l a r pl a ces .

T hi s m a t eri al i s common ly obt a i n ed i n on e thi ckn ess of

i n i n rolls 3 6 i n wi d e
. . I t is a
. ls o us ed for ta r pa ul i n s for g en e ra

tors s wi t ch es a
,
n d s u ch a pp a ra tus Yel low oil ed cotton drill
.

i s al i ght un bl ea ch e d cotto n d ri ll t r e a t ed wi th oil a n d ov en

cu r ed to s e t t h e film to afirm s u rf a ce I t i s ma . de in .

thi ck a n d i n roll s 3 0 i n wi d e . I t i s oft en us ed for coi l s ep a

. ra

t ors i n tra n s fo r m e rs a n d r e gu l a tors .

P re s s boa r d s Fi bre s a
, nd P a p e r s F i b e rs —
l e a t h e r
,
o i d s a n d
s u ch m a t eri als a r e es p eci a
, lly s el ect ed for th eir hi gh i n sul a ti ng
prop erti es a n d th ey a
, r e t r ea t ed to r en d e r th em mor e pli a bl e
a n d ea s i ly wo r k ed .Th e t r ea tm en t do es n ot a pp r eci a bly
a ff e ct t h e thi ck n es s ex ce pt i n t h e ca s e of t h e s h el l a ck ed

ma t eri a ls Thi s t r ea
. tm en t a dds a pproxi ma t ely in .

i n thi ckn es s to t h e si z e of ea ch s h e et Wh en o rd eri n g t r ea

. t ed
ma t e ri a l from t h e m a n uf a ctu r e r t h e thi ckn es s a lwa ys r ef ers
to t h e un t rea t ed m a t e ri al Th e fol lowi n g ki n ds of thi s cl a
. ss

of t rea t ed m a t eri a ls a re a va ila bl e :

P re ss boa
rd Varn i sh e d ra
w hi de fibe r
Ja p a n n e d p re s sboa
rd Leat h e roi d
Oi l e d p re s s boa rd E x pre s s pa
rch m en t pa
pe r
S h el l ack e d p r e s sboard S h el l ack e d e x p re s s p a
p e r

Va rn i s h e d p ress boa rd Va rn i s h e d e xpre ss pa pe r

Horn fibe r Re d rope p a pe r

Ja pa n n e d h orn fibe r Oil e d re d rope pa p e r

Oi l e d h orn fibe r S h e ll ack e d re d rope pa pe r

S h el l ack e d h or n fibe r Va rn i s h e d re d rope pa pe r
Va rn i s h e d h orn fibe r Shel la ck e d bon d pa p e r
 I N S UL A TI N G C OI L S A N D S L OTS

Ra
whi de fibe r A s bes t os pa pe r
Ja
p a
n n ed r a
w h i de fibe r Oi l e d as be s t os pa
pe r

Oil e d aw h i de fibe r
r Va
rn is h e d a
s be s t os pa
pe r
S h e ll a
cke d ra wh i de fibe r

P res s boa
r ds .
—
bo ard i s a
P res s p eci a
s lly pr epa r ed p a p er whi ch
i s d en se fl exi bl e a
,
n d ea si ly wo rk ed I t r ea di ly a bs orbs oil s
.

a n d va rni s h es whi ch r en d e r i t l ess h yg r os cO i c th a

p n i n it s
un t r ea t e d s ta te I t i s us ed very exten si ve ly a
. s la ye r i n sul a ti on
a nd s pa ce rs i n va ri o us typ es of g en e ra tor moto r t ra n sfo rm er
, ,

a n d r e gul a tor coi l s C ol l a rs a.n d s hi eld s on hi gh volt a ge -

t ra n sf orm ers a re a ls o ma d e of thi s form of i n s ul a ti on On e .

ma n uf a ctur er ca rri es thi s m a t eri a l i n s t o ck i n t h e follo wi n g

Si z es :

Ja
pan n e d pr es s boa rd i s us ed for s epa ra tors a n d fil l e r s

in a rm a tur e a n d fi eld co i l s I t i s ma . d e in t h e sa m e s i z es
lis t ed i n t h e pr ece di n g pa ra g r aph O i l e d p r.es s bo ar d i s u s e d
i n t h e sa m e wa y a s j a p an n e d p r e
s s bo a r d an d i t i s s om et i m es
,

pref err ed si n ce i t i s mo r e fl exi bl e I t i s s uppl i ed i n t h e s a

. me
si z es a s g i v en for pr es s bo a rd S h ell a ck ed p r e ss bo a
. r d fin d s

i t s pri n ci pa l appl i ca ti on a s s e pa ra tors i n bo n d i n g ra i lw a y

a rm a ture coi l s Th e s h el l a
. c upo n t h e a ppl i ca ti on of h ea t ,

m elts form i n g aclos e un i on b etw een t h e s e p a

,
ra tor a n d t h e co i l .

Th e pri n ci pl e thi ckn es s u s ed i s 1 0 m i ls or in a lthough .

other si z es a re a va ila bl e Thi s ma . t e ri a l i s oft en m a d e up

loca l ly by ma n uf a ctur e rs A n y s i z es p r evi o u s ly li s t ed a
. re

a va il abl e .

P ress bo a rd v a rn i s h ed a n d ov en cu r ed i s us ed f or fill e rs a nd

s e pa ra tors Th e us u a
. l si z es a re a va il a bl e a s l i s t ed a bov e .

Horn Fi bers H o rn fib e r i s a to u gh fl exi bl e i n s ul a

—
ti n g
ma t eri al of hi gh m echa n i ca l a n d d i el ect r i c s t r e n gth I t is .

us ed for s ep a rators slot cha ,

n n els a n gl es a n d j oi n t i n s ul a
,
ti o n ,
1 60 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

a n d wh er ev e r ahi gh d eg r ee of fl exi bil i ty i s ess en ti a l This .

ma t eri a l ca n be bought i n both s h eet s a n d r ol l s A l l ho rn .

fib ers a r e obt a in a bl e i n t h e s a m e thi ckn es s es a s lis t ed for

pres s bo a rd . Ja p a n n i n g g r ea tly i n c r ea s es t h e fl ex i b i l i ty a n d
di el ect ri c s tren g th of horn fib er On e s p eci a l a
. ppli ca ti on of
ja pa n n ed ho rn fib e r is a s fill ers for b ra ck e t i ns ul a ti on a nd

a rou n d ro ck er a rms .

Tr ea t ed wi th oil a n d ov en cur ed ho rn fib er m a k es as up eri or

di elect ri c m a t e ri al for g en era l work S h el la ck e d ho rn fib e r
.

fin ds i t gr ea
s
t est a ppli ca ti on a s s lot a rmo rs i t b e i n g cus tom a , ry

to form t h e a r mo rs b e fo r e s h e ll a cki n g Va rn i s h ed ho rn fib er
.

i s us ed for fill ers a n d s e pa ra tors i n pref ere n ce to pr es s bo a rd

on b ett er m a chi n e s a n d es p eci a l ly on hi gh s p ee d un i ts b eca us e

i t i s mo r e fl exi bl e a n d do e s n ot d i s i n t egra te a s ra pi dly wh en
s ubj ect ed to vi b ra t i on .

Ra whi de Fi bers Ra whi d e fibr e is aha

—
rd er p r ess e d m a t e ri al
th a n ho rn fib er a n d co n s e qu e n tly l a cks s om e of t h e fl exi b i li ty

of t h e la tt er I t i s very tough a
. n d ca n be r en d e r ed mo r e

fl exi bl e by tr ea tm en t wi th j a pa n oil s h ell a c or v a

, rn i s h .

U n t r ea t ed i t i s us ed wh er e toughn es s i s ess en ti a l a n d wh er e

gr ea t fl exi bi l i ty i s n ot r equi r ed Th e thi ckn ess es of t h e s tock.

s i z es of t h e d iff er en t fo rm s of ra whi d e fiberju s u a l l y foun d on t h e

ma r k et a re : in in .
,
in a nd
.
, in S h eets
. .

or roll s a r e 40 i n to 48 i n wi d e S h eets a
. . r e us u a
. lly 72 i n .

to 1 20 i n lon g J a
. pa .n n ed r a whi d e fib er h a s i n cr ea s ed d i e l

e ct r i c s t r en gth a n d i s mor e fl e xi bl e th a n t h e u n t r ea t ed fiber .

I t i s us ed for t h e mo r e s i mpl e s h a pes of slot a rmo r a n d for

fill ers a n d s ep a ra tors R a whi d e fib er tr ea

. t ed wi th ahi gh
gra d e oil a n d ov en cu r ed to p r odu ce a firm s u rfa ce i s u s ed for

t h e sa m e purpos es .

S h el l a ck ed r a whi d e fib er is us ed for t h e s a m e pu r poses a s

s h e ll a ck ed ho rn fib e r wh er e gr ea ,
t fl ex i bil i ty i s n ot r equ i r ed .

Va r n i s h ed r a whi d e fib er i s t h e mos t fl ex i bl e of t h e ra whi d e

fib ers a n d i s u s e d for fill e rs a n d s ep a ra tors .

L ea ther oi ds In a.
—
pp ea ra n ce l e a th eroi d i s qui t e si m i l a r to

ra whi d e fib er I t i s us ed for t h e s a
. m e g en era l pur pos es a s

t h e ra whi d e a n d ho rn fib e r I t i s how ev er mo re r es i s ta
.
, nt
,

to h ea t i s mor e d en s e a
,
n d molds mo r e r ea di ly tha n ei t h er of

t h e oth ers Th e us ua
. l thi ckn es s es a va i la bl e i n s h e ets or rolls
 I

1 62 A R M A TU R E '
WI N DI N G A N D M OTOR REPA I R
in ma ki n g l a y er i n s u l a ti ons wh er e h ea t r es i st a n ce i s n e e d e d .

Thi s ma t eri a l mus t be pur cha s e d u n d e r s p eci fica t i on s h a vi n g a

t es t or i n s p ect i on cl a u s e i n o rd er to gua rd a ga i n st t h e p r es en ce
of con ducti n g pa rt i cl es of I ron o xi d e I t i s furn i s h ed us ua
. lly
i n roll s 3 6 in wi d e a . n d i n t h e followi n g th i ckn ess e s : 6 m il ,

1 5 m il a n d 2 0 m il % 2 i n ,
.
hi s
,
i n an d .
34 i n A s b s
e to s
. p a p e r

t rea t ed wi th hot oil a n d ov en cu r ed i s u s e d i n ra i lw a y motor ,

fi eld a nd a rm a tur e coi l s a n d i n ma chi n ery Op era ti n g a t hi gh

t e mp era tu r es .

Wh en t h e a s b es tos p a p er i s t r ea t ed wi th as p eci a l bla ck

pl a s t i c va rn i s h a n d ov en cu r ed i t b ecom e s ag r ea t m oi st u r e
'

proof i n s ul ati on a n d i s u s ed i n fo r m s f or cor es or s pool s It .

i s us ed a s a moi stu r e proof h ea ,

t r es i s ti n g i n s ula
- ti on for motors
i n t en d ed for n a va l mi n e or s i mi l a
,
r s e r v i ces .

C oi l a n d S lo t I n s u l a t i on U s e d i n On e La r g e R e pa i r S h 0p .

Th e followi n g gra d es a n d thi ckn e s se s of co i l a n d s lot i n s ul a ti o n

i s ca rri e d i n s t o ck a n d us ed by on e l a rg e r e p a i r s hop wh er e a ll
typ es m a ,
k es a n d si z e s of motors a r e r e wou n d .

Fi s h P a p er : I n s h e e t s 4 ,
7 1 0 , 1 5,
a n d 2 3 m i l s t hi c k .

Fi s h P a p e r w i th M i c a S pl i tt i n g s : I n s h e e t s 1 3 m il s th i ck .

Fu l l er boa r d: I n s h e et s 7 1 0 a ,
n d 1 5 m i l s th i ck
,
.

S h el l a cked F u l l er boa r d : I n s h e ets 7 1 0 a ,

n d 1 5 mi l s th i ck .

Tr ea ted C em en t P a p er a n d M i c a S p l i t ti n g s : I n s h ee t s 1 4 m i l s

thi ck .

Ba rr en P a p er : I n s h e e t s 3 a n d 5 m i l s th i c k .

E m pi r e C l oth : I n s h e et s 9 mi l s thi ck .

C otton D u ck : I n s h e et s 1 2 mi l s th i ck .

C otton Ta p e : I n w i dth s a n d 1 % i n 7 m i l s
. th
,
i c k .

Tr ea ted C l oth Ta p e : I n w i dth i n 8 m i

. l s
, th i c k .

U n d e r t h e d i ff e r e n t h e a di n gs of C ha pte r I I I de a li n g wi th t h e
wi n di n gs of p a rt i cul a r ma ch i n e s d e t a ,
ils a re gi ve n co n ce rn i n g

t h e u s e s of t h e d i ff e re n t i n s ul a ti n g m a t e ri a ls d e s cri be d he re .

M i ca rt a f ol i um . A s p e ci a
—
l i ns ula ti n g m a t er i a l ha s b ee n

d e ve lop e d by t h e We s ti ngho u se E le ctri c Ma n ufa ctur i n g

C omp a ny wh i ch i s k n own a s m i ca r ta I n t h e form of

.

m i ca r taf o li u m i t c a n b e u se d a s a w r a pp i n g T h i s i ns .ul a t i o n

i s u se d on t h e l a rg e r a l t ern a t i n g cu rre nt a -
rm a ture wi nd i ng s ,

pa r t i cula rly tho s e of a lte r n a t i ng cu rre nt t urbo ge n e ra

-
tors - .

I t is a l s o u s e d for d i re ct cu rr e n t a -
rm a tu re w i nd i ngs For .
 I N S UL A TI N G C OI L S A N D S L OTS

c om m uta tors it is us e d b e twe e n t h e bottom of t h e s egme nts

a nd t h e s lee ve on t h e d ri v i ng s p i n d l e I t is a l s o u s ed i n .

di re ct curre nt ma
-
ch i ne s for fl a s h gu a r d s b e twe e n t h e com

m uta t ors a nd t h e a rm a tu re wi nd i ng of la rg e u ni t s For .

i ns ul a ti ng s tud s a nd t h e ca pp i ng of nu t s a nd bolt h e a ds it
ha s a lso be e n fou nd s a ti s f acto ry Th is type of i ns u la . tio n
is m a de i n s hee ts blocks a n d tub es
,
.

Thi ckn e ss of I n s ul a t i on R e qui r e d i n S l ot s P rof A lfre d S till —

.

i n h i s book on E le ct ri ca l D e s i g n un de r t h e h e a di n g of slot
,

li ni n g po i n t s out th a t t h e in s ula ti on m a y b e pl ac e d a r ou n d
t h e i n di v i du al co i ls or i n t h e s lot b e fo re t h e co il s a re i n se rte d .

Pa rt of t h e i n s ul a ti o n m a y a l s o b e pl ace d a r o un d t h e co i l s

a n d t h e re m a Th e e ss e n t i a
.

i n de r i n t h e form of s lot l i n i n g l .

thi n g i s to ha v e su ffi ci e n t thi ckn e ss of in sul a t i on be tween t h e

cotto n cov er e d co n du cto rs a
- n d t h e s i d e s of t h e s lot I n thi s .

co n n e ct i o n t h e followi n g figur e s a re gi ve n by P r of S ti ll for .

t h e thi ckn e ss of s lot l i n i n g re qui re d for m a ch in e s of d i ff e ren t

volta ge s Th e thi ckn e ss i n i n che s i s for on e s i de on ly of t h e

.

s lot a , n d is a s w ell t h e th i ck n e s s th a t should be p rovi de d be

tween t h e uppe r a n d low e r co i l s i de s i n t h e slot .

O v ol t a
pe r rt i n g
ge S l ot i ns u l a
t i on —
on e s i d e
for di rect -c urre n t m a chi n es
AI B’
i n ch
i n ch
i n ch
i n ch

For l t e r na
a ti ng -c urr e n t m a
ch i n es

500 t o s a
m e a
s for d i r e ct -cu rr e n t m a
ch i n e s

Up to i n ch i n ch
U p to i n ch i n ch
Up to i n ch 0 1 8 5 i n ch
.

Up to in ch i n ch

I n sul a
t i on of pra
Form e d C oil s
ct i ce of mo s t moto r .
—
Th e
man uf a
cturi n g comp a
n i e s i s to i n s ula te co i ls for two or thre e
ra
n ges of volt a ge I n m a ki n g ch a n g e s i n t h e co nn e ct i on s of
.

1
Prof . A l fre d S t i ll —
P r i n ci pl es of E l e ct r i ca
l D es i g n .

H M . . Hoba
rt — Des i g n of P ol y ph a
s e Ge n e r a
t ors a
nd M ot ors .
1 64 A RM A T U R E WI N DI N G A N D M OTOR RE P A I R

in du ct i o n moto rs th e re fo re wh er e t h e ch
,
a
n g e s i n volv e s an ,

i n cre ase i n volt a ge i t i s i mport an t t o kn ow tha,

t t h e ch a n ges

do n ot subj e ct t h e co ils to avolta ge outs i de t h e r a n g e for

whi ch the y we re i n s ula te d Thi s pre ca uti on doe s n ot of . ,

cou rse a pply whe n reco nn e ctin g for alow er volt a

,
ge .

FI G . 119 —
Di a pe d coil i n s u l a
m on d s h a t ed a n d i m p re g n a
te d wi t h com p ou n d
re a
dy for u se ( Wes ti ng hou s e E l e ctri c dc M f g C om pa n y) . .

Th ep ract i ce of on e l a
rg e m a n uf acture r i s to i n s ul ate coi l s
for th re e ran ge s of volt a ge a s follow s :

I Di rect curren t a
. n d A l tern a
—
ti n g cu rren t Gr ou p C oi l s for V ol -

a
t g es up to 220 .

For pa
l i n coi l s ot h er t h a
—
n ph a
s e coil s

1 Wou n d w i t h dou bl e cot t on -covere d w i re

. .

2 . B i n di n g pa p e r ove r s l ot si d e , i n ch t h i ck .

3 . 1 % t u r n s t r ea t e d cl ot h on s l ot s i de , i n ch t h i ck .

4 C . ot t on a
t pe , on e-h lf l pped a a ll a
a rou n d , to i n ch
t h i ck .

5 . E di ppe d i n i n su l a
n t i re coil t i ng com pou nd a n d ba ked
a
.

For ph a s e coi l s t h e s a m e in s u l at i on i s prov i de d n d i n a ddi t i on a

la y e r of e m pi r e cl ot h a
nd t a p e o v e r e a
ch en d o f t h e coil u p t o t h e

s t ra i g h t s i des T h e di a m on d poi n t s a
. r e pa i n t e d re d t o d i s
t i n g u is h t h ese coi l s from pl a i n coi l s Pha s e coil s a re u s e d a
. t
be g i n ni n g a n d e n d of ea ch ph a s e g rou p .

II . Di rect -
curren t a
nd A l tern a
ti ng -
cu rrent Gr ou p C oi ls f or V ol
a
t g es up to 500 .

For p a
l in coil s —
ot h e r th a
n ph a
s e coi l s

1 . Wou n d w i t h dou bl e cot t on -cov ere d w i re .

2 . B i n di n g pa
pe r ov er sl ot si de , i n ch t h i ck .

3 . 1 % t u rn s m i caa n d fis h pa p e r on s l ot si de , i nch t h i ck .

Th is i s m ade u p of fis h pa
p ,
e r i n ch ; t h r ee l a
y e rs m i c a
s pl i t t i n g s e a
ch , to i n ch t h i ck ; J pa a
n es e pa p ,
e r 1
i n ch t h i ck . Al l s h el l a
ck e d t og et h er .
 I N S UL A TI N G C OI L S A N D S L OTS

u n de r pressu re a n d w il l com e ou t of t h e press w i t h s u ch as h a

pe a
n d s iz e

a
t h t it w il l sl i p e as il y i n t o t h e s l ot .

(g ) Di p t h e e n d s of t h e coi l i n e l a
s t i c i nsu l a
t in g v a
rn is h .

For a 500 -vo l t, dou bl e-l a

yer wi n di n g h a
vi n g fi ve tu rns per
coi l , a
nd thi r ty con du ct ors per s l ot ,
w i th th e cond u ctors covered

wi th doubl e -
cotton coveri ng s :

a
( ) P u t o n e t u r n of i ns u l a
t i n a
g p p e r 5 m i l s t h i ck a rou n d t h e s l ot

a t of t h e t w o co n du c t o rs t h a t for m t h e i n d i v i du al oil T h i a
p r c s s p p e r .

s h ou l d e xt e n d 94 i n ch beyon d t h e e dg e of t h e s l ot a t ea
a
ch e n d I t form s .

p r t of t h e i ns u l at i on b e t w een t h e i n d i v i du al coil s in t h e s am e s l ot a nd

a l so pa rt of t h e i ns u l a t i on from w i n d i n g t o core .

(b) P ut on e t u rn of em pi r e cl ot h 1 0 m il s t h i ck a
r ou n d t h e t h ree coi l s

a
t h t form on e g rou p n d l p i t a a ov er a t t h e en ds . Al l ow t h is i n su l a
t i on
a
t o ext e n d s before 91 i n ch t e a a
ch e n d of t h e s l ot .

(c) P u t on e a
t u rn of p per 5 m il s t h i ck on t he s l ot art p of t he coi l a
nd

la
p it on the t op . A s i n t h e ot h er c ses a a
l l ow the pa
pe r to e x t e n d ov e r

the sl ot l en g t h 94 i n ch .

(d) Ta
pe t h e e n d s of t h e g rou ps of t h ree coil s w i t h on e l a
y e r of h lf a
la
p cot t on a t pe 6 m il s a a
t hi ck n d c rry t his t pe on t o t h e pa pa e r f or 34
t o se a
.

i n ch l t h e coil .

(e) Win d t h e m a chi n e wi t h t h es e coil g rou ps pu tt in g a l in i n g of pa p e r ,

1 0 m il s t h i ck i n t h e s l ot a n d t h e n h ol d t h e coi l s dow n w i t h ba n d w i r es .

(1) Pl a ce t h e a rm a t u re i n a va cuu m t a nk a n d ba ke it a
t 1 00 C
°
.

to ex pe l m ois t u r e , t h en force i m pre g n a t i n g com pou n d i n t o t h e t a nk a t a

pr ess u r e of 60 l b pe r s u a
. r e i n ch a
qnd m a inta i n t h i s press u r e for sev e r a
l
h ou rs u n t il t h e wi n di n g h a
s bee n t h orou g h l y i m pre g n a t ed .

(g ) R ot a rm a
te t h e a t u re wh il e i t is s t il l h ot a
t ah i g h s pee d so a
s to

g et ri d of t he e xcess of com pou n d wh i ch wi l l ot h erwi s e com e ou t w h en t h e

m achi n e is ca rryi n g a h eavy l oa d .

(h ) P a i n t t h e e n d con n ect i on s wit h el sat i c fin is h i n g v a

rn is h ,
t a
ki n g
a
c re t o g et i n t o a
ll t h e corn ers .

C oil I ns ul a
t i on for I nduct i on M ot or Win di n g s Th e fol .
—

lowin g recommen da ti o n s a n d e r G ra
re gi ve n by P r of A le xa y .

(E l Ma
le ctri ca ch i n e D e s i gn C h a pte r XX on A C I n sula ,
ti on ) .
- .

for t h e coi l a
n d s lot i n s ul ati on of in du cti o n moto rs
For 440-vol t wi re wou n d coi l s of dou bl e la
,
-
ye r wi n di n g s : -

(a ) Dou bl e cot t on cov e ri n g on t h e con du ct ors .

( b) A l a
y e r of e m pi r e cl ot h s i x m i l s t h i ck be t w e e n h or i z on t a
l l a
y e r s of
con du ct ors .

( )cO n e t u rn of pa p e r 1 0 m i l s t h i c k o n t h e s l o t p ar t o f t h e coi l t o h ol d
t h e con du ct ors i n l a y ers .

On e l a y e r o f h al f -l a ppe d e m p i r e cl o t h t a
p e s i x m i l s t h i c k al l a r ou nd

t h e coil .
 1 68 A R M A TU RE WI N DI N G A N D M OTOR R E P A I R

( e) On e t u rn of pa
pe r 1 0 m il s t h i ck on t h e s l ot pa
r t of t h e coi l t o prot e ct
t he em pi re cl ot h .

0 ) O n e l ay e r o f h al f-l a e d
pp co t to n tape s i x m i l s t h i ck on t h e e n d con
n ect i on s t o prot e ct t h e e m pi r e cl ot h .

e ba ked a n d i m pre g n at e d be fore t h e pa

(0 ) Th e co il s h o u l d b pe r a nd

cot t on a a
t pere pu t on a n d d i pp e d i n fin is h i n g v a
rn is h a
ft e r t h ey a
re a
ll
pu t on a
ke
to m it wa a
t e r n d oi l proof .

a2200 ol t i n ducti on
For -v
m otor wi th s tri p cop per coi l s a
nd

adouble-layer wi n di n g
(a) On e l a y e r of h a l f -l a pp e d co t t on t a p e s i x m i l s t h i ck on e a
‘

ch con du e

t or t o for m t h e i n su l a t i on be t w een t h e con du cto rs .

( )
b O ne l ay e r o f h a l f -
la p pe d co t t o n t a p e s i x m i l s t h i ck all ar ou n d t h e

coil t o bi n d t h e con du ct ors t og e t h e r .

( c) On e t u rn of m i ca n i t e 20 m i l s t h i ck on t h e s l ot pa r t of t h e coi l .

a -l a
( )
d T w o l y e rs o f h a lf pp e d e m p i r e cl o t h s i x m i l s t h i ck al l arou n d t h e

( e) On e t u rn of pa
pe r 1 0 m i l s t h i ck on t h e s l ot par t of t h e coi l t o pr o t e ct
the em pi r e cl ot h .

(f ) O n e l ay e r f
o h a lf -lapp e d co t t on t a p e s i x m i l s t h i c k o n t h e e n d co n

n e ct i ons t o pr ot e ct t h e e m pi re cl ot h .

(g ) B a ke a n d i m pr e g n a te t h e coi l be fore t h e pa p e r a n d t h e l as t t a i
p g n

of cot t on t a pe a r e pu t o n A f t e r t h at
.
,
t h e s l o t p a r t o f t h e c o i l s h o u l d b e

h ot press e d and a l l ow e d t o cool u n de r pr e s su r e . Th e n t h e coil c n a be

di ppe d i n finis h i n g v a ke i t w a
rn is h t o m a t er a nd oil proof .

C oil a
nd S l ot I n s ul a
ti on E m pl oye d by aLa
rg e Ma
nu

fa
ct ur e r .
—
Th e fol lowi n g i n s u l a a
ti on for coi ls
n d s lots r e pre

s en t s t h e p ra ct i ce of al arg e m a n uf a ctu r er s p e ci a
li zi n g i n t h e
co n s t ru cti o n of moto rs a n d g e n er a to rs i n awi d e ra n g e of

s i z es an d f or a l l comm er ci al volt a g es .

I . For S m a l l Di r ect-curren t M a chi n es U s i n g Wi r e-wou nd C oi ls

1 C oi l s a
. re w ou n d w i t h dou bl e co t t on -cov e re d w i re .

2 Di ppe d i n v a rn i s h a
n d bake d t o a bou t 1 00 C u n t il coil s
°
. .

a re f ree f r om s t i ck i n e ss .

3 Ta p .e d w i t h 6 m i l l i n e n t a
-
p e .

4 C oi l s a
. re t h e n pl a ce d i n a rm a t u re a n d s ol de re d t o com m u t a t or
ri s e rs Aft e r cl e a
. n in g t he a rm a t u re i s d i ppe d or s p ra
, y e d w i t h
va rn is h a n d ba ke d .

5 Th e fin a
. l ope r a t i on is t o S pra y w it h s h el l a c .

6 For s l ot i n s u l a
. t i on 1 0 m i l p ress boa - r d rs u se d .

I I For E n g i n e Type Di rect cu rr en t A rm a

.
- tu r es U s i n g S tri p C opper C oi l s
1 C oppe r s t ri ps a
. re t a p e d w i t h 6 m i l l i n e n t a p e y pp
- l a e d W id t h,
.

of l i n e n t a p e i s 1 o r 1 34 i n ch d e p e n di n g u p on s
, i z e o f t h e co il .

2 C oi l is t h en d i ppe d i n g ood in s u l a
. t in g va rn is h a n d ba ke d u n t il
fre e from k i n e ss
s t ic .
 170 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

4 . Di ppe d i n g ood i ns u l a t ing va rn is h an d ba ke d . Or i f t h e v a rn is h

ha s a i r d ry i n g qu a
l i t i es , t h e coi l s a
re d ri e d i n a
i r u n t i l f ree f rom
s t i ck i n ess.

IV . I nsu lati on f or S tator C oi ls o f A lt er na

ti n g-cu rren t M ach i nes f or 600
V olt s a
U nder U si n g Wi r e-wou n d C oi ls :
nd

C oi ls a re w ou n d w i t h dou bl e cot t on -cove red w i re .

w He a t ed a n d di ppe d i n i ns u l a rn i s h a
t i n g va n d bak ed .

a
c Ope ra t i on t w o re pe ated .

s
s Ta p e d w i t h 6 p lf la
-m i l l i n e n t ae h a
ppe d .

g
n
C oi l i s t h en s h a p e d .

Di p pe d i n v a rn i s h a n d ba k ed
z
c .

s Ope ra t i on si x re pe a
r
t ed .

o
o Ope ra t i on f ou r re pe a t ed .

proof v a rn is h a n d ba ked un t i l a
o Dig
pp d i n g ood
e m o is t u re -
ll
cre v i ces a re w e l l fil l e d .

1 0 For s l ot i n s u l a
. t i on l O-m i l p res s boa rd i s u se d .

V I ns u la
. ti on f or S ta tor C oi l s of A l ter n a ti n g-curren t M a chi n es , M a de u p
of S tr i
p C op per :
1 On e -t u m coi l s a
. re t a p e d w i t h 6 -m i l li n e n t ae on e i n ch w i de
p ,

ha lf l a pp e d T w o . t u rn c oil s a re t a p e d w i t h o n e t u rn as a b o ve .

Th re e t u rn coi l s h a v e m i ddl e t u rn t a p e d F ou r t u
. rn co i l s h a v e

firs t a n d t h i rd t u rn s t a p e d .

C oi l i s t h en t a d i h i l i a h a l f l a d

t
p e w t 6 -m l n en t p e pp e .

Di ppe d i n i n s u l a t in g v a rn is h a n d ba ked .

Ope ra t i ons s e ve n , e i g h t a n d n in e a s f or wi re coil s a re t h e n a ppli ed .

For s l ot i n s u l a t i on 1 0-m i l p ress boa rd i s us e d

!
0 .

V I I nsu l a. ti on f or C oi l s U s ed i n 2 2 00-vol t M a ch i nes

C oi l is W ou n d wi t h dou bl e cot t on -cove red w i re

g .

eg Wra pp e d w i t h 6 -m i l li n e n t ae h a
p l f l a pped .

He a t ed a n d di ppe d i n i n s ul a t in g v a rn is h a n d ba ked
o
c .

h Ope r a
s t i on t h ree re pe a t ed .

m Ope ra t i on t w o re pe a ted .

a
e C oi l i s t h en f orm e d .

s La
t
st ta p e is n o w re m o v e d f ro m c o i l , w h i c h w a s p u t o n i n o r d e r

t o prot e ct t h e firs t li n e n t a p e w h i l e t h e c o i l w a s b e i n g s h a p e d .

c
c Wra pp e d w i t h 9 -m i l oi l m us l i n h a lf l a pp e d a n d b rus h e d w i t h b e s t
qu al i t y i ns ul at i ng v arn is h .

9 Ope r a . t i on e i g h t re pe a t ed .

1 0 Wra d w i t h 6 -m i l l i n e n t ae h a lf l a d
pp. e p pp e .

l l C oi l i s t h e n di ppe d in i ns u l a
. t i n g va rn is h a n d ba ke d .

1 2 Ope ra . t i on t e n re pe a t ed .

1 3 Ope ra . t i on el ev en re pe a t ed .

1 4 For s l ot i n s u l a
. t i on , 1 0 t o 2 0-m i l p ress boa rd is us e d a n d f or i ns u

la t o b t we en l a
i n e y e rs l o — m i l p re ss b o a r d .

In m a k in g u p coil s for a n y k in d of e l e ct ri ca l ma chi n e ry , t h e m a in

t h i n g t o be a r i n m i n d is t o a pp y l s u c h p r o c e sse s a s t o e l i m i n a t e m o i s t u re

from t h e coi l E ven f or 22 00-v ol t m a

. ch i n e s , e xcept i n s pe ci a l ca s es , t h e
 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

a
p r ct i ce of t he p a
comn y e m p y g t h e i ns u l a
l o i n t i n g m e t h ods descri be d is
t o u se oi l m u sl in a n d d e pen d t o ag re a t e x t e n t u pon t h e p rope r v a rni s h

t re at m en t Af t e r m u ch e x pe ri m e n t i n g w i t h v a
. rn i s h es i t h a
s be e n f ou n d

p o ss i bl e t o w i n d c oi l s t h at w i l l w i t h s t a
n d h i g h v ol t ag es e qu ally a s wel l a s

in s u l at e d coi l s w ou n d f or t h e s a m e v ol t a g es .

I n sul a
ti on of E nd C onn e ct i on s of
C oil s I n adoubl la
. ye r e-

wi n di n g t h e volta
, ge b e twe en t h e e n d con n e cti o n s of t w o
co i l s wh e re th e y cr o ss ea ch oth e r a t t h e en d s of t h e s lot m ay
be a bout e qua l to t h e t ermi n a l volta ge S u i t a bl e i n s ula
. ti o n
s h ould be u s e d a t th i s po in t A b e lt of cotton du ct i s u sua
. lly
u sed b e twee n t h e e n d co n n e cti on s for thi s p rote ct i on a nd a ls o ,

to p rote ct t h e co i ls from me ch a l i n j ury by rubb i n g a

n i ca ga in st
ea ch othe r .

A l s o t h e s lot i n s ula ti on should be a llowe d to e xte n d ol i t e a ch

en d of t h e s lot a ce rt a n ce d e p e n d i n g upo n t h e m a
i n d i st a ch i n e

volt a ge P rof A lexa

. .n d e r G ra y gi ve s t h e followi n g va lue s a s

typi ca l of good pra ct i ce .

Ter m i n a
l v ol t a
ge of m a
ch i n e L eng t h of i ns u l at i on o u t of sl ot

C o i ls for a lte rn a ti n g curre n t win din gs mu s t be woun d to

-

sta n d t h e li n e volt a ge t o grou n d I n aY con n e cte d m a

. ch i n e
—

t h e tota l i n sula ti on from coppe r to copp e r be twe e n two co i ls

s hould s t a nd a bout ti m e s thi s va lue Th e fir st coil of .

ea ch ph a s e i n aY co n n e ct e d m a -
ch i n e h a s avolta ge e qua l to
t h e li n e vol t a ge to gr ou n d (volts b e twe en li n es V 3) a ga in s t
w hi ch to i n sula te a n d should be g i v e n ap rot e ct i o n e qu a l to
t h e li n e volt a ge Th e firs t a . n d la s t co il s of e ach ph a s e gr oup

must a ls o ha ve ex tr ai n s ula ti o n for pr ote ct i on a t t h e poi n ts

w he re th e y cros s T h es e a r e ca
. ll e d t h e ph a s e co i ls On e .

la ye r of s i x m il e mpi re cloth on t h e e n d con n ecti on s cove re d

-

w i th s i x m il cot to n ta
- pe h a lf la ppe d i n a ddi ti on to t h e co i l
i n sul a ti o n wi ll gi ve suffi ci en t i n s ula ti o n to t h e pha se co i ls

e x ce pt i n ca se s of volt a ge s p a s t 2 30 0 (S ee p a ge 1 65 for
.

pha se co i l i n sul a ti on for 2300 volts ) .

17
4 A R M A T U RE WI N DI N G A N D M OTOR R E P A I R

re la ti ve ly wi de core s I n te rn a l hot s pot te mpe ra

. ture s ,

con s i d e r a bly hi ghe r tha n tho s e m e a s ur a ble by the r mome t er ,

ex i s t .On a ll s u ch ma chi n es e a ch co n du ctor of t h e co i l i s a

,
ls o
i n s ula te d wi th m i cata pe .

R e pa i ri n g C oil s Da ma g e d i n W i n d i ng P r o c e s s I t oft e n —

occur s tha t t h e in s ul a ti on of acoi l be come s da ma ge d from

ch a fin g or fr om ca r e le s s n e ss i n t h e u s e of tool s wh e n l a yi n g
t h e co i ls i n t h e a r ma t ur e s lot s S u ch da ma ge s hou ld be re
.

pa i re d a t o n ce t o pre ve n t po s s i ble t r ouble la ter whi ch wi ll

ma k e t h e re p a i r more di ffi cult a n d e x p e n s i ve To r e p a ir .

ada ma ge d coi l whe re t h e i nj ury to i t i s o n ly s li ght t h e coi l ,

s hould be r e move d fr om t h e s lot a nd a l l t h e i n s ul a ti o n r e move d

from t h e i n jure d se ct i on T he n a pply a
. n ove r la ppi n g wr a pp e r

FI G . 1 23 .
—
A t t op , on e w h ol e a
nd t w o da
m a
g ed E i cke m e y e r coil s t a
k en
f ro m a
n el ev a
t or m ot or A t bot t om
.
, fibe r dr if t s , t i on h a
sl ot i n s u l a , m m er ,
p a
ral l e l jaw p l i ers an d coi l l if t e r .

of tre a te d cloth a nd a roun d th i s ap r ot e cti n g cover i n g of cot

t on t a pe Glue down t h e en d s of t h e ta
. pe se cure ly a nd a pply
agood he a vy co a t of she l la c c ca
T h e s he ll a n be d ri e d qu i ckly
.

by t ou chi n g ali ghte d m a t ch to i t whe n t h e a lcohol i n whi ch

.

i t i s d i ss olve d w i ll bur n wi th ablue fl a me C a re mus t be .

ta k e n th a t t h e ta pe i s n ot bu rn e d i n do i n g thi s I n s u ch a .

ca se t h e fl a me wi ll tu rn ye l low a n d s hould be s moth e r e d a t

on ce Th e he a
. t of t h e bu rn i n g a l cohol i s n ot us u a lly s uffi ci en t
t o bu r n t h e t a pe A fte r thi s t h e coi l i s dry a
. n d ca n be put

ba ck i n t h e s lot Wh i le thi s m e thod of r e pa

. i r ca n be s a fe ly
use d i n s m a ll arma ture s i t i s n ot good e n ough for la
,
r ge a r ma

tures I n t h e la
. tter ca se a n e w coi l s hould be us e d or t h e old

on e s t r i pp e d a n d compl e te ly re i n s ul a te d di pp e d a n d ba ke d ,
.
 I N S UL A TI N G C OI L S A N D S L OTS

On accoun t of t h e s t iff n es s of t h e i ns ula ti on on t h e termi na ls

of form e d coil s be fore co nn e cti o n s a
, re m a de t o t h e commut a tor
i t i s agood pla n to s ofte n t h e le a d s wi th a rm a la c
“
or a s im i la r

a r ma ture compoun d a t t h e po in t s wh e re t h e le a d s le a ve t h e
bottom coi l s i n t h e sl ots Th is w il l pre ven t b rea
. ks whil e
ha n dl in g t h e le a ds .

V ol t ag e t o u s e w h en T e st i n g C oil a n d C o m m u t at or I n s ul a

t i on.
—
U n d e r ce rta i n co n d i t i o n s t h e di ff e re n ce of pot e n ti a l
be twee n coi l s a n d t h e i ro n core of ama chi n e m a y b e e qu a l to
t h e te rmi n a l volta ge U n de r a bn or ma
. l ope ra t i n g con di t i o ns
it m a y e v e n b e g r ea t er I t i s i mp o.rt a n t th e r e fo r e,
th a t t
,
h e

i n s u lati on of coi ls a n d commut a tor sha l l be s uffi ci e n t to st a nd

avolta ge co n s i de ra ble la r ge r th a n t h e t er min a l volta ge of t h e

ma chi n e wi thout deve lopin g g roun ds For thi s re a . son a

high volt a
- g e te s t i s m a de on a rma ture wi n din gs of both d i re ct
curre n t a nd a lte rn a tin g curre n t ma -
ch i n es a n d t h e commut a tor
of t h e forme r be fore t h e w in d in g i s fin a lly comple te d .

Th e fo l low in g va lue s of test volta ges tha t s hould be a ppli e d

a re gi ve n by P r of A lex a n d e r Gra
. y ( E le ctri cal Ma chin e D e s i g n ,

pa ge 34) b a se d upon t h e s t a n da t i on rule s of t h e A me ri ca

r d iz a n

I n st i tute of E le ct ri cal E n g in ee rs .

of m a
ch i n e

Dou bl e -ra
ted v ol t a
ge .

S om e i ns ul a
tin g ma t eri als will wi ths t an d v er y hi gh volt a ges
before us ed on coi ls For in s t a n ce
. agood qua li ty of oi l ed
,

mus l i n wi ll wi ths t a nd a s hi gh at es t volt a ge a s 1 50 0 t o 2000

volts per m il for 9 m il thi ckn es s how ever when a
- ppli ed to
, ,

,
ti n g properti es will dim i ni s h b eca
coi ls i t s i ns ul a us e of ha n dli n g .

Thi s i s of cours e t h e rea

, s o n why s o mu ch i n s ul a
,
ti on i s us ed
on coi ls t o prot e ct th em f rom b ecomi n g groun d ed
,
For .
 176 A RM A TU R E WI N DI N G A N D M OTOR R E P A I R

c oils tha t a r e to be us e d f or m a chi n es b e low 2 20 0 volt s n o ,

s t e ps a r e us u a l ly t a ken to t es t coi ls b efor e pl a ci n g th em i n

t h e ma chi n e . H ow ev er for volt a

, g es over 2200 t h e coi ls a ,
re

t es t ed b efor e th e y a r e pl a ce d i n t h e s lot s . For i n st a n ce coi ls,

tha t a re to be us ed on m a chi n es of 6 600 volt s a r e t es t e d for

,

groun d a t volts by wra ppi n g th em wi th t i n foi l b efo re

pla ci n g th e m i n t h e s lot s . Th en th ey a re t e s t ed wi th

to volts a ft er b ei n g pl a ce d i n t h e s lot s . Fi n a lly at es t

of a t l ea s t t wi ce n o rm a l volt a ge i s ma d e for on e m i n ut e .

Fi e l d C oil I n s u l a t i on .
—
For t h e i n s ula t i o n of fie ld co i l s ,

1 0 m i l pa pe r hi s in ch ca
, rdbo a rd a n d 6 m il t a p e ca n be u se d

whe re t h e fie ld coi l h a s aca r dbo a r d s pool . Th e i n s ul a ti on

ca n be a ppli e d i n t h e orde r n a m e d u s i n g 2 la ye r s of t a pe a nd

pa p e r wi th t h e p a pe r n ext t o t h e wi re s on t h e s pool Th e .

co i l s s ho u ld the n be b a ke d i n av a cuum t a nk a n d i mp re gn a t ed .

Va rni sh e s a n d I m pre g n a ti n g C ompoun ds f or C oil s —

Th e
va rn i s h u se d ov e r t h e out s i d e of i n s ul a te d co i l s s hould be
wa te r oil a
,
nd a ci d pr oof a n d dry qu i ckly i n a i r fo r m i n g ah a rd

s mooth su rf a ce S u ch va
. rn i s he s a re ma d e by an umber of
ma n uf a cture r s .

C ompou n d s for u se i n i mp re gn a ti n g coi ls a re a ls o a va il a ble

i n t h e ope n m a rke t a nd a re u s u a lly a n a s ph a ltum or apa ra ffin
ba se d i ss olve d i n a s ui t a ble t h in n in g s oluti on I t i s M port a
. nt

t ha t t h e ma teri a l w ill n ot a tt a ck coppe r ,

i r o n or i n s ul a t i ng
ma t e ri al s use d a n d for m as ol i d a t a l l te mpe ra tu re s be low
2 1 2 F w i thout con tr a ct i o n wh e n ch a n gi n g fr om t h e flui d to
°
.

t h e s oli d s t a t e Thi s ma . te ri a l s hould n ot be a ppl ie d a t

te mpe ra ture s a bove t h e bre a kdown of cotton ma t e ri a ls ,

tha t is a , bove ate mpe ra ture of 248 F °

.

B eca us e t h e d es i ra bl e ch a ra ct er i s t i cs f or ap erf e ct va rn i s h

ca n n ot be combi n e d i n to on e compo u n d a ,
n umb er of v a rn i s h es

ha v e b een d evelop ed ea , ch h a vi n g i t s own cha ra ct e ri s ti c .

T h e pur pos es of s om e i n s ul a t i n g va rn i s h es of t h e S h er wi n

Wi lli a ms compa ny a re i n d i ca t ed i n t h e a ccomp a n yi n g t a bl e .

Wh e re mo re tha n on e v a rn i s h ca n be s u cces s fully u s e d t h e

di ff eren t typ es a r e i n d i ca t ed a s first s e co n d a

,
n d t hi r d choi ces .

A l l of t h e va rn i s h es m e n t i o n ed i n t h e t a bl e a r e of t h e

ba ki n g typ e However i n s ul a
.
,
t i n g va rn i s h es i n g en era l
m a y b e d i vi d e d i n to s e v e r a l g e n e r a l c l as s es ,
s u c h as c l ea r v a r
 178 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

On s ta ti o n ary win d gs , a s on a
in l t ern at g u r ren t s t a intor -c

wi n di n gs , t h e varn i s h i s not s ubj ecte d to ce n t ri fuga l s t res ses

an d th er e i s no a dva n ta ge i n us i n g acl ea r va rn i s h C e rta in .

bla ck va rni s h es a
r e ma d e from pl a s t i c ma t eri a
ls a n d ha ve t h e
a bi li ty to wi ths ta n d lo n g co n t i n u ed h ea
- t in g wi thout ha r d en i n g .

B la ck va rn i s h es a s a rul e a r e ch ea p er th a n cl ea r va rni s h es a nd

a r e mo r e commo n ly used f or th a t rea s on .

Th e chi e f diff e ren ce b etw ee n ba ki n g va rn i s h es a nd a ir '

dryi n g va rn is h e s is i n t h e p ropo rti o n of o xi di zi n g in gr ed i en ts

con ta i n ed . Th e b a ki n g v a rn is h es a re tough er ,
more ela s ti c ,

mo re res i s ta n t to oil a n d wa t er a ,
n d ha ve lon ger li f e un der
h ea t S p e ed i n d ryi n g is a
. l wa y s a c c ompl i s h e d a t t h e e x p e n se

of t hes e cha ra ct eri s t i cs a ,

nd t he a i r d ryi n g va
- rn i s h es a re le s s

d u ra bl e a n d el a s ti c tha n t h e ba k i n g va rn i s h es . Th e a ir
d r yi n g v a rn i s h es fin d th ei r p ri n ci pa l fi eld of us eful n es s on
a ppa ra tus wh er e s ever e con di ti on s of usa g e a r e n o t en c ou n t e r e d
a n d for qui ck r e p a i r work .

C ha ra ct e ri s t i cs of I n s u l a ti ng V a rni sh e s —
A n i mpo rta nt

fa cto r co n cern i n g i n s ul a ti n g va rn i s h e s i s tha t t h e di el ectri c

r es i s t a n ce I n cr e a s es di r e ctly wi th t h e l en gth of b a ki n g or dry
i n g p eri od t h e s low va
,
rni s h es i mp a rt i n g t h e hi gh es t d eg r ee of

i n s ul a ti o n a n d fl exi bi l i ty a n d p rodu ci n g atough fl e xi bl e film ,

whi ch m a y a l so b e d e p e n d e d upo n f or m ec h a n i c a l s t r e n g th a n d
ex t r e m e dur a bi li ty B la
. ck va rn i s h e s a re cl a i m ed t o be
b ett er for wor k wh er e atra n s pa r en t co a ti n g i s n ot a bs olut ely
es s en t i a l b eca us e th ey produce amor e fl exi bl e a n d hi ghly

i n s ul a ti n g film tha n cl ea r va rni s h es of t h e s a m e cl a ss Va

. r

ni s he s s hould n ot crys t a lli z e un d er pr olon g ed vi bra ti on a nd

,

th ei r m echa n i ca l s tr ucture s hould be el a s ti c a n d homog en e o us .

Th e a ccomp a n yin g ta bl e ( pa ge 1 79) gi ves t h e cha ra ct eri s t i cs ,

us es d ryi n g ti m e a
,
n d s olv e n t s of s e v er a l va rn i s h es .

S ol ve n t C h a r t f or I n s u l a ti ng V a rni s h e s S i n ce va rni s h i s
—

!
us u a lly s old i n con cen tra t ed fo rm ca r e m us t be t a k en i n
di ss olvi n g to a voi d wri n kl es or s t ri n g y dri p formi n g on coi ls
when va rn i s h i s t oo h ea vy B en zi n e i s p ref era
. bl e to ga s oli n e

a s a s olv en t but ga s oli n e ca n be us e d . Th e s olv e n t a n d va rn i s h

s hould be a pproxi ma t ely t h e s a m e t emp era ture a nd n ei th er

s houl d be u n d er 60 F Th e cha rt on p a ge 1 80
°
.

s hows t h e p e rcen t a g e of 58 de g ree s b en zi n e t o be a dd ed t o every

1 82 A R M A TUR E WI N DI N G A N D M OTOR RE P A I R

s ou r ce of ex ci ta ti on a pp roxi ma te ly t wo thir ds of t h e n orm a

- l
di re ct curre n t volta
- ge .

T he re i s a lwa ys da n ger of se ri ous i nj ur y t o t h e w in di n gs

whe n dryi n g out wi th curre n t si n ce t h e he a t gen era te d i n t h e

i n n er pa rts i s n ot rea di ly di ssi p a te d ; furt hermore coi ls con ,

ta i n i n g moi s ture a re mu ch mo re s u sce pti bl e to i n j ur y fr om

over he a ti ng tha n whe n thor oughly dry . Th e te mp e ra ture

of a ll a ccess i ble p a r ts s ho uld be ca re fully ob se r ve d duri n g

t h e dryi n g out p r o ces s a n d n ev e r a llow e d t o ex cee d 80 C °

.

tot a l te mpe ra ture S e vera

. l hours or e ven da ys
m a y b e r e q ui r e d fo r tho r oughly d r yi n g out l ar g e m achi nes .

D uri ng t h e d ryin g out pr o ce s s t h e t e mpe ra ture s hould

n ot be a llowe d to drop b elow tha t of t h e surroun di n g
a ir a s mo is tur e th e n con d en ses on t h e co i l s urf a ce s a n d t he

e fi ect of t h e previ ous dryi n g would be la rge ly los t At

'

re gul a r i n terva ls during t h e dr yi n g out run re a ,

din gs of t h e
i n s ul a ti on resi sta n ce (s ee p a g e 1 85) m a y b e t a k e n a t r e gul ar

i n t e rv a ls a n d plott e d a s a curv e u si n g t i m e for t h e ho ri zon t a

,
l
s ca le a n d re si s t a n ce for t h e v e r t i ca l s ca. le Th e d ryin g s hould
co n t i n ue u n t i l t h e resi s t a n ce h a s b e g un t o in cre a se I f the .

i n s ul a ti on con ta ins a ppre ci a ble moi sture t h e resis ta n ce w i ll

de cre a se dur i n g t h e firs t p a r t of t h e dryin g out pr o ces s .

Hea ti n g win din g s by curren t i s more efie ct i ve tha n a ny

pr o cess of he a ti n g from t h e outs i de s u ch a

,
s e n clo si n g t h e

ma ch i n e a n d he a ti n g t h e a i r by res i s t a n ce or fir es b e ca ,use i n
t h e for m er m e thod t h e in s i de of t h e co i l s be come s hott e r t h a n

t h e out s i de a n d mo i s tur e i s d ri ve n outw a rd Wi th ext e rn a

. l
he a ti n g t h e reverse i s t rue .

Dryi ng Out S yn ch r on ou s M ot or s a n d Gen era t or s Syn —

ch r on ou s motors a n d ge n e r a t o rs ca n be d r i e d out by rot a t

i n g t h e motor or ge ne ra tor a t a n y con ve n i e n t spe e d a n d s ho rt

ci r cui ti n g t h e a rm a ture be yo n d t h e a mme ters Th e fie ld.

s hould be exci t e d so th a t t h e de s i re d he a tin g curren t will flow

in t he a rm a ture wi nd in g For win di n gs of 2400volts or lowe r
.
,

t h e te mpe ra ture a
, s me a s u re d by th e r mom e te rs prop erly
a ppl i e d to t h e hottest a cce s s i bl e p a rt of t h e wi n d i n g s hould n ot

be h i gh er th a n 80 C For 6600 volt w in d i n gs t h e

°
-
.

t e mper a ture s hould n ot be h ig he r tha n 7 5 C

°
. a n d for

to - volt win di n gs n ot hi gher tha n 65 C

°
.
 I N S UL A TI N G C OI L S A N D S L OTS

Th e aon for spe ci fyin g t h e lower te mpe ra

re s ture for t h e hi ghe r
volta ge wi n di n gs i s t h e gre a t er difle re n ce i n te mpe ra ture be
'

twee n t h e i n si de of t h e co il a n d t h e out s i d e ( wh e n t h e t e m

p e r at ur e i s m e a s u r e d w i th a th e r mom e t e r ) i n t h e co il s h a v i n g
t h e thi cke r i ns ula ti o n .

I f alow volta ge (5 t o 1 5 per cen t of n orm a . l ) ca n be obt a ined

from t h e ta ps on atra n sf o r m e r for exa mple t h e a
,
r ma ture
wi n di n g ca n be d ri e d out by a pplyi ng thi s low volta ge t o t h e
a rm a ture te rmin a ls t h e r otor re m a
,
i n i n g st a t i on a ry . Th e
field win din g s hould be s hort-cir cui te d a n d t h e t e mpe ra t ur e
of t h e ca ge wi n di n g on t h e rotor s hould be w a t che d L e ss
.

tha n n or m a l curr en t w i ll be n e ce ss a ry on a ccoun t of t h e

a b sen ce of ve n ti la ti on .

For m e d i um s i z ed a ltern a tors a n d s yn ch ro n ous moto rs a

‘

sa ti sf a cto ry w a y of d r y i n g out both fi e ld a n d s t a to r w i n d i n g s

i s to co n n ect t h e ma chi n e to a n a lt ern a ti n g curr en t ci r cui t

-

a n d ru n a s a motor wi th fields overex ci ted a t z ero pow er f a cto r.

Thi s m e thod i s both ch ea pa n d eff e cti v e .

Dryi n g Out I n duct i on M ot or s —

S ma l l motors ca n be b a ke d
i n ove n s .Th e te mpe ra ture s houl d be ra ise d gra dua lly t a ki n g
s e ve r a l hours to b ri ng i t t o t h e ma xi mum va lue whi ch s hould
n ot be mo re th a n 80 C a t t h e hottes t po i n t Th e
°
. .

te mpe ra ture s hould be ma in t a i n e d cons ta n t for fr om on e da y

t o awee k d e pe n di n g on t h e s i z e a n d volt a ge of t h e ma chi n e

a n d t h e hi s to ry of i t s ex pos ure t o moi s ture . I n du cti on moto rs

ca n a lso be dri e d by ope ra ti on a t n o loa d on low volta ge (t h e
pr i m a r y curr e n t a n d he a ti n g i n crea se s a s t h e volt a ge i s re
du ced) or by ast i ll low e r volt a ge tha t wi ll ci rcul a te as uffi
ci e n t l y h e a vy curren t wi th t h e roto r blo cke d I f as uffi ci en tly .

low a lte rn a tin g curre n t volta

-
ge i s n ot a va il a ble dire ct curren t
,

m a y b e u se d . T h e r e i s a lw a y s mo r e o r less d a n g e r of ov e r

he a tin g t h e win di n gs of am a chi n e wh e n dry i n g the m wi th

curre n t a s t h e in n e r p a rts wh i ch ca nn ot qui ckly d i s s i pa te

t h e he a t ge n e ra t e d i n the m a n d w hi ch ca nn ot be e xa mi n e d ,

ma y g e t d a n g e r ou s ly hot w hil e t h e e x po se d a n d mo r e e a s i ly
coole d po rti on s a re s ti ll a t acomp a ra ti ve ly mode ra te te mpe ra
ture Th e te mpe ra
. ture of t h e hotte st pa rt a cce s s i ble s hould

be me a s u re d duri n g t h e dr yin g out p ro ce ss a n d n ot a l low e d

to ex ce e d 80 C
°
.
1 84: A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

I n s ul a
t i on Te st -
dryi n g out of ama
D ur in g t h e ch i n e ,

ti o n r es i st a
i n s ul a n ce t e s t s s hould be m a de a t regul a r i n te rv a ls
a n d plott e d i n t h e fo r m of a curve u s i n g ti me on t h e ho ri zon t a l
s ca le a n d va lue s of i n s ula t i o n re s i s t a
n ce on t h e ve rt i ca l s ca le .

T h e dryi n g out s hould be con ti n u e d un t i l t h e re si s t a n ce

re a ch e s i t pr op e r v a lue Th e i n s ula . n ce i s a
t i on r e s i s t a t be st
o n ly arough gu i de i n de te rmi n in g t h e con di ti on of t h e m a
chi n e a s to mo i s t ure a n d re l a t i ve v a lue s i n t h e sa me w i n d i n g
duri n g adryin g out ru n a re of mo re va lue tha n t h e re l ati ve
va lues of wi n di n gs i n othe r m a ch i n e s .

be m e a
s u red

FI G . 1 24 —
. C on n e ct i on s of dou bl e-p ol e , dou bl e t h r ow s w i t ch a
nd 5 00-v ol t
v ol t m e t e r f or m e a
s u r i n g i n s ul at i on r e s i s t a
n ce .

Am eg ger i s a ls o s om eti m es us ed for t es ti n g t h e con di ti on

of t h e wi n di n gs duri n g t h e dryi n g out prcoes s .

Th e i n s ul a t i o n re s i s t an ce of am a chin e i n good con d i t i o n

a nd a t i t s ope r a ti n g tempe r a ture wi ll us ua lly n ot be les s tha n

t h e va l ue gi ve n by t h e fo l lowi n g for mula :

Ma chi n e volta ge
I n s ul a t i o n re s i s t a n ce i n megohm s
Ra te d Kv a 1 000 .

For e xa -
mpl e a 1 00 Kv a
0 - . volt motor s hould ha
,
- ve a n

i n s ul a ti on resis ta n ce if cl ea
,
n a n d dry of m egohms
, .

Th e i n s ul a ti on res i s ta n ce of fie ld w i n di n g s wil l i n ge n e r a l be , ,

mu ch hi gh er i n propor ti on to t h e oper a ti n g vol t age tha n th a t

of t h e a rm a t ure S in ce la
. rg e a rma ture s ha ve mu ch gre a ter
a re a s of i n s ul a ti on the i r i n s ul a
,
t i o n r e s is t an ce w il l be p r opo r

t i on a t e l y lower th a n t ha t for s ma ll m a chi n e s Th e in s ul a

. ti on
 C HA P TE R V I I I

RE P AIR S H OP M E TH OD S FOR RE WI N DI N G A LTE R

N A TI N G C UR R E N T M A C HI N E S
-

I . WI N DI N G S M A L L S I N GL E - P HA SE M OTOR S

Th e compl t st a
e e t o wi n di n g of mos t s ma
r ll sin gle pha
- se

i n du cti o n motor s i s m a de up of two win din gs ; t h e m a i n wi n d

i ng of m a n y turn s of h e a vy wi re a n d wh a t is kn own a s the

te a s er
”
or s t a
rt i n g w i n d i n g Th e l a tte r i s n e cess a
. r y be ca us e
as i n gle pha-
s e moto r i s n ot s e l f s t a rt i n g a n d there fo re re qui re s
-
, ,

s ome me a ns of produ ci n g ar ot a ti ng fie ld t o ove rcome this

d e fi ci en cy Thi s t h e s ta
. rt i n g wi n d i n g doe s I t i s of s m a ll er
.

wi re tha n t h e ma i n w i n di ng a n d of hi g h res i s t a n ce .

Th e me thod of w i n d i n g s in gl e ph a se moto rs d i ff e rs fr om th a
-
t
u se d for othe r a lte rn a ti n g curre n t motors i n tha
- t as ke i n
wi n di n g is often us e d Th a . t i s t h e win din g coi l i s i n t h e
,

form of askei n of wi re whi ch i s loope d ma n y ti m e s thr oug h

s e ve ra l slots to fo rm apole of t h e wi n di n g Th e det a i ls of .

this me thod of wi n di n g a s gi v e n i n wh a t fol lows a re b a s ed ,

on a rt i cl e s th a t ha ve a ppe a re d i n t h e E lectri c J ou rn a l by
G I Sta
. . de ke r a nd C A M We b e r
. . . .

I n s ul a ti n g Li n in g for S l ot s Th e s lot s s hould be l i n e d wi th a

—

pr ote cti n g cell of fis h p a per cu t to fit t h e slot I n s i de thi s a .

ce l l of t re a te d cloth s hould be pla ce d ou t so th a t it s e dge s will

pr oj e ct a bout i n ch be yon d t h e e n tra n ce to t h e s lot In .

those slots whi ch wi ll con t a i n both t h e m a in a n d t h e s ta rt i n g

wi n di n g a ,
n ext r at re a te d cloth ce l l s hould be in s er te d over
t h e ma i n wi n di n g to e n clo se t h e s t a r ti n g co i l s E n d pl a tes of .

fuller boa r d or fib er a re use d to i n s ul a te t h e core from t h e

wi n di n g s Th e e n d conn e cti ons of t h e ma
. in a n d s ta r ti n g

wi n di n gs s hould be se pa ra t e d by fri cti on cloth .

Wi n di n g th e S k ei n C oil I n re pa .
—
i ri n g amoto r t h e n umb e r ,

of t i me s t h e ske i n i s to be 100pe d through t h e s lots a n d t he

l en gth of t h e ske i n ca n bes t be obta i n e d from aske i n ta ke n

1 86
 RE WI N DI N G A L TE R N A TI N G- C UR RE N T M A C HI N E S 1 87

from burn e d-out ma

t he chi ne I n re movin g t h e old win di n g
.

ca r e sh oul d be t a ke n to preserve one en ti re s kei n i f poss i ble .

I f thi s i s i mposs i ble asa t i s fa

ctor y s che m e for t h e re p a i r ma n

i s by tri a l wi th asi n gle wi re T hi s wi re s hould be la . i d in t h e

s lots e xa ctly a s t h e s k e i n s of wi re w i ll be la i d pr ope r a llowa n ce ,

be i n g m a de for t h e bu i ldi n g up of t h e ske i n en ds from s lot to

s lot Th e wi re s hould then be re move d a
. n d mea s ure d Ma ke .

up atri a l s ke in of thi s le n gth a n d w i n d i t i n t h e s lot s C or .

re ct i o n s i f n e ce ss ar y ca n be m a de on t h e n ex t sk e in s ma de up .

I ns e rti n g t h e S k e i n C oil i n t h e S lot s A fte r t h e s ke i n le n gt h

—

a n d di s tr i buti o n h a ve be en obta in e d from t h e old moto r t h e ,

a b c d e f
FI G . 1 25 .
—
S u cce ss i v e s t e p s i n a p p l y i n g as k ei n coil f or m a in
s p l i t -p h a
s e , 6 0-cy cl e , 4-p ol e , 2 4-s l ot i n d u ct i on m ot or .

ex a
ct p ro ced ure wi n di n g i s a
in s s hown rn Fi g 1 25 (a ) to (g ) . .

Th e d i s t ri buti on of a24 s lot p ri m a ry w i n di n g in d i ca

- tin g t h e ,

n umbe r of t i m es t h e m a i n win d in g s kei n i s wou n d i n to e a ch s lot ,

i s shown i n Fi g s 1 2 6 to 1 29 . Th e d is tri buti on i n Fi g 1 2 6 i s

. .

on e common ly u s e d Oth er d i s t ri buti o n s m a

.
y b e u s e d but i n ,

a l l s ke i n w in d in g s t h e wires in a n y s lot mus t be a multi pl e of

t h e wi re s i n t h e s k e i n .

A d e ve lope d vi e w of t h e p ri ma r y or s t a tor win din g i s s hown

i n Fi g ( 1 25a )
. look i n g at t,
h e t ee th w i th t h e fir s t Op e r a t i on o f
'

puttin g t h e s kei n wi n d in g i n slot s 3 a n d 5 compl e te d Th e .

e n d of t h e co i l thus fo rm e d s hould be firmly p re ss e d a ga in s t

t h e core us i n g ara , whi de or fibe r m a lle t or api e ce of s mooth
wood A ha . lf twi st is n ext ma d e i n t h e s k e in a s s hown i n ,
1 88 A R M A TU R E WI N DI N G A N D M OTOR R E P A I R

Fi g . 1 25 (b), a
loop lai d ba
nd ck ov er t h e wi n d i n g a
the nd

t h r ea d ed i n to slots 2 a nd 6 a s i n Fi g 1 2 5 ( c) Th e h a lf twi s t
,
. .

i s re pea ted a s i n Fi g 1 2 5 (d) a

,
n d t h e loop l a i d ba
. ck i n s lots 2
,

a n d 6 for t h e s e co n d ti m e as i n Fi g 1 2 5 (c) Thi s s e con d

,
. .

ha lf twi st in Fi g 1 2 5 (d) mus t be i n t h e oppos i t e dir ecti on to

,
.
,

t h e firs t on e ( Fi g 1 2 5 to brin g t h e s a
. m e si d e of t h e loop on
top Oth erwi se atwi s t wi ll be put i n t h e s kei n s whi ch wil l
.
,

1 26 —
. Di s t ri bu t i on of m in a
a nd st a
r t in g w i nd i ng co il s of a4-p ol e m o t or
s h ow i n g s k e i n s ov e r l a
ppe d .

FI G . 1 2 7—
. Di s t ri bu t i on t o a
v oi d ov e r l a
pp i n g of s k e i n s .

FI G . 1 28 .
—
Di s t ri bu t i on of a
n 8 -p ol e m a
ch i n e .

FI G . 1 29 .
—
D i s t ri bu t i o n of a
n 8 -p ol e con s e q u e n t w ou n d m a
ch i n e .

ma ke i t ha r d to wi n d s moothly e s p e ci a ll y i f i t i s loope d ba,

ck

a n d fo rth m a n y ti m e s Th e h a lf t wi s t in Fi g 1 2 5 (f ) i s ma
. de .

in t h e sa m e di r ecti o n a s t ha t i n Fi g 1 2 5 (b) B y loopi n g t h e .

turn s i n to s lots 1 a n d 7t h e wi n d i n g of t h e s k e i n i s compl e t e d .

The wi n d i n g of t h e s eco n d a n d s ub s e qu e n t co i l s i s e x a ctly t h e

sa me a s t h e fi rs t Th e compl et e d wi n d i n g for afour pol e

.
-
,

24 slot m a
-
ch i n e i s s hown i n Fi g 1 3 0 (a t top ) . .

I n s pl i t ph a se s t a rt i n g
- s qu i r r e l ca
s ge motors t h e s ta
,
r ti n g -

wi n di n g is conn e cte d a cr o s s t h e li n e un t i l a pproxim a te ly two

 1 90 A R M A TURE WI N DI N G A N D M OTOR R E P A I R

be woun d i n to e a ch s lot ar e s hown i n Fi g 1 30 (lowe r di a g ram ) . .

A fter a l l t h e s lots ha ve been fill e d t h e coi ls s hould be force d

i n to po s i ti o n w i th afibe r d ri ft t h e i n s ula tin g ce ll s folded i n ,

a n d fib er w e dges dr i ve n i n t h e s lots .

Win din g for a R e pul s i on -s ta rt M ot or For r e puls i o n .

—

s ta rt i n g i n du ct i on run n i n g moto rs t h e pri ma

,
-
ry wi n d in g i s

FI G l 3 1 ( a b l f i a i f a i l - ha
.
), ( ), ( ) c —
A t e t , p.r m r y c o n n e c t on s o r s n g e p se,

r e p u l s on s t a
i - i
rt n g i i
n d u ct on m ot or I n ce n t e r , co n n .e c t i o n s f o r a 4—
p ol e ,
sp t ph a
l i - se m o t or A t r i g h t ,. s a m e as i n c e n t e r b u t fo r a se r i e s -
p a r a
l l e l
c on n e ct i on of coil s .

I n t h e dia r a
m a t t h e l e ft N d ot n u t a
l oi n t s F or a 2 2 0-v ol t ci r cu i t l e a
ds 2 a
nd
g e n e s e r p
nd lea For a1 1 0-v ol t ci r cu i t
,

3 s h ou l d be con n e ct e d t og e t h e r a ds 1 a
.

a
nd 4 t o t h e l i n e

a
ll el t o on e l i n e a
.

le ads 1 a n d 2 s h o ul d be c on n e ct ed i n p a ra nd l e a
ds 3 a n d 4 t o t h e ot h e r .

s: s ss ess :
a
.
a l ea a a ds 2 a
nd l ea
shg w
( is e r ot t i on , ds 1 nd 3 s h ou l d be con n e ct e d to on e li n e nd 4 t o t h e
-

c omple te a s s hown i n Fi g
, 1 30 a n d t h e co i l s a r e co n n e ct e d
.
,

toge th er a s i n d i ca t ed i n Fi g 1 3 1 (a
, ) F ou r l e a
d s a re b r
. ought .

out s o tha ,
t th es e motors m a y b e c o n n e ct e d e x t e rn ally f o r

e i th er 2 2 0 or 1 1 0 volt s .

Wi n di n g S ma ll M ot or s
by Ha nd A method .
—

s om e t i m e s e m ploye d i n

wi n di n g s m a ll motors of
t h e in d u ct i on type is
kn own a s ha n d wi n d i n g -
.

F IG 1 32
. H a d wi di g m et h d f o m a
.
—
n - i n Th e C O D d u c t o r S a
n o re
r n

f p i m ay h w i Fi g 1 3 0
il co s o r r s
woun d i n t h e Si013S on e
o n n

a
. .

a t ti m e be gi n n in g a ,
t t h e ce n te r of apole a s s hown i n ,

Fi g 1 3 2 . Th i s me t hod i s mo s tly use d whe n t h e n umbe r of

.

t urn s in t h e s lots ha ve n o re l a ti ve ly la rge common di vi s or ,

there by eli m in a ti n g t h e s ke in win d i n g me thod Th e ha nd - .

wi n di n g m ethod s ho uld n ot be e mploye d for t h e s ta

_
rt i n g
 RE WI N DI N G A L TE R N A TI N G- C UR R E N T M A C HI N E S 1 91

wi n di n g of as pli t pha s e moto r b eca

- us e t h e resi stan ce of t h e
,

s ta r ti n g win di n g would n ot a lwa ys be th a t req uire d A .

s kei n wi n di n g s ho uld be us e d .

Win di n g s for Odd Fr e qu e n ci e s I t freq uen tly ha ppe ns

—

tha t s ma ll motors mus t be woun d for odd fre quen ci es s uch a s ,

1 2 5 , 1 33 a n d 1 0 cy cles on st a
4 , n dar d 60 cy cl e motor co re s
- .

Th e n umbe r of poles of s uch motors i s us u a lly l a

r ge re s ult i ng ,

i n as ma ll n umbe r of slots per pole U si n g a24 s lot pri m a . ry -

,

woun d ei ght poles t h e slots pe r pole would be th ree a

, n d t h e di s

t ri bu t i on of t h e wi n d i n g wo uld be as s hown i n Fi g 1 2 8 S u ch . .

awi n d in g i s very d iffi cult to wi n d a n d in a case of thi s ki n d ,

FI G . 1 33 ( a
) a
nd ( b) C o —
n n e ct i on s f or as i n g l e-
p h a
se , 8 -
p ol e , 24 -s l ot
, se ri e s

con n e ct e d co n s e q u e n t -p ol e , i n du ct i on m ot or s h ow n a
, t l e ft . A t ri g h t , s a me
for se ri e s p a
ra
p l l e l co n n e ct i on .

ac se en pole win di n g would be us e d wi th adis tri buti on

o n qu t-

as h h ow n i n Fi g 1 29 Th i s mo t o r would be wo un d i n t h e
. .

same m a n n er as s hown i n Fi g 1 2 5 (a ) to (g ) but all. t h e coi l s ,

would be conn ected wi th t h e s a m e pol a ri ty as i n d i ca t ed i n

Fi g . 1 33 .

C onn e ct i on s for M ain a n d S ta r t i n g Wi n di n g s Th e co i ls .

—

of e a re conn ecte d i n se r i e s , a
ch w i n d i n g a s s how n i n Fi g 1 34 . .

Th e le ads of t h e sta rt i n g w in d i n g a r e i n te rrupte d by aci r

cu i t open i n g d e vi ce Two ci r cula. r s ta ti o n a r y se gm e n ts a re

use d in on e de s i gn of motor i n s ula te d from e a ch oth er a nd

from t h e fra me a nd a re moun te d s i d e by s i d e on t h e be a ri n g

hous in g A t t h e s ta
. rt th e y a r e s ho r t ci r cui t e d by t h e r ot a
-
t
i n g s hoes wh i ch clo s e t h e ci r cui t of t h e s ta rtin g w i n d in g un ti l

ch e s t h e poi n t a
t h e s pe e d r e a t wh i ch ce n t ri fuga l force t hrows
them off Thi s is ordin a . ri ly a t a bout ha lf spee d Th e ma in .
1 92 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

a n d s ta rt i n g w i n d i n gs a re us u a lly conne cte d i n pa ra lle l outsi de

t h e ma ch i n e Th e d i re cti o n of rot a
. ti on is d e t e r mi ne d by t h e
wa y t h e c o nnec t i o n s a r e m a d e T o r e v e r s e t h e d i r.e ct i o n

of rot a ti o n i n te rch a ,
n g e ei th e r t h e two m a i n wi n d i n g l ea ds or
t h e two s ta r t i n g l ea ds ; a dopti n g t h e most con veni en t m ethod .

Te s ti n g Ou t S m a
l l I ndu ct i on
M ot or Wi n di n g swi n d .
—
Th e
i n gs should b e
t e s t e d f or
groun ds wi th 1 000 volts for
on e m i n ute E a ch w i nd i n g .

s hould a l so be te st e d for s hor t

a n d ope n ci rcui ts by a pplyin g
a ltern a ti n g curren t through a
wa ttme ter A n ex ces s i ve re a . d
i n g i n di ca tes a s hort ci r cui t ,

whi le n o rea d in g s s how a n ope n

ci r cu i t P ola r i ty ca n be tes t e d
.

by a pplyin g d ire ct curren t to

i al L a
t h e w in d i n g s a
t erm n d
n d te s t i n g wi th
e

a compa ss A dj a ce n t pol es .

s hould a ttra ct oppos i te en ds

of t h e n ee dle I f t h e wi n d .

FG 1 34 C ti f i gl
i n gs a r e co rr e ct
—
t h e e n d con
I . . on n e c on s or s n e

ph a m t
.
,
seW d g o or i n in s .

n e ct ron s s hould be d i ppe d I n

aqui ck dryi n g pla s t i c va rn i s h whi ch se rves n ot o n ly a

, s a n

i n s ul a ti n g me di um but ex clude s a , l l dus t a n d s erve s to s t iflen

t h e w i n d i n gs a n d ma ke them moi s ture proof A fter di ppi n g .

,

t h e wi n din gs s hould be thor oughly d ri e d i n a n ove n .

Wi n din g s for S ma ll P olyph a s e I n du ct i on M o t ors Th e —

me thod of win di n g as ma ll polyph a s e motor i s s i m i la r to t h e

wi n di n g of as i n gle ph a s e moto r -
Th e s lots a r e in s ul a
. te d wi th
fis h pa per a n d tre a te d cloth cells a n d t h e s k e i n s whi ch a
,
re ,

a l s o si mi la r a r e i n s e r t e d i n to t h e s lot s a
,
s s hown i n t h e wi n di n g

di a gr a m s of Fi gs 1 3 5 a nd 1 36
. E a ch s ke i n or group of co i l s
.

overla ps t h e pre ce din g on e a t t h e en ds a s s hown i n Fi g 1 3 7 ,

.
,

t h e e n ds of t h e coi ls be i n g s e p a ra te d from on e a n oth er by a

la yer of tre a te d cloth To p rodu ce asymme tri ca . l win d i n g i t ,

m a y b e n e ce ss ar y to re mov e h a lf of t h e fi r s t s k e i n b e fo re t h e

la s t on e ca n be put i n pl a ce i n o rd e r to m a ,
ke the m over la p
1 94 A R M A T U RE WI N DI N G A N D M OTOR RE P A I R

fri cti on clutch on these ma chi n es Th e y sh oul d be tes te d .

f or b re a kdown b e twe en pha se s a n d fr om ea ch pha s e to grou n d

, ,

a n d op e n ci r cu i ts a
n d for s ho rt a s d e s cr i b e d for s i n gl e pha
, se -

ma ch i n e s .

FI G . 1 3 7—
. Stat or of asm a
ll 3 —
ph a
s e m ot or com p l e t e l y w ou n d wi t h s k e i n c oi l s .

II . WI N D I N G S M AL L I N D U C TI O N M OT OR S WI TH FOR M E D
C OIL S I N P AR TIAL L Y C L O S E D S L OTS

L i ke t h e a rm a tures of dire ct curren t m a chi n e s t h e s ta

- tors ,

of s m a ll i n ducti on motors a re m a d e wi th pa rt i ally clo se d a nd

wi th ope n s lots Th e coi ls u se d wi th pa

. r ti a lly close d slots
are u s u a lly e i ther of adi a mon d s hape or of as qua re s h a pe
s u ch a s s hown i n Fi g 1 3 8 Th ese . .

coi ls a r e woun d on fo r m s a s in t h e

ca s e of d i r e ct cu rre n t co il s us i n g wi re-

ha vi n g adouble cotton cove ri n g Th e —

.

co i ls wh e n m a d e up a r e n ot i n s ul a te d
a s awhol e s i n ce t h e tu rn s of t h e co il
,

m us t be in se rte d i n t h e s lot on e a t a
t i me Th e i n s ul a ti on be t we e n coi ls
.

a n d t h e co r e mu s t th e r e fo r e be pl a ce d

i n t h e s lo t s b e fo re t h e co il s a r e in

s e rt e d Th e ch a ra cter of i n sul a t i o
F I G. A t l ft a e
. n

a a
,

bak t qu i d d h m thod of pl i g
s e
p
d a
or h t yp
}
m!
l us r e ree c n t e e s c n
At g ht a d t yp u
t h e co i ls i n t h e s ta
n m l on e co '

tor of motors
ha vi n g p a r ti ally clos e d s l ots a n d for tho s e h a vi n g open slots
are outli n e d i n wh a t follow s a cco rd i n g to re comm e n d a ti o n s
by awri te r i n t h e E lectri c J ou rn a l V ol V I I N o 9 ,
.
,
. .
 RE W N
I DI N G A L TE R N A TI N G-C URR E N T M A C HI N E S 1 95

I n s ul a
ti on f or S l ot s lea n t h e s lots wi th abl a
—
C s t of a ir to
re move a ll bur rs a n d r ough e dg es Th e n ou t afis h p a
.
-
pe r cell
la r ge e n ough to j u s t li n e t h e s lot up to t h e op e n i n g a n d so a s

to ext en d a t ea ch e n d of t h e s lot a bout thre e q ua - rt e rs of a n

i n ch . Thi s fis h p a -
pe r cell po ss e ss e s s uffi ci en t m e cha ni ca l
s t re n gth to p rote ct t h e i n n e r l a ye r or ce ll of i n s ula ti on whi ch
s hould be of trea te d cloth th a t ha ve hi gh i n s ula tin g s tre n g th
s u ch a s e mp i r e cloth or mi ca nit e .Th e i n n e r ce ll s hould be
cu t l a r g e e n ough to e xt en d b e yo n d t h e p r ot ect i n g ce ll a n d t he

e n d s of t h e s lot a bout on e qua r t er of a

- n

i n ch a n d up th r ough t h e Op e n i n g i n t h e

s lot a bout a n in ch Th e pr oj e cti o n s of

.

this cel l s erve a s a gu i de wh en i n s e r ti n g

t h e co i l s a n d p r ot e ct t h e wi r e s fr om

a n y poss i bl e a b ra s i on wh e n b e i n g i n

se rt e d . Th e win d i n g a nd t h e co re
1
s hould be in s ul a te d a t t h e e n d s of t h e t i i i g z2 53 2333235;
ll
o r

s lot s by a fu l l e r bo a r d r i n g a n d a fib e r m to h
ora iv ng p a t
r i a ll y

s tr i p a t ea
l d
C os e
ch e n d Thi s wi ll p rot e ct
.

t h e ove rh a n gi n g e n d s of t h e co i l s fr om co m i n g i n to con ta ct

wi th t h e core .

Ba s k e t C oil s —
On e C oil pe r S l ot Ba s ke t coil s a
—
re wou n d

t o as h a pe corres pon din g on ly a pproxi m a tely to thei r fin a l

s ha pe a ,
s s hown a t t h e l eft Fi g 1 3 8,
. I t i s i mpo rt a n t o n ly

tha t t h e tota l l e n g th of t h e loop be corre ctly proporti on e d so

th a t t h e en d s m a y b e fo r m e d to t h e p r op e r s h a p e a ft er t h e

wire s a re in t h e s lot Wh en as ui ta
. ble form i s n ot a va ila ble ,

t h e coi l m a y b e wou n d a r ou n d two p e g s s p a ce d t h e p r op e r d i s

ta n ce a pa rt . S ma ll pi e ce s of ta pe s hould be fa s te n e d a r oun d

t h e co i l a t con ve n i e n t po i n t s s o th a t t h e wi res m a y b e

held togeth er whi le the y a re b e i n g thre a de d i n to t h e s lot .

Ba s ke t co i ls a re l a r ge ly u s e d w i th aon e co i l pe r sl ot wi n d
-

ing . T his m e a n s th a t ea ch s i d e compl e t el y fill s on e s lot ,

s o th a t for a48 s lo t core on ly 24 coi ls a

-
re re qui re d . In
thi s cla ss of win d i n g on e en d of t h e co i l h a
,
s to d rop b e low

t h e bottom of t h e s lot i n o r d e r to pe rm i t t h e a dj a ce n t co i l

to pa ss ove r i t whi l e t h e oth er s i d e of t h e sa

,
me coi l re m a in s
on ale vel w i th or o n ly s l i ghtly b elow t h e top bo re of t h e

s lot .
 1 96 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

aTh
Win din g ph as e S t a
t or wi t
h
re eB-a
s k e t C o il s A ss um e .
—
,

for ex a
mple tha t a4 8 slot core i s to be woun d for afour pole
,
- -
,

three phas e ma
-
ch i n e wi th aco i l th r ow ( i n s lot s ) of 1 a nd 1 2 .

Ma rk two s lot s to s e rv e a s agu i d e i n pl a ci n g t h e co i l s w i th

re s pe ct to th ei r p rope r s pa n or th row A n y s lot m a y be .

co n s i d e r e d s lot 1 a n d t h e oth e r s lot lo ca t e d by co u n ti n g

t h e th r ow i n aclo ckw i s e d i r e ct i on I n th i s ca s e ( Fi g 1 4 0) t h e
. .

lower s i de of t h e firs t co i l wi ll go i n slot 1 2 Thi s s i d e of t h e .

co i l mu s t n ow be l a i d w i r e by wi re i n s i d e t h e i n s ula ti n g cell ,

i n s lot 1 2 Th e pro .

j e ct i n g e dges of thi s
ce l l ca n t h e n be cu t

off clo s e to t h e l a mi
na ti o n s t h e e n d s ,

fold e d ove r on e a n

ot he r a nd t h e s lot
FIG. 1 40 . W i d i g di a
—
g a
n mn f m t r i g clo s e d
or o orby d ri vin g a us n

bak t l ly f m d il
s e or oose or e
t l g h t fit t i n g fi be r
co s .
-

we dge be twee n t h e oute r ce ll a n d t h e t i ps of t h e t e e th Th is .

re ta i n i n g we dge s hould n ot e xt e n d mo re th a n i n ch b e yo n d t h e
co re on e i th e r s i d e a s i t i s li a,
bl e to cu rl up a n d ru b a g a i n s t t h e

r oto r . Tha t pa rt of t h e co i l pr oj e ct i n g be yo n d t h e s lot s hould

n ow be t a pe d wi th ala ye r of tre a t ed ta pe a nd a cove r i n g of

cotto n t a pe for a bout h a lf i t s le n gth on e a ch s i d e of t h e co r e ,

a n d fo r m e d to d r op b e low t h e bot t om of t h e s lo t Th i s i s .

kn own a s t h e bo t tom pa rt of t h e co i l a s d i s t in g u i s h e d f r om ,

t h e oth e r s i d e wh i ch wil l r em a i n on al e ve l w i th t h e s lots

kn own a s t h e t op p a rt I n co n t i nu i n g t h e wi n d i n g t h e t op
.
,

pa r t s hould be l e ft out for t h e p r e s e n t of s lot s 1 3 5 7a nd 9 , , , , ,

s i n ce i n compl e t i n g t h e w i n d i n g t h e co i l s i n s l ot s 2 4 6 8 , , ,

a n d 1 0 wh i ch d r op b e low t h e s lot s mu s t be i n pl a
,
ce b e fo re ,

t h e s e t op p a r t s ca n be i n s e r t e d Th e s e coi ls wh i ch h a . v e on e
s i d e l e ft out of t h e s lo t u n t i l t h e r e s t of t h e w i n di n g i s com

p l e t e d ,
a re k n ow n a s t h r ow c o i l s I n t h e p r e s e n t c a s e th
. e y
a re co i l s 1 1 2 3 1 4 5 1 6 7 1 8 9 20
,
—
,
—
,
—
,
—
,
—
.

Th e fir s t co i l th a t ca n be wou n d i n to two s lots a s a top a nd

bott om coil i s 1 1 22 Th e coi l i n s lo t 22 b e i n g abo t t om coi l

—
.
, ,

i s i n s e r te d i n t h e s a me ma nn er a s t h e coi l i n s lot 1 2 a lrea dy

d e scri b e d but i s n ot t a
,
pe d or s h a pe d un t i l i t s oth e r s i de i s
1 98 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

s ha pe of t h e coi l en ds I t is pa r ti cul a
. rly n eces s a ry t ha t both
ta pi ngs should be a ppli e d a s ti ghtly a s po ss i ble a s afa i lure ,

to wa tch this poi n t will res ult i n t h e t a pin g be comi n g loose

a n d ba gg y when th e coi l is s ha pe d Thi s i s es pe ci a ll y t rue
.

if t h e s lot i s ve ry dee p a s t h e process of di ppi n g or s ha pin g

t h e bottom co i l b elow t h e bottom of t h e s lot h a s ate n d e n cy

to pull t h e ta pe a wa y from t h e la mi n at i ons To a voi d this .

ten den cy i t is des i ra ble to us e glue on thos e turn s of ta pe

tha t cove r t h e p roj ecti n g en ds of t h e fish p a pe r cell -
.

FI G . 1 42 .
—
A t h ree-ph a
se st t or p a
a rt l y a
w ou n d wi t h b s k e t coil s .

Du ri n g t h e oper a ti on of ta p i n g t h e b e gi n n i n g a
,
n d e n d of

ea ch coil s hould be br ought out i n s u ch a ma n n er a s to l i e on t h e

s i de of t h e wi n di n g fa r th es t from t h e bor e of t h e s t a to r a n d so

pla ce d th a t t h e be gin n i n g of on e coi l fa ce s t h e e n d of t h e

a dj a ce n t co i l i n am a
,
nn e r co n ve n i e n t for co nn e cti ng Th e .

m ethod of wi n d in g jus t d e s cri be d s hould be con ti n ue d un ti l

a ll t h e co i l s a re i n pl a Th e w i n d in g i s compl e t e d by pla ci n g
'

ce .

t h e top p a r ts of t h e th row co i l s i n th e i r r e s pe ct i v e s lots .

Th r e a d e d Di a m ond C oil N o C oil s P er S lot

—
Th e —

threa ded type of di a mon d co i l i s woun d wi th i nsul a te d w i r e ,

e i th e r on a form whi ch fin i s hes t h e coi l to s h a pe or on as huttle ,

whi ch wi n ds t h e coi l fi rs t i n t h e s ha pe of aloop a fter whi ch ,

t h e loop i s pl a ce d in aun i ve rs a
”
l former or p uller In “
.

this devi ce (see pa ge 457 C ha pt er X V I I ) t h e two stra

, ,
i ght
 RE WI N DI N G AL TE R N A TI N G- C UR RE N T M A C HI
NE S 1 99

si des a re cl a mpe d be tween s ui ta ble j a ws a nd a re pull e d

a pa r t t h e re qu i re d d i s ta n ce t h e co i l a s s um i n g t h e s h a
, pe
s hown on th e ri ght in Fi g 1 3 8 Th is ty pe of wi n di n g is si m i la
. . r

t o t h e ba s ke t wi n d in g i n s o fa r a s t h e s lot i s i n s ul a
, ted ins te a d
of t h e coi l On t h e othe r ha
. n d t h e s t ru ctu r e a n d t h e s ha
, pe
of t h e fin i sh e d coi ls is i de n ti ca l wi th tha t of a n ope n s lot

i n s ul a ted coi l I t is the re fore not n ecess a

.
, r y t o s ha ,
pe t h e
co i l a fte r i t h a s be e n pl a ce d i n t h e s lot a s i n t h e ca s e of t h e

ba s k e t w in d i n g Th e s lot i n s ula
. t i o n i s p ra cti ca ll y i den ti ca l
wi th tha t of t h e ba s ke t wi n di n g wi th t h e a ddi ti on of afiber
ce n te r s t ri p to se p a ra t e t h e uppe r a n d lowe r co i l s in t h e s a me
s lot . I n thi s ca se howe ver t h e s lots s hould be la
, ,
i d out i n
groups a cco r d i n g to a wi n d i n g di a gra m t h e n umbe r of g roups ,

be i n g eq ua l to t h e product of t h e n umbe r of pole s by t h e pha se

of t h e motor Th is groupi n g m a
.
y b e e i th e r u n i fo r m a lt e r n at e ,

or i rr e gu la r a ,
cco r di n g to t h e d e s i gn of t h e wi n d i n g Whe n .

t h e gr oup i n g i s un i fo r m a ll g r oups co n s i s t of a
, n e qua l n umbe r
of s lots a , n d co n t a in a n eq ua l n umber of coi ls I n a l t e rn a te .

groupin g e ve ry other group con ta

,
i ns a n eq u a l n umbe r of
s lots a n d co i ls I n i rr e gula
. r gr oup i n g th e re is n o a ppa r en t

un i formi ty in t h e n umbe r of s lots a n d co i ls pe r gr oup .

W di n g aTh r e ph a
i n e - s e S ta t or wi t h Di a m on d C oil s In .
—

pre pa ri n g to wi n d t h e m a chi n e t h e s lot s fo rm i n g t h e b e gi n n i n g

,

of e a ch gr oup s hould be m a r k e d to i n d i ca te tha t t h e co i l s

to be pla ce d i n th em mus t be fu rn i s h e d w i th a dd i ti on a l in
sul a t i on a t t h e en ds Th i s i s n ece ss a
. ry a s t h e s e co i ls fo rm a

boun da ry b e tw ee n ph a ses a nd co ns eq ue n tly a

,
re s ubj e ct

to pha s e po t e n ti al whe re a s t h e pot e n t ia

,
l be twe en a n y oth e r

two a dj a ce n t coi ls i s mu ch l e ss S u ch co i ls a r e ca lle d t h e

.

“
pha s e co i ls of t h e wi n d i n g .

Ta k ga
i n s an e xa mple a72 s lot s i x pole three pha
- - s e moto r
,
-
,

wi th athrow of 1 a nd 1 1 Th e re wi ll be 6 X 3 . 1 8 group s
of four co i l s e a ch wi th 1 8 t a p e d pha s e co i ls i n t h e wi n d i n g
“
- .
,

T h e wi n di n g of t h e co i l s i n to t h e s lo t s ca n be s ta r ted by th r e a d
i n g t h e bo t tom of t h e firs t co i l i n t o s lot 1 1 t h e uppe r h a lf ,

of t h e co i l be i n g l e ft up a s athr ow co i l Th e bott om pa rt s .

of t h e n e xt n i n e co i l s s hould be i n s e rt e d i n rota ti on thus m a k ,

i n g t en co i l s l e ft up a s th row co i l s Th e su cce e d i n g co i l s hould

.

be pla ced in two s lot s 11 a nd 2 1 ,

Th e rul e to follow i s .
,
200 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

th a
t no u pp er p a r t o f a c o i l c a n be p l ac e d i n to a s l o t th e lo ,w e r

p a r t o f w h i ch i s em p ty A ft
. e r e a c h bottom co il h a s b ee n

th rea de d i nt o i t s ce ll both t h e in s ula

,
ti n g cell a n d t h e co i l

s hould be ra i s ed to t h e top of t h e s lot a n d t h e p r oj e c ti n g

s i d e s of t h e ce ll cu t off a s clo s e t o t h e l a mi n a t i on s a s po s s i ble .

Th e co il mus t th e n be fo rce d b a ck to t h e bo ttom of t h e s lot .

Th e e dge s of t h e i n sul a tin g ce ll should be folde d ove r e a ch

oth e r a n d h e ld i n pl a ce by t h e fibe r ce n t e r s tri p Th e l a

. tter
s ho u ld be of aw i dth to m a ke ad ri vi n g fit i n t h e s lot so a s to

hold t h e lower coi l a n d ce ll fi rmly i n pl a ce a n d s hould be lon g

,

e n ough to p r oj e ct out of t h e s lot be yo n d t h e s t ra i ght pa rt

of t h e coi l .

E ve ry fourth co i l in t h e pr es e n t ca
,
s e i s on e of t h e s pe ci a
,
l
pha s e co i ls a n d s hould be t a pe d a t t h e e n d from i ro n to
”
,

i ro n wi th a n ove r la ppi n g la ye r of i n s ul a t i n g ta pe a nd a proteo

t i ve l a ye r of cotton ta pe Th e re ma . i n i n g co il s m a y b e l e ft
wi thout a n y s p e ci a l i n s ula ti o n a t t h e e n ds .

Th e pl a ci n g of t h e uppe r p a rt of t h e co i l i n t h e s lot re qui r es

mo re ca re a n d s k i ll s i n ce t h e r e m a
,
i n i n g s pa ce i n t h e s lot i s

j us t l a r ge e n ough to r e ce i v e t h e co i l w i th i t s w i r e s lyi n g p a ra lle l

to e a ch oth er . Fi g 1 39 s how s t h e cr o s s se cti o n of acoi l
.
-

thre e wi re s wi de by four d ee p t h e wi re b e i n g t hre a ,

d e d th rough
i n s u ch awa y th at w i r e 1 i s fi r s t p a s se d th r ough t h e s lot ,

the n 3 a n d fin a lly 2 Thi s s hould be con ti n ue d wi th e a

. ch

s u cce e d i n g l a yer un ti l t h e whole coi l i s i n pl a ce Th e ce ll

.

ca n th e n be fold e d i n a n d t h e s lot clo s e d w i th afibe r w e dge .

Th e two coi l s mu s t compl e te ly fill t h e s lot I f t h e i n s ul a

. ti o n
a lre a dy m e n ti on e d i s n ot s uffi ci en t to do thi s a dd i ti on a
,
l
fil l i n g s tri ps of full e r bo a r d or t r e a ted wood s hould be pa cke d
'

, ,

i n to t h e bottom or s i d e s of t h e s lot a s m a y b e re qu i r e d u n t
,
i l
t h e co i l i s ti ght e n ough to p r e v e n t mov e m e n t i n t h e s lot .

Th e uppe r a n d low er p a r ts of t h e w i n d i n g out s i d e of t h e s lots

mu s t be ca r e fully i n s ul a te d from e a ch oth er by as t r i p of

tr e a te d du ck cloth Thi s s tri p s hould be wi d e e n ough to

.

e x te n d fr om t h e fis h p a pe r ce ll to t h e porti on of t h e co i l
-

fa rth e s t a wa y fr om t h e s lot a n d s hould be t h re a

,
d e d be twee n
t h e e n d s of t h e co i l s a s t h ey a r e i n se rt e d i n t h e s lots .
 202 A R M A T UR E WI N DI NG A N D M OTOR R E P A I R

be dri e d in amod era te te mpe ra ture in orde r to ex pe l a ll moi s

ture th en whi le s ti ll hot the y s hould be di pped in a
, , , n i n s ul a

t in g compoun d a nd a ga in s ubj e cte d to mod e ra te hea t un ti l t h e

compoun d i s tho r oughly d r i ed Th i s compoun d serves to fil l
.

up a ll t h e po res i n t h e i n s ula ti n g m a t e ri a ls a n d ma ke t h e coi ls

dus t a n d moi s ture p roof B e for e i n s e rti n g t h e coi ls i n t h e
.
'

s lots t h e l a tte r s hould be lin e d wi th ce ll s of pa ra ffin ed fis h

pa p er cut wi d e en ough to proj e ct out of t h e top of t h e sl ot wh en
fold e d a,
n d to s e rv e a s agu i d e t o t h e coi l s -
The se wi n d i n g .

cell s s om e ti m e s ca lled s li ppe rs furn i s h m e ch a

“”
ni ca l prot e c
ti on on ly t o t h e coil s .

Wi n di n g aTw o ph a - s e S ta t or H a vi n g Ope n S l ot s A ss um e .
-

as ta tor d es i g n e d for s i x pol es 72 slots two pha , se w i th aco i l ,

-
,

throw (in s lots ) of l a nd 1 2 Th e tot a l n umber of groups wi th

.

u n i fo rm gr oupi n g i s e qua l to t h e produ ct of t h e n um be r of

pole s by t h e pha s e of t h e moto r i n th i s ca s e wi ll be 1 2 w i th si x
, ,

s lot s e a ch . Th e group s s h ould be l a i d off i n a clo ckwis e

di re cti on t h e outs i d e slots of ea ch gr oup b e i n g m a rke d it o
”

r e ce i ve ph a se co i l s of wh i ch th e re a
, r e two pe r group Th e .

co i l s ca n be i n s e r t e d in re gul a r o rd e r be gin n i n g wi th t h e ,

bottom pa r t of ph a s e co il i n s lot 1 2 a n d i n s e r t i n g ph a s e coi ls

,

W h e re ve r in d i ca ted The y s hould be d ri ve n i n to pla

. ce by

mea n s of afib e r d r i ft a nd ma lle t P a ra ffin m a y b e u.s e d as a

lubri ca tor i f n e ces s a
,
ry a s t h e co il s hould be a
,
good d ri vi n g fit
i n t h e pr ot ecti n g ce ll Th e top pa
. rt s of t h e firs t e le ve n co il s ,

wh i ch a re to be t h e thr ow co i l s wi ll be i n s e r t e d o n ly te mpor a r i ly

un til t h e bottom coi ls ha ve be e n in se r te d i n to these s lots

. .

Th e re m a i n in g co i ls s hould be d ri ve n ti ghtly i n to pla ce t h e ,

proj e cti n g e dge s of t h e wi n d i n g ce ll tri mm e d off clos e to t he

co re a n d fold e d i n a ,
n d t h e s lot clo s e d by d r i vi n g a fibe r re ta in
i n g w e dge i n to t h e g r ooves a t t h e t op of t h e s lot I n s ome .

ma ch i n e s th i s w e dg e cov e rs t h e e n ti r e fa ce of t h e coi l wh i l e ,

i n o t h e rs s ho rt w e dges a re d ri ve n i n a t ea ch s i de le a vin g th e ,

co i l e x po s e d a t t h e m i ddle of t h e co re .

Te s ti n g th e Wi n di n g s A fte r a ll t h e co il s a
.
—
re i n pl a ce on

e i th e r of t h e ty pe s d es cr i be d t h e w i n d i n g mu s t be ca,
r e fully

i n s pe cte d for m e ch a n i ca l de fe cts A l l coil s mus t clea . r the

bore of t h e s ta tor by a t le a s t on e s i x t ee n th of a n i n ch a
-
nd a ny ,

co i l wh i ch ob s t ru cts t h e bo re s hould be ta ppe d do wn wi th a

 RE WI N DI N G AL TE R N A TI N O-C URR E N T M A C H I N E S 203

ma lle t a n d fibe r d r i ft t o g i ve t h e a llowe d clea ra n ce A l l ce lls

.

mus t be i n ta ct a n d s ou n d es peci a
, lly a t t h e bottom of t h e
sl ots . I f t h e pu n chi n g s h a ve bee n s prea da pa rt by d ri vi n g i n

t h e fibe r we dge s th e y mus t be clo se d up a

,
ga in Th e pun ch
.

i n gs s houl d a ls o be ins pe cted t o see tha t n o fra gm e n ts p roj e ct

i n to t h e bore of t h e s ta t or wh e re t h e rotor wi ll ru b a ga i ns t
t he m .

Th e w i n d i n g s hould th e n be s ubj e ct e d t o ab rea k d ow n te s t

to ma ke s ure tha t t h e i nsula ti on is s oun d a t th ose po i n ts wh i ch

i n se rvi ce wi ll r e ce i ve t h e mos t s t ra in . The se po in ts a re fr om ,

co i ls t o i ro n a ,
n d from ph a s e to ph a se C on n e ct a
. ll co i ls of
t h e sa me pha s e toge th e r by api e ce of coppe r w i r e Th e n .

conn e ct t h e te r m i n a ls of at e st i n gt ra n s form e r b e t w ee n t h e dif

feren t pha se s a n d from e a ch ph a s e to i ro n a nd a pply t h e re

quired volta ge for alen gt h of ti m e d e pe n di n g upo n t h e cha ra c

t e ris t i cs of t h e m a ch in e s .
( S ee p a g e 1 7 5 C h a ,pt e r V I I ) I n .

ca s e th i s t es t pun ctu re s t h e i ns u l a t on of a n y co i l or t h e i n s ul a

tin g ce ll in a n y of t h e s lots th i s i n s ul a
,
ti on m us t be remove d
a n d re pl a ce d . If t h e pun ct ure o ccurs i n at op co i l i t m a y ,

s om e t i m e s be re p a i re d by ra i s i n g t h e co i l out of t h e s lot ,

r e movi n g t h e pu n ctu re d i n s u la ti o n a ,
n d ca re fully r e pla ci n g

i t wi th n e w ma t e ri a l I f howe ve r abottom co i l or ce ll i s
.
, ,

pun cture d i t must be re moved by ra

,
i s in g t h e to ps of t h e ove r
la ppi n g coil s Th e s a. me p ro ce dure mus t be followe d if a
co i l h a s to be re pla ce d a ,s i n t h e ca se of abu rn ou t du e to a -

s ho rt ci rcui t
- . S u ch apro ces s a moun ts pra ct i ca lly to ret ra ci n g

t h e op e ra ti o n p erfo rm ed i n t h e ori gin a l win di n g un ti l t h e

i n jure d co i l is ex po se d .

I n s e rt i n g aN e w C oi l i n aWi n di ng I n r e pa
—
. i r wo rk wh e re
on ly on e co il of aba s k e t wi n di n g i s bur n e d out or d a ma ge d ,

a n d i n ge n e r a l if t h e coi ls ha v e be e n p a i n te d a nd a re s t i ff en e d ,

ra ther tha n to re move a ll t h e th row co i ls i t i s freq u e n t ly

,

ea s i er to thr e a d in an e w coil To do th i s cu t t h e d a
. ma ge d
coil a t ea ch s i d e of t h e co re a n d pull t h e wi res out N e w fis h
.

pa per a n d t re a ted cloth ce lls mus t be i n s erte d I n e merge n cy .

,

f ul l e rboa rd or r ope ce m e n t pa pe r m a y b e u s e d i n pl ac e of fi s h
p a p er . T h e t r e a t e d c loth i s v a r i ou s ly k n ow n a s t r ea te d
cloth ,
oi le d li n en empi re cloth e t c (S e e C h a
, ,
. pte r V I I ) .

I n th i s Ope ra ti on co il s ca n be be n t s l i ghtly to g e t th e m out of

2 04 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

t he w y a Doubl e cotto n cove re d wi re of corre ct s iz e a

.
-
n d s ui t

a ble len gth for re wi n di n g mus t be us ed Th e len gth a n d s i ze .

ca n be obta i n e d from t h e old coi l by coun ti n g t h e turn s a nd

me a s u rin g t h e l e n gth of on e To m a k e t h e w i r e t h re a
. d in
ea s i ly i t ca n be rubb e d wi th pa raffin e I f t h e co i l con s i s te d.

of two or more wir e s in pa ra lle l tha t n umbe r s hould be use d

,

i n re wi n d i n g Th e n um b e r of wi re s i n pa
. ra lle l i s t h e n umbe r
e n t e ri n g a gi ven coil from a n y j un cti o n po i n t of co i l te rm i n a ls .

Grea t ca re mu s t be e x e r ci s e d du ri n g t h e th re a di n g pro cess to

FI G . 1 44 . M e t h od
-
of t h re a
di n g i n _
an e w coi l to repl a m a
ce ad a ged on e .

se e th a ta ll t h e wi re s l i e pa rall e l in t he slots nd a re fre e from a

kin ks Othe rwi se i t wil l be i mpos s i bl e to g e t t h e full n um ber of
.

turn s i n to t h e s lot I n ca .se a la rg e n umb e r of turn s a re n ee d e d

( mo r e th a n 2 0 p e r s lot ) two o r mo re l e n gth s of w i r e m a y b e

woun d a t t h e sa m e ti m e a n d co n n e ct e d i n s e ri e s afte r win din g ,

t h e jo in t b e i n g m a d e outs i d e of t h e s lot Wh en t h e req uired .

n um b e r of turn s h a ve bee n i n se rte d t h e e dge s of t h e cell s ,

s hould be t ri mm e d a n d fold e d i n t h e co i l w e dge d i n p l a ce a nd

a
,

ta pe d a t ea ch e n d I t s hould th e n be p a
. in t e d wi th n i nsul t »
t i g pa t
n i n .
a a z i t 11 1 u
2 06 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

s tubs m a y b e w r a pp ed w i th fin e b a re c opp e r w i re a n d th e n

s old e re d .

Th e te rm i n a ls of t h e va ri ous g r oups s hould n ex t be conn ect ed

i n to proper ph a s e r e lati o n s ( see C ha pt e r X I ) wi th double

bra i d e d rubb e r cove re d w i r e or ca
-
ble Th e s i ze of w i re a nd .

t h e gra de of i n s ula ti on wil l d e pen d upon t h e curre n t a n d vol

ta ge J oin ts i n ca
. bles or wi re la r g er th a n N o 6 s hould be .

ma d e by wra ppi n g wi th fin e ba re coppe r w i re Grea t ca re .

mus t be ta ken wh i le co n n e cti n g a n d s old e ri n g j o i n t s to pro

te et t h e win d i n g from t h e molte n me t a l A fte r s old eri n g .

,

a ll j o i n ts a n d S pl i ces s ho u ld be rubbe d s mooth w i th e m e ry

cloth a n d i n s ul a t e d w i th tr ea te d cloth t a pe cove re d w i th ,

on e or mo re l a ye rs of cotton ta pe a n d sa tura te d w i th a ,
n

i ns ula ti n g v a r n i s h or s h e ll a c Th e con n e cti n g ca

. ble s shou ld
th en be a rra n g e d ov e r t h e e n d of t h e w i n d i n gs i n su ch a ma n n er

a s to o ccupy t h e l e a s t po ss i bl e s p a
ce a n d y e t k ee p th e m cl e a r

from t h e fra m e or en d bra ck e ts .

P oi n t s t o C on s i de r wh e n C onn e cti n g C oil s Th e fol .

—

lowi n g poi n ts s hould be ca re fully w a t che d i n o rd e r to m a ke a

good j ob i n con n e cti n g in du cti on moto r win d i n gs .

1 A l l wi res s h ould , if pos s i ble , be ti n n e d be fore t h e conn e ctors a

. re

p u t on I f t.hi s cann o t be d o n e t h e y m us t b e t h orou g h ly cl e a

n ed by
s cra i
p gn .

2 . All s ol deri n g m us t be th oroug h ly done , m ki n g as m ooth a

a nd

so li d joi n t .

3 . Th e wi res of t he j t
oi n s s h oul d la
p if s p a
ce pe rm i t s .

4 . aci d fl u x s h ould be u s e d
No .

5 Th e wi res or ca
. bles m ust be a rra n g ed i n s u ch awa y as t o o cc u py
t h e le a s t s pa ce a n d n ot obs tr u ct ve n t il a ti on .

6 Wi re s or ca
. bl e s m ust be cl a m pe d or ti ed dow n t o a void vi bra ti on .

7 J oi n t s m ust be ca
. reful l y i n s ul ate d .

8 A ft e r con n e cti n g t h e wi n di n g s h ould be t e s ted for ele ctri ca

.
,
l
ba lan ce by ca u s i n g acu rre n t t o fl ow t h rou g h i t a n d com p a rin g t h e

vol t a g e a n d cu r r e n t re adi n g s of e ac h p h as e .

Th e wi n di n gs on t h e s i d e on wh i ch t h e con n e cti on s a re m a de ,

us ua lly ca lle d t h e fron t si d e a re a s a r ul e mo re ri gi d th a

,
n those

on t h e re a r s i d e du e to t h e fa ,
ct th a t t h e conn ecti ons exert a
b ra ci n g e ff e ct S i n ce t h e w in d i n gs in t h e rea
. r la ck th i s b rac

i n g eff ect i t is us ua ,
lly n e ces sa ry wi th di a mon d wi n d i n g s t o
 RE WI N DI N G A L TE R N A TI N G-C U R R E N T M A C H I N E S 2 07

s upply as uppo rt in g rin g of in s ula te d s tee l to whi ch a ll t h e

coi l s a re la ce d w i th rope ma de of s ix or ei ght ply wa xe d en d s
-
.

Th e i n s i de d i a m e ter of thi s ri n g should jus t be la r ge e n ough

to m a ke ag ood fit over t h e wi n d in g I f i t i s mu ch la . r g er th a n

tha t of t h e win d in g t h e coi ls wi ll be un d er te n s i o n whi ch

,

will in ti me ten d t o loosen the m from t h e s upport i n g ri n g .

Ca re s hould be e xer ci se d i n la ci n g t h e co i l s t o t h e ri n g wh en ,

t h e r ope i s l e d through e n d s of t h e co i l s w i th a s tee l n ee dl e ,

t o see tha t n o da ma ge i s don e to t h e i n s ula ti on .

C le ats a n d Te rm i n a ls Th e w i re s th a
.
-
t ta p i n to t h e wi n di n g
a n d exte n d t o t h e outs i d e of t h e fra me a re ca lle d t h e l e a ds .

To a voi d t h e poss i bi li ty of the s e le a d s t ra n s mi tti n g j e r k s

a n d vi b r a ti on s to t h e s olde re d j oi n ts of t h e wi n di n g th e y ,

s hould be fa st e n e d to t h e fra me by i ron or porce l a in cl ea ts .

S uch cl ea ts s hould a lso be use d t o s upport t h e l ea d s from sa g

gi n g whe re ve r th e y pa ss clo s e to t h e i ro n or movi n g p a rts .

Pa in ti n g —
A l l of t h e w i n d in g s a n d es p e ci a
, lly t h e ta pe d
j oi n ts should be tho roughly brus he d wi th s hella
, c or afin i s h

i n g va rn i s h . Th i s ma t e ri a
l se als up a n y por ous pl a ce s in t h e

i n s ula tio n a,
n d ex clud e s d i rt a n d mo i s tu r e ( s e e p a
-
ge
IV . I N DU C TI ON M OT OR S E C ON DAR IE S

Th e s qui rrel a ge se con da

-c ry i s t h e s i mpl e s t m e ch a n i ca lly ,

a nd a t t h e sa m e ti m e is t h e mos t rugge d a n d compa ct fo rm

of movi n g ele men t t o be foun d i n a n y e l e ctri c motor Th e .

opera tin g cha ra ct e ri s t i cs of a s qu ir re l ca ge rotor a-

re d e pe n d e n t

on i t s res i s t a n ce A w in d i n g of low re s i s ta
. n ce w i ll h a ve
good effi ci en cy a n d sma ll sli p but wi ll ha
, ve poo r s ta rt i n g

torque for agi ven ma xi mum cur re n t A wi n d i n g of h i gh

.

r es i s t an ce on t h e oth e r h a
, nd wi ll h a
, ve lowe r runn i n g e ffi
ci e n cy a n d la r ge s li p but w i ll gi v e a
,
h i gh s t a rtin g t o rqu e wi th

mi n i mum curren t a n d i s s ui t a
,
ble for mi ll or cra n e wo r k

where s ta rt i n g un d e r h ea vy loa d i s freq ue n t a n d ope ra ti on

i s for short i n t erva ls on ly Whe re i t i s n ece ss a
. ry how e ve r , ,

to s t a rt a h ea vy lo a d wi th sm a ll s tart i n g cu rre n t a n d op e ra
,
te
for lon g in te rva ls wi th good e ffici e n cy or wh ere ver i t i s n ecos
,

sa ry to va ry t h e s pe e d or ope ra tin g cha ra ct e r i s t i cs of t h e moto r

from ti me t o tim e awoun d se co n da,

r y s hould be u s e d Th e .

win di n gs ha ve alow res i s t a n ce and a ,

re co nn e cte d i n s t a r
2 08 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

wi th t h e open en ds con n e cte d to s li p ri n gs A djus ta ble ex .

l re s i s ta
te rn a n ce can th e n be co nn e ct e d i n s e ri e s wh e n s ta
rt

in g a fter wh i ch t h e rin g s ca
, n be s ho r t ci r cu i t e d -
.

FI G 1 46 . .
—
S q u i rr e l - ca
g e r ot or f or a 3 5 0-h
p , 3
.
- l1 a
p s e , 44 0-v ol t , 1 465 r .
p m
. .

i n d u ct i on m ot or ( C r a cker- Wh ee l e r C om p a n y) .

S quir r e l -
a
c ge a
S e con d r i e s of as qui rrel a
—
Th e ge o
c re —c

roto r i s bu i lt up of l a m in at e d s t e e l on as pi d er a n d k e ye d ,

l n pl a
ce wi th a th e r ke y on t h e s pi d e r a
fe a n d ri n g k e y s a
t t h e en d s .

FI G . 1 47 -
l r ot or ca
S oli d m e t a g e wi n di n g of s q u i rr e l a
g e i n du ct i on m o t or
c

( Fai r ban ks -M or s e ( i t C om
pa
n y) .

Th is r ot or ca g e is m a d e by ca s t i n g e n d r i n g s of copp e r or br a ss a r ou n d t h e e n ds of t h e
r ot or ba rs w h 1 e h h a v e p r e v i ous l y be en t r e a t ed s o t h at t h e m et al of t h e ba rs i s m e l t ed and
fus ed t og e t h e r wi t h t h e m e t a l of t h e r i n g i n t o as ol 1 d m a ss Th 1 s m aes ar ot or ca k ge
T h e i r on cor e of t h e r ot or w a
.

w h 1 ch 1 8 of o n e p i e ce w i t h ou t joi n t s s r e m ov ed i n or d e r t o
ob a i n t h 1 s p h ot og r a n d i n g on l y , t o s h ow t h e ch a ra
.
_

h f h i ct e ri s t 1 c s t r u ct ure fr om
t p o t e w
w h i ch t h e n a s q u i rr e l ca
o

i s der 1 v e d
“ "
m e ge .

V e n ti l a
tors ar e u s e d on t h e roto r s wi th w i d e co re s R ectan gul ar .

c opp er ba
rs are us ua lly us e d cu t from soft d ra
,
wn ba r st o ck -
.
21 0 A R M A T URE WI N DI N G A N D M OTOR R E P A I R

pl e t e o il m a
c y b e comp o s e d of s e v e r al s t r i p s e a c h c ompl e t e ly,

in sul a te d wi th awra ppe r of trea te d cloth a n d aw i n d i n g of

cotto n ta pe I n s ome types of ma

. ch i n e s d e s i g n e d for e s pe
,

ci a ll y h ea v y s e rvi ce t h e i n s ula ,
ti on is compos e d of s he et m i ca n

i t e w ra
,
pped wi th cotton ta pe A ce ll of fish pa . pe r should be
in se rte d i n t h e slot for m e cha n i ca l prote cti on a n d t h e s t ra ps
thre a d e d in on e by on e Th e ce ll m a .
y th e n b e fold e d i n a n d
awedge in s ert e d Wa ve w i n d i n g s a
. r e u s e d for fo rm woun d -

roto rs .

C oll e ctor r i n gs a re m a d e of coppe r or bra ss I f moun te d i n .

s i d e t h e b ea r i n g s th e y a re u s u a
,
lly provi d e d w i th lugs whi ch
a re bolt e d th r ough i n s ula t i n g wa s h e rs to ar i n g i n as m a ll
s pi de r I f moun ted outs i d e t h e be a
. ri n g s t h e le a ds a re ,

brought out t hrough t h e hollow s h a

‘

ft a n d bolt e d to t h e ri n gs .

V . WI N DI N G L AR GE A L TE R N A TI N G -C UR R E N T S TA TOR S

Th e ma ch i n es wh i ch fa ll un der thi s h ea d in g i n clude l a rge

‘

i n du ct i on motors us e d i n i n dus tr i a l pla n t s e n g in e a n d wa,

te r
wheel d ri ven gen e ra tors motor ge n e ra to r s e ts s yn ch ron q u s
-

motors a
, ,

n d fre qu en cy ch a n ge rs Whi le in m a . n y ca s e s d iff e r

e n t type s of w in d i n g s a re u s e d t h e m e thod of wi n d i n g t h e
,

s ta tors i s ess en tia lly t h e s a m e in a ll ca se s Pa rt i cul a r re fe r

.

e n ce w i ll be m a d e howe ve r i n t h e wi n d i n g de ta
, ,
i ls to t h e us ua l
co n s t ru ct i o n a n d re qui r e m e n t s of i n du ct i on moto rs Th e .

re comm e n d a ti on s for i n s ula ti on of slots m a ke up of coils a

,
nd

th eir i n se rti on a r e tho s e of awr i te r i n t h e E l e ctri c J ou r n a l ,

V ol V I I N o 1 2 a
.
,
. n d r e pre s e n t good p ra
, cti ce both for close d

a n d ope n s lot co n s t ru ct i on .

C oil s f or P a r ti a l ly C l os e d S l ot s Wh en i t is n ece ss a
.
—
ry to

repla ce t h e co i l s i n l a rg e ma ch i n es th e y s hould be pu r ch a
,
se d

from t h e m a n ufa ctu re r s i n ce i t i s v e ry d iffi cult t o pr ope rly

fo rm a n d i n s ul a te an umbe r of la rge h e a vy coi ls wi th t h e fa ci li

ti e s a va i la ble in a n o rdi n a ry re pa i r s hop or a t t h e lo ca t i on

whe re t h e m a ch i n e i s ope ra ted s u ch a s agen e ra
,
t in g s t a ti o n
or i du s t ri a
n l pl a nt .

Th e pa rti a lly clos ed s lot re qui res aform of coil whi ch ca n

be e i th e r th re a de d i n th rough t h e s lot ope n i n g or i n s e rted

-

from t h e en d A s i t i s o rd i n a
. ri ly i mp ra ct i cable to in s ula te
 RE WI N DI N G AL TE R N A TI N G-C UR R E N T M A C HI N E S 21 1

t he slots for t h e volta ges commonly use d on la r ge m a ch i n e s

by t h e me thods used for threa de d i n coil s i t is n e cessa

-
, ry

e i th e r t o i n s ul a
te ea
ch s t ran d for t h e full volt a ge or to us e
s om e form of win d i n g i n wh i ch t h e comple te co i l ca n be i n

s ul a t ed from groun d a n d i mp re g n ate d a n d then in se rte d i n to

t h e s lot from t h e en d .

Th e forme r me thod m a y be u se d wh e re st rap d i am o n d c o il s

of ali mi te d n umbe r of turn s a re to be u se d a n d t h e volta

, g e s

La
rg e i ndu ct i on m ot or s t ator p a
'

F m 1 49 -
rt l y w ou n d sh owi n g t ype of coil
‘

. .

us e d (Genera l E l e ctri c C om pa n y).

a
re mod e ra
te tan da
. A rd a
s ppli ca ti on of thi s me thod whi ch
1 8 mu ch us e d on la rge i n du ct i o n moto rs co n s i s ts of afou r co i l

p e r s lot w i n d i n g T w o s
. t r a
p d i amo n d c o i l s f or e ach s lot a r e

compl e t e ly i n s u l a ted a n d i mp re gn a te d Th e wi dth a

. n d d e pth

of t h e in s ula te d coi l a re e a ch e qu a l to ha lf t h e wi dth a n d d e pth

of t h e s lot Th e wi dth of t h e open i n g a

. t t h e top i s on e h a lf -

t h e wi dt h of t h e s lot a n d t h e wi n d in g p ro cess i s t h e s a
,
me a s

for a n open s lot wi n d i n g e x ce pt th a ,

t there a re tw i ce a s ma ny

coi ls for t h e n u mbe r of s lots a s in a n o r d in a ry wi n d i n g .

Wher e an umber of turn s per s lot a re re qui re d wi th a pa r tly

clo se d s lot aco n cen tri c s hove d th rough coi l ca n be us e d .

21 2 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

Th i s a
m y h a
v e a s m an y tu rn s as d e s i r e d Th e coi l s m a y b e
.

formed from double cotton cove re d wi re s roun d i n t h e s ma ,

ller
s i zes a n d s qu are i n t h e l a
r ge r Th e w i re s s hould be cu t off in
.

l en gth s e qua l to t h e tota l len g th of t h e coi l plus e n ough to

a llow for j oin ts a n d boun d toge the r i n alo n g s t r a
, i g ht ba r ,

ha vi n g t h e corre ct cross s ecti on for t h e coi l Thi s ba

-
r 18 .

FI G . 1 50 .
—
S e ct i on o f s t a
t or of wa
t e r-w h e el dri v en g e n e r a
t or s h ow i n g ch a
in
wi n di n g .

the n cla mpe d by t h e mi ddle i n aformi n g m a ch i n e a n d the ,

en d s a re b e n t ove r s u i t a
ble woode n forms to gi ve t h e corre ct
sha pe to t h e fin i s he d e n d of t h e co i l Th e two fr e e en ds s hou ld
.

be left s tr a i ght s o t h at th e y m a
, y be s hov e d th r ough t h e s lot s .

C oi l s f or Ope n S l o t s A l t houg h t h e clos e d s lo t h a

—
s s ome

adva n ta ges i n t h e cas e of i n du cti o n moto r s t h e for m of w 1n di n g ,

n ece s s ary for mor e th a n four or a t mo s t s i x tu rn s pe r s lot i s ,

 21 4 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

the throw of t h e coi ls is g rea t A ll t h e coi ls in ag roup a

. r e of

diflere n t s i z e a n d s ha pe howe ve r a nd the a dj a cen t g roups

'

, ,

m us t be of difi e ren t len g th . On a ccoun t of t h e n u mbe r of

difleren t coi ls use d re pa irs a re diffi cult to m a ke a n d ala r ge r

'

s upply of ex traco i ls mus t be k e p t i n s to ck For thi s rea

. s on

t h e di a mon d wi n di n g is qui te gen e ra lly use d A di a mon d

.

co i l i s of as i mpl e fo rm ea , s y to bu i ld a n d i n s ula te a n d on e ,

fo rm of coi l is used throughout R e pa . i r pa rt s ca n thu s be

red u ce d to a mi n i mum .

La p a n d W a v e C o nn e c t i o n s E i—
th e r t h e l ap o r w a v e fo r m
of di a mon d wi n din g m a y b e us e d T h e e
. n d c o nn e c t i o ns by ,

wh i ch t h e co i l en ds a re co nn e cte d i n to g roups a n d t h e gr oups

i n to ph a s es a r e v e ry mu ch mo re s i mpl e w i th t h e wa
,
ve wi n d
ing . This fo rm of w i n d i n g i s th e re fo re us e d wh en e ve r a
, , pp l i
ca ble Th e volta
. ge be twee n a dj a ce n t co i l en d s i s much

g r e at er but
, as t h e co i l mu s t b e i n s ul at e d f o r full l i n e volt a g e

un d e r a n y co n d i ti o n s th is doe s n ot m a
, ke a n y pa rt i cula r diff e r

e n ce . Wh e re mo re tha n on e tur n pe r co i l i s re qu i r e d howe ver , ,

or wh e re as e r i e s pa - ra lle l combi n a ti on i s n e ces sa ry t h e wa ve ,

win d i n g i s mo re cumbe rs ome th a n the la p w i n d i n g I t i s .

a cco r d i n gly u se d o n ly wi th aon e tu rn pe r s lot co i l wh e re a ll

,

t h e g roups in a pha se a re co n n e ct e d i n s e ri e s Th e l a .
p w i n d i n g
i s thus mu ch mo re common a s mo s t h i gh volta ge m a ch i n es

re qui re mor e th a n on e tur n pe r s lot Th e coi ls m a

.
y b e wou n d
from roun d or s qua re wi re or coppe r s t r a p d epe n di ng on t h e
,

n umbe r of tu rn s a n d t h e s i z e of t h e con du cto r .

I n s ul a ti o n of C oil s —
Th e i n s ul a ti on to g roun d is p ra cti ca lly
t h e sa me for agi ve n volta ge for a ll type s of co i ls Th e wi re .

i n wi re woun d co i ls s hould be cotto n cove re d a

- n d n o oth e r
,

i n s ula ti o n i s n ee de d be twe en turn s Wh en t h e co i ls a . re m a de

up of two or mo re la ye rs of con du ctors howe ve r t h e la , y e rs
,

s hould be s e pa ra te d by d ri lli n g cotton ta ,

pe or trea te d p a pe r ,

a ccor d i n g to t h e type of co il use d S t ra. p con du ctors m a y b e

i n s ul a te d betwe en turn s wi th overla pp in g cotton or mi ca

ta pe I n mos t ca
. se s howe ve r t h e t a
, ,
pe i s use d ove r t h e e n ds
of t h e coi ls o n ly t h e stra
,
i ght p a rt s b e i n g i n s u l a te d by i n te r
we a vi n g a n i n s ula ti n g ce ll of ce men t pa pe r a n d m i ca be twe en
the m Wh e re s e ve ra
. l s t ra p s a r e co n n e c t e d i n p a r a ll e l f o r

grea ter con du cti vi ty the y a ,

re o rd i n a ri ly en a m eled cotton ,
 RE W N
I DI N G AL TE R N A TI N G-C U R R E N T M A C HI N E S 21 5

cove re d or ta p e d t p
o re v e n t ed d y c u rr e n t l oss . Th e s e v e r a l
turn s whe t her conn e cted in pa
,
ra lle l or seri es m a , y b e b o un d
t og e th e r wi th n on overla - ppin g cotton ta pe a n d i m p re g n a te d
be fore be in g i n s ul a ted from groun d Whi le dryin g t h e st ra
.
, ig h t
p a r ts s ho u l d b e cla mp e d i n a p r ess so th a t th e y w i ll d r y p e r

fe ct l y s tra i ght a n d wi thout a n y i n te rs ti ce s be tw een t h e turn s .

Th e h a r d e n e d i mp re g n a tin g gu ms th en bi n d t h e d ri ed coi l
in to a compa ct un i t .

Th e i ns ula ti on to groun d m a y c o ns is t of t r ea t ed ta pin g ove r

t h e whole co i l w i th a ,
prote cti ve cove rin g of cotton ta pe Th i s .

ma te ri a l is wi d e ly us e d on t h e s m a lle r ma ch i n es a ,
n d for com

p a r a t i v e l y low volt ag es . F o r l a r g e r m a c h in e s,
how e v e r a n d ,

for hi gh volt a ges t h e cus toma

,
ry i n s ula ti on co n si s ts of awra p
p e r o f c e m e n t p a p e r a n d m i ca o n t h e s t r a i ght p a r t s a n d t re a t e d
ta pe or mi cata pe on t h e en ds wi th aprote cti ve la
, ye r of nu
t rea te d cotton ta pe or mi cata pe on t h e whole co i l ove rla ,
pp in g
o n h
t e en d s a n ove rla
n d o n - pp in g on t h e s tra i ght pa rt s Th e .

e n ti re co i l m a y th e n b e d i pp e d tw i ce i n a n i n s ul a t i n g v a r n i s h ,

a n d d ri ed tho roughly i n a n ove n a fte r e a ch d i ppi n g Th e .

re qui s i te i n s ul a ti on for t h e h i gh volta ge m a ch in e s ca n be s e

cur e d by ext r aturn s of ce m e n t pa pe r a n d mi cawr a pper .

N ot ove r thre e a n d on e h a -
lf turn s is o rdi n a ri ly use d how e ver , ,

on a ccoun t of t h e d i fficulty of p rope r ly i mp re gn a tin g s u ch a

coi l . Whe re this does not gi ve s uffici e n t in s ul a ti on two or ,

m o re se pa ra te wra ppers m a y b e u s e d , a n d t h e c o i l d i pp e d
t wi ce in va rn i s h a n d dri e d a fte r t h e a ppli ca ti on of ea ch

wra pper (see p a ges 1 63 to

I n s erti ng S h ove d Th r ou g h C on cen t ri c C oil s . Wi n d in g s
—

us in g co il s of t h i s type m a y b e d i v i d ed in to two c l a ss e s d e ,

p e n d in g o n wh e th e r t h e e n d s a r e b e n t dow n at o n e e n d o r b e n t
d own a t both e n ds Th e win d in g pro ce ss e s a
. r e p ra cti ca lly
s im il a r for both . C oi ls be n t down a t on e e n d a re us ed on

both two-ph a se a n d th re e ph a -
s e ma ch i n e s t h e two w i n d i n g s
,

be in g pra cti ca ll y i d en ti ca l wi th t h e ex ce pti on of t h e en d con

n e ct ors . I n atwo ph a -
se m a ch in e t h e a lte rn a te g roups a re of

t h e sa me pha se tha, t is a ,
ll t h e coi ls in ea ch ba n k of co i l e n d s

b e lon g to t h e sa me ph a se .

I n ath ree pha - s e ma ch in e w i th a ,

win di n g of t hi s type every ,

th ird group be lo n g s t o t h e s a me pha se a n d t h e gr oup s of ea ch

,
 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

ph a se a lte rn a te from on e ba n k to t h e oth er I t should be

.

n ote d i n thi s ca s e th a t t h e groups of t h e sa me pha s e do n ot l ie

a dj a cen t to on e a n oth er but a ,

re s e p a ra te d by ad i s ta n ce

eq u a l to t h e pole pi t ch a n d th a t the re a re o n ly th r ee gr oups of

co i l s pe r p a i r of pol e s Wh er e t h e groups of e a
. ch ph a s e ha ve
on e s i d e a dj a ce n t to a n oth e r gr oup of t h e s a me ph a s e un d e r ,

t h e sa me pole wi th s i x groups of coi l s per p a

,
i r of pol es i t is ,

n ece s s a ry to h a ve th ree ba n ks to a llow t h e en d con n e cti on s to

,

cro ss on e a n oth e r . I n thi s ca s e t h e coi l s of two of t h e b a n ks

mus t be b e n t down on both en d s Th e e n d s of t h e th i r d .

ba nk a re ,
there fo re b e n t down a
,
ls o to secure un i fo rm i ty of
,

t h e w i n d i n gs .

C o ns i d e r a ble ca r e i s r e qu i r e d i n i n s e rt i n g co i ls of t h e s hov e d

thr ough typ e i n to t h e slots Th e slots mus t be firs t cl e a

. n ed

from a l l fo rei g n m a tter Th e coi ls s hould then be rubbe d

.

w i t h pa ra ffin e a ,
n d t h e s lot s li n e d w i th pa ra ffin e d fis h pa pe r ,

cu t a n d ben t t o a n e xa ct fit Th e coi l i s thus m a

. d e to s l i p
ea s i ly i n to po s i t i o n and a
, t t h e sa me ti me i s prote ct e d from
da ma ge by s ha r p e dge s of t h e i ro n A t i ght d ri vi n g fit is
.

a b s olutely e s s en t i a l wi th thi s typ e of wi n d i n g I f on t ri a . l, ,

t h e fit i s too loo s e s t r i p s of t re a te d full e rbo a r d or wood ca

.

,
n

be pl a ce d i n t h e s lot or t a ,
pe d to t h e co i ls .

Th e s m a ll e st co i l i n e a ch gr oup s hould be pla ce d in t h e

s lot s fi rs t ,
a n d wo r k e d i n to t h e m both s i d e s a t o n ce u n ti l ,

t h e fo rm e d e n d com es wi thi n as ho rt d i s ta n ce of t h e i r o n .

Wood en d i st a n ce blo cks of a ppropri a t e d i m e n s i o n s ca n be

us e d to s e cure u n i for mi ty Th e oth e r co i l s m a .

y th e n b e

i n se r te d i n o rd e r . A l l t h e co i ls of on e ba n k s hould be i ns e r te d

before t h e oth er ba n k i s s ta rt e d Wh er e atwo b a

. n k wi n di n g
-

i s u se d a ,
n d t h e co i l s a r e b e n t do wn a t on e e n d o n ly i t is ,

n e ce ss a ry to i n se rt t h e co i ls of t h e d i ff e r e n t ba n k s fr om op

p o s i t e s i d e s of t h e c o re B y . th i s m e thod t h e w i n d e r fo r m s

o n ly t h e s tra i ght e n d of t h e co i l s a n d h i s wo r k i s v e r y mu ch
,

s i mp li fi e d . Wh en athre e b a n k wi n d i n g i s us e d
-
howe ve r , ,

t h e w i n d er mus t b e n d down t h e e n d s of a l l t h e co i ls a s he

co n n e ct s th e m . I n th i s ca se it i s ea s i e r to i n s e r t a l l t h e co i ls
from on e en d A fter a . l l t h e co i ls a re i n pl a ce a fiber r e t a in in g s
we dge s hould be dri ven i n ove r t h e t op of ea ch co i l t o hold

i t t i g htly i n pl a ce t h e fit b e i n g a
, s clo s e a s po ss i bl e w i thout
218 A R M A TU R E WI N DI N G A N D M OTOR R E P A I R

through t h e s lots On e or two ba . rs m a y b e u s e d pe r s l ot .

Wi thi n a n i n ch or s o of t h e e n d t h e ba r i s un i n s u la
,
te d an d the

ba re e n d s a r e ti n n e d E n d co n n e cti o n s of d i a
. mon d or i n
volute form i n s ula te d a
, n d p rovi d e d wi th t i n n e d e n d s a re ,

us e d to comple t e t h e coi l I n ord e r to fa . cili t a

te t h e ope ra ti o n
of s old e ri n g t h e en d s of t h e conn e cto rs a
, re s lotte d or d ri ll e d ,

FI G .l 53.
—
t or of aw a
S e ct i on of t h e s t a t e r-w h ee l dri v e n g e n e r a
t or s h ow i n g
t w o-p a r t ba r coil s , h or n fi be r s l ot i n s u l at i on , w ood w e dg e s a n d v e n t il a
ting
sp a ce s i n t h e cor e .

for wi thou t th e s e ope n i n gs i t i s di fficult to fo rce t h e s old e r

in t o t h e ce n t e r of t h e jo i n t .

I n t h e ca s e of atwo ba r pe r s lot w i n d i n g
-
i t i s n e cessa
,
ry

t ha t t h e ba r n e x t to t h e r otor be s ho r t e r s o th a t t h e join ts
a t both e n d s of t h e co n n e cto rs wi ll be a cces s i ble to a s old e ri n g

i ron . I n t h i s case s u ffici e n t filli n g mu s t be pl a

, ce d b e t w e en

t h e two b a rs i n t h e s lot to a llow t h e e n d co n n e ctor to sli p

over t h e top ba r w i th s u ffici e n t cle a ran ce for t a pi n g I n ca se .
 RE WI N DI N G A L TE R N A TI N G-C U R R E N T M A C HI N E S 21 9

there i s n ot s uffici e n t room in t h e s lot to a llow of thi s filli n g ,

t h e top b a rs a re cu t a wa y Th e con n ecto r is sh a

. pe d a s ,

sh ow n in Fi g 1 54 s o a .
,s to a llow i t to s li p between t h e low er
ba rs a n d ove r t h e en d s of t h e uppe r on e s A ll co n n e ctors .

must be s old ered i n pla ce a n d t h e j o i n ts t a ped Wi th thi s type .

of win di n g re pa i rs a r e v e ry e a s i ly m a de a s a n y ba r ca n be ,

re mov e d w i thout d i s tu rb in g t h e b a rs i n a n y o t h e r s lot It ,

i s n ot a da pta ble to hi gh volt

a ges however on a
, , ccoun t of
'

t h e li m i te d n umb e r of po s s i bl e
turn s Furth ermore t h e e n d
.
,

con n e cti o n s a r e v ery difi cul t to

bra ce a deq u a te ly .

Di a m on d C oil s On l a
.
—
r ge
ba a d
ma a s pli t fra F 1 54 St b f d
—

ch i n es m e con IG . . u s or r n en

onn t wi d i g
c e c or n n

is n e ce ss a
.

s tru cti on ry A ft er .

t h e ma ch i n e i s compl e te d a n d t e s t e d t h e w i n d i n gs a ,
re re

move d by t h e ma ke r a t two po i n t s i n o rd e r to a ,
llow t h e
fra me to be di s con n e cte d for s h i ppi n g S ome form of wi n d .

i n g mu s t t he re fo re be u s e d th a
, ,
t ca n re a di ly be d i s con n e cte d
a n d re co n n e ct e d on a rri va la t i t s d e s ti n a
,

ti on Thi s con d i t i on .

is m os t rea d i ly m e t by t h e Ope n s lot di a mon d coi l Th e .

di a mo n d wi n di n g i s by fa r t h e ea s i e s t to put i n pl a ce to ,

re mov e wh e n n e cess a ry w i thout d a ma ge to t h e coi l to con ,

n e ct i n to group s a n d ph a s e s to b ra ce a
,
t t h e en ds e t c I t is ,
.
,

therefore mu ch use d on la
, rge or hi gh volt a ge m a ch i n es .

Th e a sse mbly of w a ve a nd la p w i n d i n g s w i th th e s e c o i l s i s

pr a cti ca lly t h e sa me a n d t h e p ro ce s s e s on t h e la
,
rg e r m a ch i n e s

a re s i m i l a
r to tho s e e mploy e d on t h e s m a lle r o n e s Th e s lots .

sh ould be cle a ned a n d l in e d wi th p a pe r prote cti ve ce lls .

Th e co i ls m a y th e n b e in s e r t e d o n e a ft e r t h e oth e r i n o r d e r ,

no a tte n ti on bei n g pa i d to gr oupi n g a s t h e co i l s a

,
re a ll a li k e .

On al a r ge m a ch i n e t h e ca ,
r e ful w e dg i n g of t h e coi l s i n t h e

s lots i s e s pe cia lly n e ces sa ry a s t h e m e ch a

,
n i ca l s tr es s es th a t
a re br ought to b e a r on a ccoun t of t h e h e a vy cu rren ts i n ca se

of short cir cui t a -

r e ve ry l a
,
rge H e n ce t h e co i l mu s t fit v e ry
.

ti ghtly i n i t s pla ce I f n e cess a ry s t r i p s of t re a

,
te d ce me n t
pa pe r full e rbo a r d or wood s hould be pl a ce d i n t h e s i d e s a
,

,
nd

bottoms of t h e s lot s to e n s ure at i ght fit .

220 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

Wh en in s e rti n g t h e coi ls t h e firs t ha lf of ea

,
ch co i l s hould

be dr i ve n ti ghtly i n to t h e bottom of t h e s lot w i t h afibe r

dri ft a n d ma lle t Th e coi l whi ch goe s ove r i t mus t a
. ls o
be d ri ven s n ugly i n to pla ce Th e fis h pa pe r ce ll ca
. n th e n be
-

cu t 03 e ve n w i th t h e top of t h e s lot a n d fold e d ove r t h e co i l .

I n o r de r th a
t th is cell m a y n ot b e to rn by t h e w e dg e a s t r i p ,

of trea ted fulle rbo a r d t h e full w i dth of t h e co i l m a

, y b e l a i d ,

Sta of a3 h a Fa i ba k -M ors e be l t e d t a
l t e rn a
t or
'

FI G . 1 55 —
. t or p - s e r n s y pe
w ou n d wi t h t h e coil s s h ow n i n Fi g 1 1 7
. .

i n t o t h e s lot , so we dge wi ll sli d e ove r i t r e a

t ha
t the di ly a nd ,

a t t h e sa me
ti me comp res s t h e coi l t i ghtly i n to t h e s lot s .

Th e we d g es m a y f o r co n v
,
e n i e n ce be d i vi d e d
,
i n to s ecti ons

6 to 8 i n ch es lo n g a n d d ri v e n i n to po s i ti o n by m ea n s of a

sta n dard w e dg e d r i v e r or ablu n t chi s el I f t h e w ed ge is

.

avery ti ght fit t h e coi l should be dri ven down wi th adri ft

,

j us t ah ea
d of t h e we dge .
 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

de pen di n g on t h e a rra n ge m e n t of t h e co i ls a n d gr oups Th e .

co i l s of e a ch group a r e co n n e cte d i n se ri es but t h e g r oups i n

apha se m a y b e co nn e c te d i n se ri es p a r a ,
ll e l o r s e ri e s p a r a ll -
e l ,

a lthough for volta ges of 2200 or hi ghe r th e y a re n e a rly a l

wa ys co n n e cte d in se ri es Th e ph a . se s on a two ph a se m a
-
chi n e

a re n e ve r co n n e cte d toge th e r i n s i d e t h e m a ch i n e .

S ta to w d n g s of lt a
r i n i a e r n ti g curren t ma
n - chi n es m a y b e

co n n e ct e d e i th er st a r or d e lt at h e choi ce d e p en d i n g upo n m a
,
ny

co n di t i o n s . For ma chi n es of 22 00 volt s a n d ov e r i t i s a d

vi s a bl e to conn ect t h e wi n di n g i n sta r b eca us e t h e volta ge
from a n y on e t erm i n a l to groun d i s on ly ( 2200 of t h e
volta ge be twee n t ermi n a ls a n d th e refo re t h e wi n di n g h a s a l ess
ch a n ce to b re a k down to groun d How ever thi s i s n ot .
,

as tri ct rul e for s om eti m es i t i s more co n ven i en t to ha ve t h e

s ta tor de ltacon n e ct ed for t h e r ea s on tha t as ma ll er si ze of
wi re ca n be us ed a n d al a rge r n umb er of tu rn s .

On aco n ce n t ri c wi n d i n g t h e gr oups a re r ea di ly dis ti n gu i sh

a ble I n adi a
. mon d or in volute wi n di n g t h e n umbe r of coi ls ,

p e r gr oup mu s t b e c ou n t e d o ff an d t h
, e g r oup s t e m po r a ri ly
co n n e ct e d by b e n d i n g tog e th e r t h e l e a ds from awir e co il or
by s li ppi n g acoppe r con n e cto r over t h e s tubs from as tra p
co i l . Th e y s hould be p e rm a n e n tly co n n e ct e d by s old e ri n g

t h e j o i n ts s o m a d e On mos t ma
. chi n e s t h e con n e ctors be
,

twe en groups con s i s t of i ns u l a te d coppe r s tra p wi th s ui ta

,
ble
Ope n i n g s a t ea ch en d to s li p ove r t h e group le a ds .

A ll joi n ts a fter be i n g ca r e fully s old e r e d s hould be s mooth e d

,

up wi th e mery cloth s o tha ,

t no sha r p po in t e d e dges a
-
re le ft

to d a ma ge t h e i n s ula ti o n .

Th e co n n e cto r s be tw e e n co i l s o rd i n a ,
r i ly ca lle d s tubs s hould ,

be i n s ul a te d wi th tre a t e d cloth ta pe a n d ap r ot e ct i v e cove r

,

i n g of un tre a te d cotto n ta pe La rge s tub s a

. r e s om e ti mes

cove re d w i th d r i ll i n g ca p s s e we d to s h a
,
pe a n d pa ,
i n te d wi th
i n s ula t i n g va rn i sh a ft e r the y ha ve b e e n f a s ten e d i n pla ce .

Tre a t ed t a
o

p e s hould b e wou n d ov er t h e jo i n t s i n t h e i n s ul a t i o n .

Th e thi ckn e ss of t h e t a pin g a n d oth e r i n s ul a ti on d e pe n d s on “

t h e volt a ge of t h e ma chi n e Th e con n e cto rs be twe e n g roups

.

a re o r d i n a r i ly i n s ul a te d a n d i mp re gn a te d be fo re the y a re pu t

on t h e m a ch i n e . Th e j o i n ts be twe e n t h e con n ec tors a n d the

group le a ds s hould be in s ula t e d in t h e s a me wa a t h t b

”

y s e s u s .
 RE WI N DI N G A L TE R N A TI N G-C U R R E N T M A C HI N E S 2 23

Where double win di n gs a re use d th e y a re us ua lly a r ra n ge d

for t h e conn e ct i o n s to be ma de on opposi te si d es of t h e

ma ch i n e .E a ch w i n d i n g m a y b e c o nn e ct e d as if i t w e r e

e n ti re ly in de pe n d e n t .

B ra ci n g N e e d ed f or He a vy Win ding s Th e stress es occur

—
.

ri n g i n t h e en d co n n e ct i o n s of a la r ge m a ch i n e du e to ma gn e ti c ,

r ea ct i ons be tw e e n curren t ca rr y i n g co n du cto rs a re qui te ,

la r ge . In a ddi ti on thes e e ff e cts a

, re gre a tly m a g n i fi e d i n

ca s e of as ho rt ci r cui t on t h e g e n era
- to r S ome me thod of .

bra ci n g these en d co n n e cti on s i s th e re fo re n e ce ss a ry Th i s .

or di na ri ly t a kes t h e for m of a n i ns ul a t e d s tee l ri n g to wh i ch t h e ,

co i ls a re ti ed wi th h e a vy twi n e On acon cen tri c win di n g

.

9 se pa
. ra te rin g is us e d for ea ch ba n k of e n d co n n ect i ons On .

adi a mon d wi n di n g on e ri n g a t ea ch e n d i s suffici en t On a .

la r g e ma ch i n e how e ve r i t is us ua
, ,
lly n ece ss a r y t o b ra ce th i s

ri n g by a d di ti on a l st eel s upport s bolted to t h e fra me .

VI . WI N DI N G THE S TA TOR OF A L TE R N A I G C U RR E N T
T N -

TUR B O GE N E R A TOR S
-

A lthough t h e a lte rn ati n g curre n t -

turbo ge n era t o r fa lls m
-

t h e pre vi o us g roup of lar ge m a ch i n es , on a cco un t of i t s w i n d i n g

bein g more or less s pe ci a l i t wi ll be d e a

,
lt wi th s e p a ra tely .

There a re S pe ci al fea tures of wi n di n gs for thi s cla s s of m a ch i n es ,

owi n g to t h e hi gh s pe e d a t wh i ch th e y a r e Op e r a te d a nd t h e
forced requi re men t tha t t h e i n s ide di a me t e r mus t be s ma ll on
a ccoun t of t h e ce n t rif uga l s t ra i n s of t h e re volvi n g fie ld roto r .

Th e gen e ra to r co re is there fore lo n g re qu i ri n g la r g e co i ls fre

q u e n tly mo re th a n 1 0 fee t lo n g w i th a s p an fr om 3 0 to 4 0
i n ch es a n d w e i gh i n g a s mu ch a s 10 0 poun d s On e of t h e bes t .

dis cuss i on s of t h e methods for wi n d i n g a n a ltern a ti n g cu rren t -

turbo gen e ra-

tor h a s a ppe a re d i n t h e E l ectr i c J ou r n a l V ol ,
.

VI I I N o 3
, Th e w in di n g d et a
. il s tha t follow ha v e be e n ta ken
from tha t sour ce .

C il s for A C Tur bo g en era

o - .
-
. t or s Th es e m a
.
—
ch i n e s h a ve
open s lots a n d us u a ll y e mploy ad i a mon d coi l bu i lt up in two
pi e ces for on e or sev e ra l t urn s pe r s lot Th e two pi e ce coi l i s
.
-

use d whe re t h e throw of t h e coi ls is ve ry g re a t a s i n la r ge s i z e ,

bi pola r ma ch i n es for 2 5 c y cl e s Th e on e pi e ce co i l i s u s e d
.
-
224 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

ons m aller ma chin es a n d i n fa ct wh e re ver s u ch a

,
co i l is n ot t oo
,

cumbe rs ome to h a n dl e provi de d t h e comple te coi l ca

,
n be

pass e d th rough t h e bo re Th e co i ls of ei th e r type m a

.
y b e

forme d from cotton covere d s tra p or cotto n cove r ed wi re

- -
.

Wh e re acon du ct or of la r ge cro s s s e ct i o n i s re qu i r e d i t i s o r d i
-
,

FI G . 1 56 .
—
E nd la r g e t u r bo-g e n e r a t or sl owi n g m e t h od of br a
ci n g a
nd
con n e ct i on s t o r e s i s t s h or t -ci r cu i t s t re s s e s
.

n a ri l y bui lt up of a n umb e r of s qu a re copp e r wi re s i n pa ra

ll el to ,

fa ci l i t ate be n di n g a n d to obt a i n pr op e r l a mi n ati on Th e .

i n di vi dua n ds a
l s tr a r e u s ually cotton cove re d M os t t ur bo .

gen e ra t o rs re qui r e mor e th a n on e tu rn per s lot i n o r d e r t o

obt a i n t h e d e si re d volta T h s e s e v e r a
l tur ns a r e bou n d
g e e .
2 26 A R M A TU R E WI N DI N G A N D M OTOR R E P A I R

m et a l to t h e sa me di s ta n ce th a t th e y wi ll be se pa rate d whe n
i n s ul a ted a n d pla ce d i n t h e m a chi n e Tw o-pi ece coi ls ca
. n

be formed fr om le n gths of stra i ght coppe r s t ra p Th e en ds .

s ho u ld be be n t a t asui t a ble a n gl e to t h e s t ra i ght pa rt of t h e

co i l a roun d two pi n s s pa ce d ad i s t a n ce eq ua l t o t h e le n gth of

t h e s tra i ght pa rt Th e con du cto r m a
.
y th e n b e cl amp e d i n a
mould a n d t h e e n ds b e n t i n to s h ape Th e s e ve ra . l con due
tors i n acoi l ca n be for m ed i n t h e s a me mo ul d a n d se p a ra ted ,

by s tri ps of coppe r s tra p .

a
I n s u l ti on for Turbog e n er t or C oil s a .
—
at urbog en
S in ce
cra tor m a y a t ti m es be s ubj e ct e d to v e ry h ea vy overloa ds ,

t h e i n s ula ti on s hould be a s n ea r ly h ea t proof a s pos s i ble .

For thi s rea s on ,

mi ca i s mu ch use d Wh e re s eve ra . l con
du ct ors pe r co i l a r e re q ui r e d ,
t h e i n s ul a ti on be twe en con d ue
tors usua lly con si s ts of fl e x i ble m i cata pe a n d m i ca ce ll s Th e
.

i n d i vi dua l con du cto rs m a y th e n b e s u i t ably bou n d tog e th e r .

A ll coi ls s ho ul d be i mpre g n a te d wi th a n i n s u la ti n g compoun d

be fore t h e i n s ula ti on from groun d i s suppli e d Th e s tra . i ght
pa rt s m a y b e c l amp e d t i ghtly i n m e t a l c la mp s a n d i mp re g
na t e d or m a
, y b e i mp re g n a t e d w i t hout t h e c l a mp s a n d pl a ce d
i n cla mps t o dry E i ther m ethod re s ults i n acompa
. ct un i ,

fo rm con s tru cti o n s o tha t t h e coi l m a y b e fitt e d t i ghtly in to

t h e s lot wi th m i ni mum ri s k of d a ma gi n g t h e i n s ul a ti o n .

T h e i n s ul a ti on from g ro un d us ua lly con s i s ts of wra ppers of

pa pe r a n d mi caove r t h e s t ra i ght pa rt . Th e co i l e n d s s hould
be i n sula te d by la yers of trea t e d ta pe wi th acove ri n g of
,

un trea t e d ta pe a,
n d t h e whole co i l t rea ted wi th i n s ul a tin g
va rn i s h . A s i n t h e ca s e of e n g i n e typ e gene ra to rs i f extra
,

i n su la ti on i s re qui re d a dd i ti on a l w ra ppe rs of t h e pa pe r a nd

mi caa re fr e qu e n tly u s e d ,
t h e coi l b ei n g di ppe d a n d d ri e d

a fte r e a ch wra pp er i s a ppli ed Thi s m a

. kes t h e bui ldin g of a
hi gh volta
-
g e c o i l a lo n g p r o ce s s,
two w e e k s or mo r e fre qu e n tly

be i n g re qui r e d for t h e completi on of asi n gle coi l .

Te s ti n g Tur bog e n e ra t or Wi n di n g s .
—
Ope n co i ls m a y b e

tes ted for short ci r cu i ts by a

- pplyi n g as ui ta ble v olt a ge be tween
co n du cto rs . N o s ho rt ci rcui t te s ts a
- r e u s ua lly m a de on t h e
i n di vi du a l close d coi ls but a ,
n ove r volta
-
ge te s t should be
a ppli ed a fter th e y a re on t h e m a ch i n e . A l l co i l s s hould a lso
be te s t e d for i n s ul a ti on by wra ppi n g t h e out s i de wi t h t in
 RE WI N DI N G A L TE R N A TI N G-C U R R E N T M A C H I N E S 2 27

foi l and a
,
l i
pp y g n from to two a
t wo n d aha lf ti mes n o rm a l
opera ti n g voltage across t h e i ns ula t i on .

I ns ert i ng th e C oil s in aTurbog en era tor E x ce pt for t h e

.
—

g re a t w e i ght a
n d lar ge s i ze of t h e co i ls w h i ch m a k es th e m mo re

di fficult t o h a n dle t h e w i n d i n g of at ur boge n er a

,
to r i s i n a ll
ess e nti a r t o t h e wi n d i n g of a
ls si mi la n e n g n e t y pe g e n e ra
i - tor .

Th e s tra i ght part of t h e co i l s hou ld be wa xe d a n d la i d ove r

t h e slot openi n g i n s i de ap a
,
pe r ce ll wi th whi ch t h e la tte r i s

F m . . t or s t a
1 57— Turbo-g e n e r a t or p a rt l y w ou n d u si n g on e p i e e e co i l s .

T h e Op e r a t or i s bi n di n g t h e coil s i n p os i t i on .

l i n ed . orde r to a
In voi d ben di n g t h e coi l awood en d r i ft ,

a s lon g a s t h e s t rai ght pa rt m a y b e u s ed to dri v e i t i n to t h e

bott o m of t h e s lot Th e bottom h a

. lve s of two par t coi ls -

s h ould be i ns e r t e d firs t i n a l l s lo t s in t h e s pa n of on e coi l ,

t h e t op ha lves be in g in sert ed la ter On e p i e ce co l s s hou l d be

.
-

i n s ert ed i n reg ula r order A fte r ea. ch top co i l h a s b e en fi t t e d

i n t o pl ace t h e ce ll wh i ch li n es t h e s lot m a
, y b e fold e d o v e r ,
2 28 A R M A TU R E WI N DI N G A N D M OTOR R E P A I R

a n d r e ta i n in g we dges i n s hort s ect i o ns dri ven i n pla ce ove r t h e

full le n gth of t h e coi l E n ough s t ri ps of e xtram a . teri a l mus t

be us e d i n t h e slot t o ma ke t h e we dges fit ti ghtly over t h e coi l .

Th e we dges m a y b e d ri v e n i n pl a c e by a t o ol o f s p e c i a l s h a p e ,

ope ra te d by acompresse d a i r ha mm er -
.

I n ord e r to g e t t h e bott om ha lf of t h e la s t fe w on e p i e ce -

coi ls i n to t h e s lot i t i s n e ce ss a
,
ry to li ft t h e top h a lf of t h e
coi ls wh i ch go i n t h e s a m e s lots Wi th aful l pi tch wi n di n g
.

thi s would me a n on e ha lf of t h e coi ls on atwo pole m a

-
ch i n e -
,

a n d on e four th t h e co i ls on afou r pol e m a

-
chi n e
-
Wi th a .

cho rd e d or fra cti o n a l pi t ch wi n di n g how e ve r t h e n umbe r

“ ”
, ,

of th ro w coi ls i s le s s Th e th row of t h e coi ls ca

. n be r e a di ly
s ee n i n Fi g 1 57wh i ch s hows ag en era
. tor pa rtly wou n d w i th

on e pi e ce coi ls
- .

I n s om e ca s es t h e i mp rove d S p a
,
ce f a ctors th a t ca n be s e

cu re d m a kes i t wor t h wh i le to us e aon e co i l pe r s lot wi n di n g - - -

.

Thi s w i n d i n g ca n be i n s e rt e d i n t h e s a me wa y a s t h e two c o i l -

p e r-
s lot w i n d i n g e x c e pt ,
th a t a lt e r n a t e s lot s c o n t ai n r es p e c ,

t i v e l v fr o n t a
. n d rea r e n d s of co i ls .

B ra ci n g f or Wi n di n g s T h e i n s ta . n ta
—
n eo u s cu rr en t wh i ch

flows i n ca se of a s ho rt ci rcui t to a -
tu rbo ge n era tor or i n fa
-
ct , ,

a n y oth e r ge n e ra tor i s ve ry la ,
rg e a n d t h e ma g n e ti c s tr ess es ,

whi ch va ry a s t h e s qu a re of t h e cu rr e n t a n d t h e s pa n of t h e

e n d w i n d i n gs a r e co n se qu e n tly e n o r mou s i n t h e tu r bo g e n e ra -

For th i s r e a s on a d e qua t e b ra ci n g of th e coi l e n d s i s of

'

t or .

s up re me i mpo rt a n ce Grea tes t re l i a

. n ce i s pla ce d on m e t a lli c
b ra ces s e cu re ly bolte d t o t h e g e n e ra to r fra me For i n volute .

co i ls b ra ce s m a b u d th a t o i t of h a p d l v
a
U i
whi ch a
, y e se c n s s s e c e s es

re tho r oughly i n s ul a te d wi th tre a t e d t pe a n d bolte d

to t h e ma ch i n e f ra me a t t h e en ds thr ough s pa For di a

'

ce rs .

mon d coi ls t h e b ra ,
ces t a ke t h e form of m a lle a ble i ron br a ck e ts

bolte d to t h e fra me Th e coi ls should be ri gi dly se cured

.

to thes e bra ces by n o n m e t a lli c cla mps rei n fo r ce d by bra , ss

pla t es a s s hown i n Fi g
,
1 56 a n d fa .st en e d t o t h e bra ces by

i n s ula te d bolts .

C onn e cti n g t h e Wi n din g T ur bin e wi n di n gs a

—
re a lm os t
a lwa ys con n e cte d wi th on e group of coi ls per pole per pha se .

Th e co i ls of e a ch gr oup a re co n n e ct e d i n s e ri e s I n s ome .

ca s e s th e s e co n n ecto rs a re r i v e te d a s w ell a s s old ere d i n pl a ce .

 C HA P T E R 1 X

TE S TI N G IN DU C TI ON M OTOR WI N DI N G S FOR M I S
TA KE S A N D FA U LTS

A fte r t h e oils h a ve been pla

c ce d i n t he s t a tor of a n in du ct i o n

motor a n d co n n e cte d by t h e wi n d e r t o g i v e t h e r e qui re d com

bi n a ti o n of ph a s es volts a n d pol e s t h e n ex t s te p i s to co n n e ct
, ,

t h e motor to ates t cir cui t a n d n ote wh e th e r or n ot t h e curre n t

ta ke n i s t h e s a me i n a l l t h e le a ds I f i t is n ot or t h e m otor .
,

do es n ot ope ra te prope rly i n othe r re s p ects t h e wi n di n g mus t ,

be ch e ck e d a n d t es t e d for po ss i bl e e rr o rs i n co n n ecti o n of

coi ls a n d for oth e r d e fe ct For a n e x pe ri e n ced i n ducti on

s
.

motor wi n der thi s i s as im ple j ob a, n d on e th a t is do n e very

qui ckly For t h e repa . im a n who h a s ha d l ess ex pe ri en ce i n
co n n e cti n g i n du cti o n moto rs t h e job i s n ot so qui ckly per,

form ed Yet i t is n ot adi fficult on e whe n t h e proced ur e i s

.

co r r e ct On e of t h e mo s t ea
. si ly un d e rs tood m e thod s of pro

ce d u r e for ch e cki n g i n du cti on moto r wi n di n gs h a s b e e n form u

- ~

la t e d by A M D udl ey a . n d publ i s h ed i n t h e E l ectri ca

. l J our na l .

I t i s s o s i mpl e y e t compl et e th a t a n y r e pa i rm an ca n w i th a

li ttl e pa ti en ce di s cover a n d co rr ect e v e n t h e mos t puzzlin g of

e rr o rs a n d d ef ect s I t i s gi v e n compl e t e i n wha

. t follows .

Th e e rr ors whi ch m a y, o cc u r i n i n du ct i o n moto r w i n d i n gs

-

ha v e be e n a rr an g e d by M r D udle y i n t h e a pproxi ma
. te order
of thei r o ccurre n ce a s follows :

1 . S h or t C i r cu i t a
n d Gr ou nd s .

1 . S h or t ci rcu i t s or g rou n ds of on e or m or e t u rn s i n a
n i n di v i du a
l
abre a
a
co il c u se d k in insul a
by t i on .

2 S h ort ci r cu i t of acom pl e t e coi l ca

. u s e d by con n e ct i n g t og e t h e r t h e

t w o e n ds of t h e coi l Th i s is kn own by w i n de rs a s t u bbin g a

“
. s

coil d e a
”
d .

3 S h ort ci r cu i t i n g acom pl e t e pol e ph a

.
-
s e g rou p - -
.

4 S h ort ci rcu i t in g on e com pl e t e p h a

.
-
s e of t h e w i n din g .

I I R evers a
. l Of P a r t Of th e Wi nd i n g .

1 Th is m a a a a - ha
'

.
y b e c on fin e d t o s in g l e c o i l or i t m y b e p o l e p s e

g ou p or acom pl e t e ph a
r se
 TE S TI N G I N D UC TI ON -M OTOR WI N DI N GS

l . a
C u sed by a ct u a
ll y l e a
v i n g t h e w in din g dis con n ect e d or ope n

at som e poi n t .

IV P lac i n g On e or M ore C oi ls too M a n y or too Few i n a P ol e p has e g rou p - - .

V . U s i ng a
I m pr oper Gr ou p C on n ecti on
n .

1 For . e xa m pl e , com i cct i n g in s e r i e s w h e n t h e w i n di n g s h ou l d h a ve

bee n i n pa ra l l e l or vi ce vers a Th i s i s ca l led

.
“
con n e ct i n g f or

dou bl e or h a l f v ol t a a
”
e
g , re s pe ct i v e l y A s i m i l r e rr or w ou l d be
.

conn e ct i n g de l t ai n s t e a
d of s t a r .

VI . C on n ecti n g f or the Wron g N u m ber of P ol es .

1 . Wh i l e t h is e r ror com e s u n de r N o V , i t i s u su a l l y re g a
. rde d a s d if

fe ron t a t e u n l e ss i t h a
n d is s om e t i m es di fficu l t t o l oca s bee n n ot i ce d

t h t t he a s pee d of t he m ot or wh e n ru n n i n g l ig h t is n ot a
w h t it
sh ou l d be .

Te s t i ng for Groun ds a
nd S h ort C ir cui t s —
Gr ou n d s of any

d e s cri pti on a
r e loca
te d by ri n gi n g out ”
be twe en the coppe r

of La
m i na
t i on

Fm . l 58 .
—
S ec t i on a
nd pl a
n vie w s as h or t i
-c r c u i t de t e c t i n g d e v i ce f o r
test in g st at o r w i n di n g s .

a n d t h e fra me wi th ama gn e to or l i ghti n g out be twe en t h e “

sa me poi nts wi th a n o r di n ar y 1 1 0 volt l i ghti n g ci r cu i t te s t -

la mp They a . r e compa ra ti v e ly si mpl e to lo ca te a n d ea s y to

r e pa ir by t h e us e of i n s ul a ti n g ma t e ri a
l us e d wi th t h e j ob .

S hort ci rcui ts of af e w tur n s or as i n gl e co i l b e come hot i n a

s ho rt ti m e if t h e moto r i s ru n l i ght on n or m a l volta ge Th e i r .

pres e n ce ca n be d e te ct e d by f e e li n g a r ou n d t h e wi n d i n g w i th

t h e ha n d i mm e d i ate ly afte r s ta rt i n g t h e m a chi n e a n d n oti n g

if a n y coi ls a re mu ch wa rm er th a n oth er s .
23 2 A RM A T UR E WI N DI N G A N D M OTOR RE P A I R

S h ort ci rcu i t Detecti ng Devi ce s A d evi ce th a

-
t ca n be us e d —

f or d e te ct i n g shor t ci r cui ts b e fore t h e r oto r is pl ace d i n t h e

s tator a n d wi thout a pplyi n g volta ge to t h e wi n di n g i ts e lf , i s

s hown i n Fi g 1 58 I t i t s om e wha . . t si m i l a r to al a r g e ho rs e

s ho e m a gn e t ex ce pt tha t t h e ir o n p a r t i s bui lt up of l a mi n a
ti o n s I t m a .
y a l s o b e co n s i d e r e d a co r e -typ e tr a n s fo rm er

ha vi n g t h e pri m a ry coi l o n l y a n d ha vi n g on e s i d e of t h e i ro n

co re m i ss i n g Th e coi l i s ex ci t e d wi th a
. lte rn a ti n g cu rr en t of
asui ta ble vol t a ge a n d th en

t h e compl e te d e v i c e i s
pa ss e d s lowly a r oun d t h e

bore of t h e s ta t or a s s hown

i n Fi gs 1 59 a n d 1 60 . Th e .

la mi n a ti o n s of t h e sta to r
co re compl e t e t h e m a gn e ti c
ci r cui t of t h e t e s ti n g de

vi ce a nd a n a ltern a ti n g
ma gn e ti c fi eld flows i n t h e
s ta tor core a s s hown by t h e

d otted li n e s i n Fi g 1 59 . .

Wh e n movi n g t h e d e vi ce
a rou n d t h e s t a tor bore a nd ,

F a 1 59
l . M th d f .
—
i g th
e o h t
O
i t pa
us n
s s e s ov e r aS h or t ci r
e s or fi
O

m t d t
cl r c tm g d e ec h w F g
e v 1 ce s o n 1n 1
d tu o l u h
.

1 58 .
c u l t e r n o r c r s c ,

s ho rt ci rcui t ed turn or co i l
-

i mme di a tely a cts a s as ho r t cir cui t e d s e co n d a -

r y coi l on a

tra n s form er of wh i ch t h e ex ci ti n g co i l on t h e t e s ti n g d e vi ce is

t h e pr i m a ry A s in a . n y s hor t ci r cui t e d t ra n s fo rm e r a
- n in

cre a s e d cur re n t flow s both i n t h e p ri m a ry a n d i n t h e s e co n d a ry

co i l a n d ca n be d e t e ct e d by a n a mm e te r i n s eri e s wi th t h e
d evi ce or by t h e h ea ti n g whi ch i mme di a te ly ta k e s pla ce i n t h e

d e f e cti v e co i l i n t h e wi n di n g or by t h e a ttr a ct i o n whi ch t h e

oth er s i d e of t h e s ho rt ci rcui t e d coi l h a -

s f or as tr i p of s h e et

i ro n B y pa
. s s i n g t h e d e v i ce s lowly a r ou n d t h e co re a n d oh

s e rvi n g i t s b e h a vi or fr om poi n t to poi n t s hort ci r cui ts ca ,

n

r ea d i ly be d e te ct e d Thi s r e fe rs pa . r ti cul a rly to s ho r t ci r cui ts

i n i n d i vi dua l turn s or i n on e comple t e coi l A s hor t ci r cui t of .

acomple te pole pha s e gr oup i s mo r e r e a

- -
di ly lo ca te d by acom
pa ss t es t a nd a ,
s ho r t ci rcui t of a n e n ti r e ph a s e ca n be foun d
23 4 A RM A TU RE WI N DI N G A N D M OTOR REPA I R

i n gs a
re ex ci ted by acompaa
ti velyr low volt a
d e ct curre n t
i r - ge
s o chos e n tha t t h e curre n t i s li mi te d to area s on a ble va lue .

I f t h e wi n di n gs a r e s o ex ci t e d a n d acomp a s s is pl a ce d i n s i d e

t h e bor e a n d pa s se d a r ou n d s lowly followi n g t h e i n n e r pe ri ph

e ry ,
t h e n e e dl e of t h e comp a s s w i ll re v e rs e i n pa s s i n g from

an orth pole to as outh pole g roup a n d vi ce vers a I f a n i n di

“

vi du a l coi l i s re vers e d i t wi ll show aten den cy to re vers e t h e

compa s s n e e dl e wh e n t h e n ee dl e i s di r ectly ov er th a t coi l I f .

a n e n ti r e pol e ph a - s e gr oup i s re v ers e d t h e comp a

- s s n ee dl e wi ll

i n d i ca te t h e sa me di r e cti on of field on two s u cces s i ve g roups .

A ls o if acoi l i s l eft out of cir cui t or is d e a d a

“ ”
s a lrea, dy m en
t i on e d i t wi ll i n d i ca
,
te a n i r r e gul a ri ty a t t h e i n s ta n t t h e com

pa s s pa s s e s d i re ctly a bove i t B y checki n g t h e three pha

. s es

of a thre e ph a -
s e wi n d i n g se p a ra t ely i n thi s m a,
n ner a nd

ma r ki n g t h e r e s ul t i n s i d e t h e bor e wi th ch a lk of d iff e ren t

colo rs i t i s pos s i bl e to che ck for t h e r e v ers a
,
l of a n e n t i r e ph a se .

Ope n ci rcu t s a
”
re b es t ch e ck ed by li ghti n g out Th is
i
“
.

tes t i t m a de by" co nn e ct i n g a1 1 0 volt li ghti n g ci r cu i t a

-
nd a n

i n ca n d e s ce n t l a xn p i n s e ri e s wi th t h e wi n di n g I f th e.r e i s a n

open ci rcui t t h e la mp wil l n ot li ght .

P la cin g t h e wr on g n um ber of coi l s i n two or mo re ph a se

groups ca n ha r dly be de t e ced oth e r wi s e t h a n by a ctu a lly

ma ki n g aphysi ca l coun t S i n ce thi s i s as imple ma
. tter t h e ,

ch eck i s b e s t m a de i n th a t wa y .

U si ng a n i m m oper g r oup conn ect i o n h a s i n g e n e ra l t he

sa m e eff e ct a s ra i s i n g or low e ri n g t h e volta ge On am a chi n e

a n d ca n b e s t be ch e ck e d by Op e ra ti n g t h e motor on wha t
s hould be t h e cor re ct volt a ge I f thi s volta
. ge 1 s con si d era bly
too hi gh a s would be t h e ca s e i f t h e wi n d i n g w a s co n n e ct e d

pa ra llel whe n i t s hould be s e ri es or d e ltawhen i t s ho ul d be

,

sta r t h e moto r w i ll e m i t mo r e th a
,
n t h e o rd i n a ry a moun t of
ma gn e ti c hum a n d wi ll p r ob a bly ove rh ea t i n as hort ti m e e ven
wh e n n ot m e ch a n i ca lly lo a d e d I f t h e volta
. ge i s mu ch too
low a ,
s would be t h e ca s e i f t h e wi n d i n g w a s co n n e cte d s e ri es ,

whe n i t s houl d be p a ra ll el or s t a
,
r wh e n i t s houl d be de lt a ,

t h e fa ct ca n be d e t e rmi n e d by t ryi n g alo a d on t h e motor .

Wh e n t h e loa d com e s on t h e dr op i n s p e e d wi ll be too gre a t

a n d t h e moto r wi l l pul l out a n d com e to a s ta n d s ti ll on a loa d
m u ch l e ss th a n n o rm a l .
 TE S TI N G I N D UC TI ON -M OTOR WI N DI N GS

C onn e ct i ng for t h e wr ong num be r of pol e s ca n mos t rea di ly

be d e te cte d by che cki n g t h e n o l oa d s peed
~

( I f~
i t h as a wou .n d
r oto r , t hi s mus t be s ho t ci r cui t e d )
r - T h e n o lo a
- d s pe e d , b e i n g
.

approxi m a tely s yn chron ous is very n ea ,

r ly e qu a l to cycles
X 1 20 n um b e r of pole s . . I f thi s gi ves ares ult d i ff eri n g
fr om th a t ex pe cte d t h e wi n di n g i s conn ecte d for t h e wr on g
,

n umber of pol es .

Order i n Wh i ch Te s t s S h oul d be M a da Th e o rd e r i n whi ch

—

thes e va ri ous ch e ck s s hould be pe rfo rm e d i s u s ua lly a s follows :

Af te r t h e wi n d er h a s compl e te d t h e co nn e ct i on t h e wi n di n gs ,

a r e ch e cke d a ga i n s t t h e wi n d i n g di a g r a m T h e c.o i l s p e r

g r oup a r e coun t e d a n d avis u a l i n s pe cti on m a d e for s hort

ci r cui ts , Ope n ci r cu i ts a n d r e ve r s ed co i l s A ba
. la n ce te s t i s

ma d e wi th low volta ge to se e if t h e s e p a ra te ph a s e s s how t h e

sa me res ult A hi gh volta

. ge tes t is the n ma d e on t h e i n s ula
ti o n to e n s ure th a t t h e coi ls a r e n ot g r oun d e d be tw e e n ph a s es

n or on t h e i r o n cor e . Th e m a ch i n e i s th e n a sse mbl e d a nd th e

r es i s t an ce of t h e comple te d wi n d i n g i s m ea s ure d on a ll ph a s es .

I f th es e ch e cks a re s a t is f actor y t h e m a chi n e ca n be p a ss e d for a

r unn i n g l i ght te s t wi thout lo a d S uffi ci en t volta

. ge is put on
t h e wi n di n gs to s ta rt t h e moto r up I f i t com es up to s pe ed
.

w i thout a pp a r e n t d i s tr ess or i r r e gula ri ty of a n y ki n d t h e s pe e d

. ,

i s che ck e d a n d t h e te mp e ra tur e of t h e wi n di n g i s tes te d wi th

t h e ha nd a ll t h e w a y a r ou n d t h e m a ch i n e I f th .i s i s n o r m a l
t h e volt a ge i s ra i s e d to i t s n orm a l va lue a n d t h e n o lo a d cur -

r en t in a l l ph a ses a n d t h e wa tts a r e re a d I f th es e va . lues

ch e ck w i th pr e vi ous ca lcul a ti on s or te sts on dupli ca te ma chi n es

t h e wi n d i n g s a re co n s i d e re d t o be co rr e ctly co n n e ct ed If no .

da tais a va i la ble on t h e n o lo a -
d curren t i t m a y b e c o n s i d e r e d
rea s on a ble if i t does n ot excee d 40 per cen t a n d is a t le a s t 20
'

p e r c e n t of
. full lo a d c u r re n t T h e
. n o lo a d-
w a tt s r u nning

li ght m a y b e c o n s i d e r e d r e a s o n abl e if th e y a r e r oughly i n

t h e n ei ghbo rhood of s eve n or e i ght pe r ce n t of t h e n orm a . l

ra tin g of t h e mot or I f t h e motor does n ot rea
. di ly com e up
t o s p ee d or t h e ph a s e s do n ot ba la n ce or th e re a re s i g n s of

u n e qua l hea
. ti n g i n t h e wi n d i n g or oth e r d i s tress t h e rotor ,

s hould be r e mov e d a n d t h e co n n e ct i o n s ch e ck e d I f t h e e r ro r
.

i s n ot a pp a r e nt a n d as ou rce of d i r e ct curr e n t i s a va i la ble t h e

comp a s s tes t m a y b e a ppl i e d .
236 A RM A T U RE WI N DI N G A N D M OTOR R E P A I R

C onn ecti ons for Appl yi ng Di re ct C urr ent wh e n E xpl ori ng

A C
-
. Win di ng s wi t h aC om pa
. ss —
Th e a ccomp a n yi n g di a
.

gra m s s how t h e me thods for ma ki n g con n e cti ons for t h e us e

of di re ct curre n t to exci te t h e wi n di n gs of ana ltern ati n g current
-

moto r s o a s to e x plo re t h e wi n d i n gs by t h e use of a comp a ss .

W h e n t h e w i n d i n g i s s t a
r co n n ect e d on e l e a d of
, t h e d i re ct

cu rr e n t ci r cu i t i s jo i n e d to A B C —
co n —
n e c t e d to g e th er a n d

F m 1 61
. .
—
M e t h od f or ch e cki n g a
3-p h s e , s t ar a n d de l t acon n ect e d wi n di n g s

w i t h d i re ct cu rre n t .

the other lea d to t h e n e utra l poi n t When t h e compa . ss is

held over t h e coi ls i n t h e slots a n d mov ed a r oun d t h e s tator ,

the re s hould be three tim es a s ma n y pol es as th er e a re poles .

i n t h e ma chi n es r e ve rs i n g a lte r n ately a n d s pace d e qu ally when

la
t h e wi n d i n g i s b a n ce d I n ca s e of a
. de ltacon n e cte d wi n di n g-
,

i t i s o n ly n e cess a ry to op e n t h e d e lt aco n n e ct i o n a s s how n i n

Fi g 1 6 1 a
. t t h e ri ght a n d con n e ct t h e two en d s to t h e di re ct

curr e n t le a ds .
 2 38 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

a be se cur ed by i n cre a
c n sing t h e a ir g a p i t m
,
a y b e po ss i bl e to
a dd are s i s ta n ce to t h e s hu n t fie l d ci r cu i t
- I n s u ch aca
. se it

wi ll be n e cess a ry t o ch eck ca re f ully t h e n o lo a d a

-
n d f ul l l oa d -

s pee d s .

I n t h e ca se of as hun t moto r acompo un d cha ,

ra ct e ri s ti c

ca n be s e cure d by i n cre a si n g t h e a ir g a p a n d th e n a dd i n g s er i es

t urn s t o t h e fie ld pol es un ti l t h e full lo a -

d s pe e d i s t h e s a me a s

i t wa s b e fo r e t h e ch a n ge . For thi s pur po se fl e xi bl e copper

ca ble ca n be woun d a roun d t h e s hun t co i l a n d bou n d i n pla ce .

I n re vers i n g this ch a tha t i s i n cha n gi n g acom po un d

.

n ge , ,

m o t or to as h un t ch a ra ct e ri s ti c t h e a
,
ir g a p s hould b e r e du c e d
a n d curr en t s hun t e d out of t h e seri es coi ls of t h e field un ti l a

con s ta n t s pe e d r a n g e i s s e cu re d .

A n i n e ffi ci en t a n d e m e r ge n cy m e th od of re du ci n g t h e spe e d

of amotor for as hort ti me on ly i s by t h e us e of are s i s ta n ce

i n th e a rm a ture ci rcui t Wh e n a va. ri a ble r esi s ta n ce i s

con n ect ed i n s e ri e s w i th t h e a rm a ture lea d s i t si mply reduces

,

t h e i mp re ss e d volta ge on t h e a r ma ture wi n di n g by us i n g up a
pa r t of t h e volt a ge i n t h e resi sta n ce . S i n ce t h e s pee d of t h e
motor i s pr opo rti on a l to t h e ope ra ti n g volta ge t h e d es i re d
,

s pee d re du cti o n ca n be thus s e cu red .

In a ll ca ses wh e r e t h e s pe e d of a motor i s i n cre a se d a tten ,

ti on mus t be pa i d to t h e a r ma ture cons tru cti on so tha t the

i n crea s e d cen tr i fuga l s t ra i ns on t h e coi ls a n d t h e ba n d i n g due

to t h e i n cre a s e i n s pe e d wi ll d e ve lop n o se ri ous d e fe ct s su ch ,

a s rubb i n g of co i ls on t h e fi e ld s hi gh commut a
,
to r b a rs a n d poor

commut a ti on Wh en t h e i n crea
. s e i n s pe e d i s 50 per cen t or .

more t h e ma
,
n uf a cture r s hould be co ns u lte d for a dvi ce a
.

t o t h e sa fety of t h e h i gh s p ee d for con ti n uous opera t i on .

C ha ng e s in Ope ra ti n g V olta g e . T—
h e s p e e d of a d i re c t
cu rr e n t moto r v a ri es di re ctly wi t h t h e ope r a ti n g volta ge a nd

( th e o r e t i ca lly ) i n v e r s e ly w i th t h e fl ux of t h e fi e ld s W h. e n

t h e ope ra ti n g volta ge i s i n cre a s e d on amotor t h e ex ci t a , ti on

of t h e fields i s a ls o a ff e cted but on a ccoun t of t h e s a tura ti o n
’

of t h e i ro n t h e fie ld flu x i s n ot a
,
ff e cte d i n di re ct pr opor t i on
s o tha t t h e s pe e d of t h e motor on a n in cre a se of volt a ge follows
a bout i n proporti on to t h e in crea se Wh en t h e volta
. ge is
n ot i n cr ea s e d or d e cre a s e d more th a n 2 5 pe r ce n t over t h e
.

ra t e d va lue for t h e motor t h e corre ct s pe e d ca n be obta

.

,
i n e d by
 C HA N GE S I N DI R E C T- C U R R E N T M OTOR S

acha
n ge of the a
ir ga
p . u ch acha
In s n ge t h e ope ra ting
te mpe ra ture of t h e field coi l s mus t be wa tche d si n ce t h e ,

te mpe ra ture wi ll va ry a bout a s t h e s qua re of t h e volt a ge .

A te mpe ra ture hi gher tha n 1 60 F wi ll i n j ure t h e i n s ul a

°
. ,

ti on To pre ven t thi s when t h e tempera

. ture of t h e fie lds
i s foun d to be a r oun d thi s figure i t wi ll be a ,
dvi s a ble
to re wi n d t h e fi eld coi ls I n ca . s e t h e ma chi n e i s op e r a te d
on un d e r volta ge wi th t h e a ir g a p a s l a r g e a s po ss i bl e ar e ,

s i st a n ce ca n be use d i n t h e s hun t fie ld un ti l t h e re qui r e d s pe e d

i s s e cure d On acompoun d motor n o lo a

. d a n d ful l lo a
,
-
d -

s pe e ds ca n be a dju s ted by cha n gi n g t h e s e ri es fi e ld coi ls i n

e i th e r of t h e ca se s m en ti on e d .

Opera ti n g a M ot or on On e h a l f or Doubl e Vol ta

-
g e .

I t fre qu en tly ha ppe n s tha t a220 volt motor mus t be ch a -

n ge d

to ope ra te on 1 1 0 volts or a1 1 0 volt motor on 2 20 volts - .

I n t h e ca se of a 2 20 volt motor i t i s us ua
_

-
,
ll y poss i bl e to con n e ct
t h e sh un t fie l d coi ls i n two gr oups a
-
n d th en co n n e ct th e s e

g r o u p s i n p a r a ll e l I n. s u c h a ca s e wh e n t h e mot o r i s c o n n e ct e d

to a1 1 0 volt ci rcui t t h e volta

‘
-
,
ge pe r coi l wi ll be t h e sa me s o
tha t t h e fie ld flux wi ll be t h e s a m e but t h e s p e e d wi ll be o n ly
,

on e ha - lf tha t on 220 volts Th e s pe ed ca . n be b r ought up

to n or ma l by i n cre a sin g t h e a ir ga p a s mu ch a s po s s i bl e a n d
us in g resi s ta n ce i n t h e s hu n t fi e ld a s ex pla i n e d i n apr e ce di n g
pa ragra ph Th e ra . ti n g i n horse power of amotor so cha n ge d

wi ll on ly be on e h a lf of wh a
- t i t wa s b e fore .

When a1 1 0 volt motor mus t be ch a

- n ge d to ope ra te on 2 20
volts t h e con di ti on s a
, re n ot s o e a sy a s i n t h e p re vi ous ca se

for i f t h e sm a lles t a ir g a p w i th t h e s hu n t fi e ld s i n s e r i es ca n n ot
be us e d t h e fie ld coi ls mus t be r e woun d
, Wh en ope ra te d
.

i n thi s w a y t h e moto r w i ll h a v e doubl e t h e ho r s e pow e r r a t i n g

on 22 0 volts th a t i t di d on 1 1 0 volts Th e cha n ge s i n t h e
.

motor whi ch ha ve be en m en ti on e d do n ot re quire ach a n ge

in t h e a rma ture wi n di n g .

C ha n g e s i n Arm a tur e Wi n di n g for Ope ra ti n g M ot ors on

On e h a -
l f or Dou bl e V olta g e T h e mo
. s t
-
s a t i s f a cto r y w a y
of cha n gi n g a motor to ope ra te on avolta ge whi ch i s on e ha lf -

or doubl e t h e ra te d volta ge i s to re wi n d t h e a r ma tur e to s ui t

t h e n e w con di ti on s Th i s i s a
. l s o t h e mo s t e x pe n s i v e wa y
a n d nee d n ot be r e s o rte d to wh e n t h e ch a n ge i n volta ge i s
24 0 A RM A T URE WI N DI N G A N D M OTOR R E P A I R
.

n ot over 2 5 pe r ce n t . A d re ct curre n t
i -
arm a ture wi n di n g ca n

u s ua lly be cha n ge d for ope r a t i on on alower volta ge i n t wo

wa ys . B y u si n g n e w co i ls 2 B y re co n n e ct i n g t h e old
. .

a rm a ture wi n di n g When t h e a
. rm a ture i s to be re wou n d
for adi ff e re n t volta ge t h e n umbe r of turn s i n se ri es be tween
,

bru s hes wi ll va r y d i r e ctly a s t h e old volt a ge to t h e n e w Th e .

cr o ss s e cti on of t h e wi re for t h e co i ls wi ll a
-
l s o va r y i n v e rs ely

a s t h e o l d volt a ge to t h e n e w For i n s ta . n ce i f a 1 1 0 volt -

motor i s to be Ope ra te d on 220 volts t h e a rma ture con du ctors

,

wi ll be double d i n n umbe r a n d th e i r cr o s s s ec t i on m a -
de on e
ha lf wh e n t h e s pee d a
,
n d ho r s e pow e r ra ti n g wi ll re ma in t h e
sa me a s b e fo re . Wh e n th e s i z e of wi re pre vi ous ly use d i s
kn own on e of on e h a
,
lf t h e cross s ecti on wi l l be thre e B
- -
S . .

ga uge n umbe rs hi gh er .

A p ra cti ca l wa y of m a k i n g th e s e c h a n g e s i n a r m a t ure

wi n di n gs i n are pa i r s h Op i s gi ve n on pa ge s 243 to 2 60 a s out

l in e d by T S chutte r (E le ctri ca
. l E n g i n eer i n g J uly a n d A ugus t
, ,

1 9 1 8) f or t h e ch a n ges of o n e ha
- lf a n d doubl e volt a ge opera
-
t i on .

S i z e of Wi re f or D C Ar m a .
-
tur e C o i l s
. B e fore w i n d i n g
.
—

t h e co i ls n e e d e d i n t h e r e p a i r of a n a rm a ture i t mus t be de ci d ed
wh e ther al a p o r a w a v e w i n d i n g w i ll b e u s e d I n t h.e l a p
wi n di n g th e re a re a s ma n y cu rr e n t p a ths or ci rcui ts th rough
the a rm a ture wi n d i n g a s th e r e a re pol e s wi th t h e co i ls con

n e ct e d i n s e r i e s i n e a ch of th es e p a th s or ci rcui ts Th e wa . ve
wi n d i n g h a s o n ly two cu rr e n t p a ths th rough t h e a rm a ture
wi n d i n g r e g a rdl es s of t h e n umb er of pol e s t h e m a ch i n e h a s .

I n ea ch of th e s e two p a ths t h e coi ls a r e co n n e ct e d i n s e ri es

-
.

C o n si d e ri n g I t h e tota la rm a ture cu rre n t a s gi v en on t h e n a me

pla te of t h e ma ch i n e a n d i t h e cu r re n t i n e a ch ci r cui t of t h e

a rma tu re wi n d i n g t h e followi n g formula

,
s ca n be u s e d to fin d

t h e ma x i mum cu r re n t th a t ca n be ca rri e d by t h e coi ls of

ea ch ci r cu i t co n n e ct e d i n s e r i e s .

For al a p w i n d i n g i n wh i c h t h e n umb e r of ci rc u i t s e qu a l s

t h e n umb e r of pole s or p ,

i = I -
p

For amulti ple l a p w i n d i n g h a

v i n g two ,
or mo re sin gle l a
p
ra
w i n di n gs i n p a lle l ,

i I mp
242 A R M A TU R E WI N DI N G A N D M OTOR R E P A I R

se d wh ere t h e vol t a
i n cre a ge as ag en era
t or i s t o be e qua l or
hi gh er tha n t h e voltage a s amoto r Wh en t h e volta ge i s to .

be low er , t h e sa me s pe e d a nd air g ap ca n u s u a
ll y be u s e d .

W en a i re curr en t ma
h d c t- chi n e i s cha n g ed from a g en era tor
to amotor t h e curren t i n both t h e a
,
rm a ture a n d s eri es fi eld
re vers es I f therefore t h e ma
.
,
chi n e i s ope r a
,
t ed a s a cu m m u

la t i v el y com poun d ed gen era tor it wi ll a l so op era te as a

,
di ff er
en t i a ll y compoun d ed motor I n ord er to us e acompoun d
.

g en era tor as amoto r i t is us ua lly n eces s a

, ry to re v ers e t h e

conn ecti on s of i t s s e ri es fi eld s Th e di a g r am s of F i

.
g s 1 6 2 .

an d 1 63 a r e s elf e xpl a
natory - .

FI G . 1 63 —
. D i fie re n t i a
l m ot or wi t h a
rm a
t u re r ot a
ti n g cl oc k wi s e a
nd se rie s
fie l d op p os i n g sh u n t fiel d .

A dju s t ing th e Ai r Ga D C Ma When i nsert

ch i n e s
‘

p on .
-
. .
—

in g t h e a rma tur e i n a
ny ma chi n e i n whi ch t h e b e a ri n gs a re

i n de pe n d e n t of t h e fra me t h e a ir g a
, p b e tw ee n t h e a r m a tu r e

co re a n d pol e fa ces s hould be ch e ck e d up A n y i n e qua li ty

of a
.

ir g a p w i ll c a u s e u n ne ce ss a r y f r i ct i o n a n d h e a t i n g of t h e

be a ri n gs a nd a n un e qua l h ea ti n g of t h e a rma ture i r on Th e .

a ir g a p m a y b e a dju s t e d ho r i zo n t a lly i n m a n y c a s es by cr o ss

b ea ms a nd j a ck s cr e w s on t h e be dpla te a n d v e rti ca lly by

thi n s he e t lin e rs i n s e rted be twee n t h e be dpla te a nd the

yoke Th e a. ir g a p ca n b e g a ug e d du r i n g t h e op e r a t i o n by
i n s er ti n g ah a r dwood w e dge on t h e fr o n t a n d ba ck e n d s of

t h e ma ch i n e a t di ff ere n t po i n ts n ot i n g t h e di s ta , n ce to whi ch

t h e w edge en te rs e a ch ti m e Th e a . djus tme n t s ho ul d be con

t i n u e d un ti l t h e a ir g a p i s t h e s a m e a r ou n d t h e e n ti r e c i rc um
fe re n ce of t h e ma chi n e .

M ot or S pe e d wh e n R e conn e ct i n g aD -C M ot or Wi n di ng . .

Wa ve t o L a p W h e
. n —
r ec o n n e ct i n g awa ve wi n di n g to form
al a p w i n d i ng w i thout c h a n g i n g t h e c o i l s o r volt a g e ,t h e s p e e d ,
 C HA N GE S I N DI R E C T-C U R R E N T M OTORS 2 43

of af l motor wi l l be in crea
our p
-o e s e d twi ce a n d t h e s pee d ,

of a n e g ht pol e motor i n r e a
i - s ed four ti m es Th i s i s be cau
p se .

t h e wa ve wi n di n g i s atwo cir cui t wi n di ng whi le t h e la -

p
wi n di n g h a s a
s ma n y ci r cui t s as t h ere a
re pole s Th e .

s pe e d th erefore va
,
ri es di re ctly a
, s t h e n umber of ci rcui ts i n

t h e wi n di n g .

C ha aD -C
.

n g e i n B rus h e s wh e n R e conne ct i n g . . M ot or
from aH i g h er to aL ower Volta
g e When re co n n e cti n g a.
—

di re ct curren t a
-
rm a ture from ahi ghe r to al ower volta ge ,

sa y 22 0 v o lts to 1 1 0 volt s t h e s i z e of co,

n du c to r s mu s t b e

doubled a s t h e curre n t wil l be a bout double i t s o ri gi n a l va lue .

Th e ori g in a l bru shes on t h e 2 20 volt ma chi n e mus t th e re fore

-

be ch a n ge d t o h a n dle thi s i n cre a s e i n cu rr e n t wi thout h e a ti n g

a n d s pa r ki n g I f twi ce a
. s ma n y b rus h e s of t h e s a m e s i ze a s

be fore ca nn ot be us e d t h e si ze of bru s h mus t be ch a

, n ged to

g i v e tw i ce t h e b e a r i n g s ur f ace A n i n cr e ase i.n w i dth of t h e

brus h s h ou l d be a voi ded t h e le n gth b ei n g i n cre a

, s e d to g e t t h e

proper bea ri ng s urf a ce A curre n t d e ns i ty of m ore tha

. n 50

a mpe res per squa r e i n ch wi ll g i ve trouble soon er or l a ter i n

are con n e cted a rm a ture .

For afour pol e moto r ori g i n a

- ll y 2 20 volts ch a n ge d to .

ope ra te on 1 1 0 volts t h e field co i ls should be conn e cte d two

,

i n se ri es a n d t h es e g roups co nn e ct e d i n p a ra llel in order to

g e t t h e sa m e fi e ld c u rr e n t .

R E WI N DI N G A N D RE C O NN E C TI GD
N IR E C T-C UR R E N T AR M A
TUR E WI NDI N GS FOR A C HA N GE OF V OL TA GE “

When adi re ct curren t a — rm a ture is to be re woun d or re

conne cte d for acha n ge from on e volt a ge t o a n oth e r the ,

numbe r of t ur ns i n se ri e s be twee n b rus h e s a s e x pl a i n e d on pa ge

2 39 w ill va ry di re ctly a s on e volt a ge to t h e oth er a nd the

crOs s -s e cti on a l a re aof t h e wi re wi ll va ry i n ve rs e ly a s t h e vol

'

ta gé s; T i llu t at t a k t h a of a 2 pol a m a tu
'

-
o s r e e ,
e c s e e r r e con

si st i ng of 24 c o i l s 2 0 t urn
,
s p e r co i l wou n d o n e w i r e i n h an d - -

us in g n umbe r 1 9 B S ga . uge wi re whi ch h a

. s across s e c ,

t i On a l are a of 12 9 0 c i r cu l a r m i ls T h e a r m a tu r e h .a s a 2 4 0-volt
wi n ding a n d i s t o be ch a n ge d s o a s t o ope ra te on a1 20 volt -

T S ch u t t e r, E l ec
. tri ca
l E n g i nee ri n g , J ul y , 1 9 1 8 .
244 A R M A T U RE WI N DI N G A N D M OTOR R E P A I R

ci r cu it Thi s ca
. n be a ccompli s h e d i n two wa ys Fi rs t by .
,

re wi n di n g t h e a rm a ture ; se con d by re conn e ctin g t h e pre s ent

,

wi n d i n g .

B y compa ri n g t h e o ri gi n al volta ge wi th t h e n ew Opera ti n g

volta ge i t wi ll be se en tha
,
t t h e n e w volta ge i s ju s t ha lf of t h e
ori gi n a l volta ge I f i t took 20 turn s pe r coi l for 240 volts
.

then i t wi ll ta ke h a l f of 20 or 1 0 tur n s pe r coi l for 1 2 0 volts .

A s t h e ma ch i n e i s to do t h e s a me a moun t of work i t will ,

ca rr y twi ce t h e cu rr e n t a t 1 20 volts th a t i t di d a t 240 volts .

For thi s re a s o n t h e wi r e mu s t h a ve twi ce t h e cross s ecti on a lar ea -

,

or 1 2 90 x 2 25 80 ci r cul a r m il a rea Th i s i s e qua l to an u m .

be r 1 6 B S ga uge wire s ti ll us i n g t h e s a
. . me n umber of coi ls
,

as b efo r e .

Ori g i n a
l 24 0 v ol t con n e ct i on

FI G . 1 64 .
—
A 2 40-v ol t l a
p w i n d i n g w h i ch i s re con n e ct e d for 1 2 0 v ol t s a
s
s h o w n i n Fi g 1 65 . .

Th e othe r method i s to re conn ect t h e wi n di n g so th a t two

coi ls a re i n pa ra lle l a n d b ri dge two commuta
,
tor ba rs Thi s .

wi ll r e s ult i n awi n di n g of 1 2 coi ls two in pa ra lle l wi th 20, ,

turn s per coil I n Fi g 1 64 t h e ori gi n a

. . l wi n di n g i s s hown a s ,
‘

it wa s woun d a n d co n n e ct e d to t h e commuta tor Th e a r ma

.

ture core con ta i n e d 24 s lots a n d th ere w e r e two coil s i d e s pe r

s lot Th e pa
. r t of t h e s lot wh i ch i s o ccupi e d by acoi l s i d e i s

ca lle d awi n di n g s pa ce Th e odd n umbere d wi n di n g s pa

. ces

a r e co n s i d e r e d a s b e i n g i n t h e bottom of t h e s l ot a n d t h e e ven
'

numb e r e d wi n d i n g s pa ces b e i n g i n t h e top of t h e s lot Th e .

ta bl e for wi n di n g coi ls i n Fi g 1 64 i s g i ve n on p a . ge 24 5 a nd

t h e co n n e cti n g ta ble for t h e ori gi na l w i n di n g a s i llus t ra

.

ted in
Fi g 1 64 on p a
. ge 24 7 .
2 46 A R M A TU R E WI N DI N G A N D M OTOR R E P A I R

TA B L E FO B C O N N E C TI N G C o rns o r Fro 1 64
.
'
ro C on u n m ron
' '

F m . 1 65 . T h e 240-v ol t wi n di n g of Fi g
—
1 6 4 re con n ect e d for a 1 20-v ol t
.

ra
ci rcu i t by co n n e ct i n g t w o coil s i n p a ll el an d u s i n g wi d e r bru s h e s .

R e conn e cti n g aL a p W i n di n g I n F—
i g 1 65 t h e wi n di n g
.

hown i n Fi g
s . 1 64 h a
s bee n r e co n n ecte d s o as to ope ra te on
a1 20 volt ci rcui t
-
.
 C HA N GE S I N DI R E C T-C U RR E N T M OTORS

As ex pl a
i ne d
q half a
i t wil l
s m u ch wi n di n g on 1 20
re ui re o e
n -

volts a s i t di d on 240 volts Thi s can b e ac compl i s h

. e d by
conn ecti n g two co il s i n pa rallel a n d us in g wi d e r br us h es ; ,

t ha t is t h e brus hes s hould be a

,
t l east as wi d e a s 1 36 com m u

ta tor ba rs a n d n ot mo re th a n t wo commut a tor ba rs I f it .

i s po ss i bl e to a rran ge for t h e us e of t h e wi d er b rus h es the ,

co m muta tor ca n be bri d g e d as s ho wn by t h e j um pers A B C

, , , ,

et c .
,
fi g . 1 65 .

TA B L E F OB C O N N E C TI N G C orL s or h a 1 65
. TO C OM M UTA TOR

I
°° i l
figg
B e g i xi f
T o ba
r n u m be r E n d of coi l n u m be r T o ba
r n u m ber
rl

By tra ci n g t h e di r e ct i o n of flow of curre n t t h rough t h e wi n d

i n g i t wi ll be se e n th a t t h e cu rre n t flows i n four ci r cui ts fr om

t h e po si t i ve b rush to t h e n e ga t i ve b r u s h I n e a ch p a
th or ci r .

cu i t th ere a re si x coi ls i n s er i e s a n d t h e four pa ths or ci rcui ts

,

a r e i n pa ra llel Thi s re con n ect i o n i s equi va

. len t to re wi n di n g
248 A RM A TURE WI N DI N G A N D M OTOR R E P A I R

th e a
r ma
tur e wi th twi ce t h e z
si e o fw i re a
n d ne ha
o - lf t he
i t wa
’

number of t urns wi t h whi ch s woun d for 240volt s B oth .

n d 1 65 s how l a
Fi gs 1 64 a
.
p or pa
rallel wi n di n gs .

R e conn e cti ng a Wa
ve Wi n di n g —
Fi g . 1 66 re pre s e n ts a
four pole wa
ve
- or s e ri e s wi n di ng ,
o
c ns i s ti n g of 31 coils . Th e

FI G . 1 66 —
Wa
ve wi n d i n g for a24 0 v ol t
-
, 4-p ol e rm a
a t ure .

a rm a ture core h a s 3 1 s lots a n d th e re a re two coi l s i d e s pe r

,

s lot .I t i s woun d s o a s to be op e rate d on a240 volt ci rcui t -

.

Th e co i ls i n thi s Fi g 1 66 a re place d s o th a
.t t h e be gi n n i n g of
ea ce d i n t h e bottom of t h e s lot a
ch co i l i s pl a n d i s r e pr e s e n t ed ,

by t h e odd n umbere d coi l s i d e s .

FI G 1 67 T h e w a
. .
—
v e wi n di n g of Fi g 1 6 6 r e con n e ct e d s o t h a
. t t h e re are
fo u r p a t h s for cu r r e n t i n s t e a
d of t w o wi t h fou r bru s h e s i n s t e a
d of t w o Th i s .

w i n di n g ca n n ow be u s e d o n a1 2 0-v ol t ci r cu i t .

By tr a ci n g t h e curr e n t f r om t h e po s i ti ve to t h e n e ga t i ve
b rus h i t wi ll be s ee n tha
, t t h e wi n di n g i s di vi d ed i n to two pa ths
or ci r cu i t s To ch a n ge thi s w i n d i n g s o th a
. t i t ca n be op e ra te d
on a1 2 0 volt ci r cu i t two m e thod s ca
-
,
n be u s e d : Fi rs t r e co n n e ct ,

t h e w i n d i n g s o th a t i t wi ll con si st of four pa th s or ci rcui t s ,

a nd a dd a n oth e r s e t of b ru s h e s a s s hown i n Fi g 1 67 Th e . .
25 0 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

TAB L E FO B C ON N E C TI N G C O IL s or FI G 1 66
. 10 M C O M M U TA N B

a T o ba
i

To b r n u m ber E n d of coi l n u m be r r n u m ber

Th e wi n d g a ins how s n i n Fi g afo ur pole l a

. 1 67
, i s p o r -

pa ra llel wi n di n g wi th four ci rcui ts or pa

, ths through t h e
wi n d i n g Th e se con d m ethod of reconn ecti n g Fi g 1 66 so a
. s .

t o ope ra te i t on 1 20 volt s is s hown in Fi g 1 68 As pre vi ousl y . .

e x pl ain e d ea, ch two a dj ace n t co il s wil l be co n n ecte d i n para lle l ,

a n d si n ce th ere a re 3 1 coi l s on t h e e n t i re w i n d i n g on e co i l ,

m us t be droppe d I n th i s wi n d i n g (Fi g 1 68 ) coi l N o 2 shown

. . .
,

wi th t h e hea vy li nes h a s n o co nn ecti on w i th t h e com m u ta t or .

 C HA N GE S I N DI R E C T-C UR R E N T M OTORS

TAB L E F OR C ON N E C TI N G C OI L s or FI G 1 67To
. T HE C O M M UTA TO R
md i
gfi; i
f c°i l
To b a
r n u m be r E n d of coil n u m ber T o ba
r n u m ber

FI G 1 68 —
T h e w a win di n g
ve 1 66 recon n ect e d for
of Fi g . a1 2 0 v ol t
- ci r cu i t
a
. .

by con n e ct i n g t w o coil s i n p a
ral lel a
n d us i n g wi d e r br ush e s . I n t hi s c se on e

coi l is d e a
d a s s h own by t h e h e a vy l i n e s
'

.
25 2 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

There are 3 1 b a l com m ut a

rs i n t h e ori gi n a t or so th a t by ta kin g ,

an y two b a rs a n d putti n g ajump e r a cro s s an d co n si d e ri n g

them a s on e ba r i t wi ll be re du ce d to 3 0 b a
,
rs Th e conn e cti o n s .

wi ll be m a de a s sho wn by t h e followi n g t a ble :

TA B L E FO B C ON NE C TI N G C on s or FI G 1 68. TO THE C OM M UTA TO R

C oi l 1 i s n ot con

n ect e d .

R e conn e cti ng Dupl e x Wi ndi ng s

wi n di n gs di scuss e d.
—
Th e
in wha
t follows a
r e wou n d wi th two w i re s i n h a nd Th e ,
.

T S ch u t t e r , E lectri ca
. l E n g i n eer i n g , A ug u s t , 1 9 1 8 .
254 A R MA T U R E WI N DI N G A N D M OTOR R E P A I R

TA B L E F OR C ON N E C TI N G C o m e To TH E C OM M UTA T OR or FI G . 1 69

Sta
rt of coil n u m ber T o ba
r n u m ber E nd of coi l n u m be r T o ba
r n u m ber

1 a n d 1 aof co i l l a
re co nn e cte d i n pa ra lle l th rough t h e b ru sh
co n n e cti ons n d by ch a
a , n g i n g t h e co nn e cti o n s s o th a
t S ec
1 3 86 H t 2 3 4: " 0

FI G . 7
1 0 —
. T h e 1 2 0-v ol t l a p w i n di n g of Fi g 1 6 9 re con n.ect ed f o r 240 v o l t s by
ch coi l i n se ri e s a
con n e ct i n g t h e t u r ns of e a n d usi n g s m a ll e r bru s h es .

nd 1 a
t i on s 1 a wi ll be in seri es i n s te ad OI i n pa
ralle l i t wi ll the n ,

be poss i ble to op era te t h e wi n d i n g on a240 volt ci r cui t Th e

,
- .
 C HA N GE S I N DI R E C T-C UR R E N T M OTORS

wi n di ng t a ble for Fi g 1 70 wi ll be t h e s m
. ae a
s for Fi g 1 69
.

bu t t h e co n n e cti n g ta
ble wi ll be a
s follows :

TAB L E FOB C ON N E C TI N G C ons or FI G . 17

0 To C OM M UTA TOR

Th e brus hes use d on Fi g 1 70 s hould on ly be a

. s wi d e as on e

commuta to r ba r B y t ra
. cin g t h e curren t th rough t h e wi n d i n g
.

i n Fi g 1 69 i t wi ll be see n th a t th ere a re th ree co i ls i n se ri e s

'

i n ea ch of t h e pa ths or ci rcui ts fr om t h e po si ti ve br us h to t h e
n e ga ti ve brus h I n Fi g 1 69 the re a
. . r e s i x co i ls i n each pa th or
ci r cui t or twi ce a
,
s ma ny a s b e fo re t h e re co nn e cti on .

I f t h e wi di n g in i g 1 69 h a
n F .d b ee n con n e cte d t o a1 ba 2- r

co m muta d of a24 ba
tor i ns te a r commuta - to r t h e re con n e cti n g
,

from 1 20 volts would ha ve bee n s om ewha t di ff e ren t I n .

Fi g 1 69 t h e n um era
. ls from 1 to 1 2 whi ch a ,
re pl a ce d a bove
a n d be tween ea ch two ba rs wi ll g i ve a,
n i d eaof h o w t h e con

n e ct i ons wo uld look For i ns t a

. n ce S e cti ons 1 a
,
n d 1 aof
2 56 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

c oi l N o 1 woul d be conn e cted a

. cross ba rs N os 2 a n d 3 i ns te ad .
,

of S e cti on 1 t o b a rs 3 a nd 5 a nd 1 a t o ba rs 4 a ,nd 6 .

Th e n t o re conn e ct t h e wi n di n g from 1 20 volts t o 240 volts

when only 1 2 commut a to r b ars a re us e d S e cti o ns 1 a nd l a ,

of C oi l N o 1 woul d ha . ve t o be co n n e cted i n seri es but n ot ,

through commuta tor co nn e cti ons a s i n Fi g 1 7 0 B y o m i tti n g . .

t h e co n n ecti on s of commuta tor b a rs No 2 4 6 8 a nd 1 0 ,

.
, , , ,

et c. a
,
n d s i mply s pli ci n g t h e en d of S e cti on 1 t o t h e b e gi n ni n g

of S e cti on l aof co i l N o 1 t h e s a m e result s wi ll be obta

.
,
in ed
by us i n g only 1 2 com m uta t or ba rs .

Fi g 1 7 1 is a dupl e x w a
.
,
ve wi n di n g for Opera
“ ”
ti on on a
1 20 volt ci rcui t
-
Thi s wi n d i n g co n s i s t s of 1 3 co i ls woun d wi th
.

t w o s tr an ds of wi re a n d co n n e ct e d t o 2 6 co m mut a tors ba rs .

Th i s wi n di n g could a ls o be co n n e cted to a1 3 ba r com m u -

ta tor Th e wi n di n g ta
. ble for Fi g 1 71 i s a s follows ea . ch coi l ,

be i n g consi dere d a s two S e cti o n s 1 a nd 1 a ,

.

TAB L E FO R W I N DI N G C OI L s IN S L OTs F OR FI G . 171

C oi l s a
re w o un d

wi n d i n g a
Th e s i t i s n ow pl a ce d a n d co n n e ct e d wi ll Ope ra te
on a1 20 volt ci r cui t -
I t i s d es i re d to ch a
. n ge i t s o th a t it
will Ope rate on a240 volt ci r cui t There a - r e two m e thod s
.

by wh i ch this ca n be a ccompli s h e d Th e firs t i s shown i n .

25 8 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

through t h e comm uta tor a n d b r us h o

c n nec ti ons they a
, re

n ow co nn e ct ed i n se ri es i n t h e same a
w y . Th e conn ecti n g
ta ble i s a
s follows :

TA B L E FO R C ON N E C TI N G C u m on FI G . 17
2 To C OM M U TA TOR

I t wi ll be s ee n t ba
tha rs N os 26 . a
nd 1 re b ri dge d a
a nd a
re

ct i n g a
a s on e ba
r . to t h e dr oppi n g of S e cti on 1
Thi s i s du e
i n coi l N o 1 for re a
. sons gi v en a bove B y tra ci n g t h e fl ow of
.

t h e curr en t from t h e po s i ti ve to t h e n e ga ti ve b ru s h i n both

Fi gs 1 7
. 1 a nd 1 72 i s wi ll be foun d th a
,
t the re a r e twi ce a s

ma n y coi ls i n seri es i n Fi g 172 a s th e re a re i n Fi g

. 171 . .

I t i s th erefore possi bl e to opera

, ,
te i g 1 72 o a volt
F n 24 0- .

ci r cui t .

Th e othe r m e thod of re co n n e cti n g Fi g 1 7 1 so a s t o ope ra te .

 C HA N GE S I N DI R E C T- C U RR E N T M OTOR S

it on a 40
2 -volt
i
c rc ui t i s s hown i n Fi g 1 73 . . Th e o i ls i n
c

s e ha
thi s ca ve b e e n pl ace d t h e s a
me as i n Fi gs . 171 a
nd 1 7 2 ,

FI G . 172 T h e du p l e x w a
.
—
v e w i n di n g of Fi g 1 7 1 re con n e c t e d f or 2 40 v ol t s by
.

con n e ct i n g t h e coi l s i n se ri e s t h rou g h t h e com m u t at or a n d t h e bru s h e s .

FI G . 173T h e du p l e x w a
.
—
v e w i n di n g of Fi g 1 7 1 re con n e ct e d by con n e ct i n g
.

t h e t u rn s of e a ch coi l i n se r i e s a l f t h e n um be r o f com m u t a
n d u s i n g On e -h a t or
ba rs I n t h i s ca
. se t w o a d jace n t ba rs m u s t be con n e ct e d t og e t h e r a
n d brus h es

w i d e en ou g h t o cov e r t w o ba rs .

the refor e t h e wi n di n g ta
bl e wi ll be t h e s a
me . Th e o
c nn e c t
ble i s a
i n g ta s follow s

TA B L E FOR C ON N E C T I N G C OI L s or FI G . 173 To C OM M U TA TO R
260 A R M A TU R E WI N DI N G A N D M OTOR R E P A I R

From t h e a
bove co nne cti n g ta
ble wi ll be s e e n tha
it t t he
e n d of S e cti o n 1 i s co n n e cte d to t h e b e gi n n i n g of S e cti o n 1 a

or i n oth er wo rd s t h e two s e ct i o n s of aco i l whi ch w e r e i n

, , ,

p a r a
ll e l wi th on e an oth e r i n F i g 1 71 a.r e n ow co n n e ct e d i n

seri es .

As a dy e xpl a
l re a i ne d t h e n umbe r of turn s pe r coil wi ll be
,

di re ctly p roporti o na l to t h e volta ge I n Fi g 1 71 a

. . s s ume

t th ere a r e 2 0 turn s pe r co i l w i th two w i re s i n p a

,

t ha rall el B y.

re co n n e cti n g a s i n Fi g 17
. 3 th e re wi ll be 40 tu rn s pe r coi l
, ,

usi ng on e wi re From thi s i t wi ll be s een tha

. t whi le th ere a re

1 3 co i l s i n e a ch wi n di n g Fi gs 1 7
,
.1 and 1 7 3 on e h a
,
s twi ce a s

ma n y tu rn s pe r co i l a s t h e oth e r Thi s fa
. ct m a kes i t pos
s i ble to opera te Fi g 1 73 on a240 volt ci rcu i t
.
- .
262 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

motor opera tin g in d efini tely i n s uch con di ti on S uch cha . n ges

a r e re p e e te d by e conn e cti n g a
r s n r - three pha se motor wi thout
-

ch a n gi n g t h e coi ls for two ph a s e ope ra

- ti on This is equ i va.

len t to ope ra tin g t h e three pha- s e mo t o r a t 1 25 pe r ce n t n orm a l .

volta ge I n a . ddi ti o n t h e coils whi ch s houl d ha

, ve ext rai n
s ul at i on wh e re t h e ph a ses ch a n ge ha ve onl y g roup i ns ul a ti on .

Th e i r on loss a n d hea ti n g m a y b e i n c r e a
s e d t o a d an g e rou s

d egree a n d t h e powe r f a cto r gre a tly de crea se d S u ch ch a .n ges

s hould o nl y be us e d i n a n e merge n cy a n d t h e prope r pe rm a n ent

cha n ges m a de a s s oon a s poss i bl e .

P oin t s t o C on s i der bef or e M a k i ng R e -conn ecti ons B e fo re —

are pa i rm a n a ttempts t o ma ke ara di ca l cha n ge i n t h e co nn e c

ti o ns of a n i n du ct i o n moto r wi n di n g h e s hould co ns i d e r ca
- re

ful ly t h e li mi ta ti o n s of t h e d es i gn a n d t h e e ff ects of t h e ch a n ges .

T h e followi n g poi n ts wi ll serve a s a g de

u i .

1 C ha
. n g es i n v ol t ag e al o n e a re t h e e as i es t a n d c an us u all y b e m a d e .

2 C ha
. n g es i n n u m be r of ph a s es a l on e ca n ra re l y be m a de sa t is fact ori l y

a nd a re us u a ll y onl y m a ke s h ift s .

3 C ha
. n g es i n n u m be r of pol e s a re l i m i t ed , du e t o t h e m ech a n i ca l form
of t h e coil s .

4 C ha
. n g es of fre qu en cy a l on e or i n com bi n a t i on w i t h v ol t a g e or ph a se

ca n s om e t i m es be m a de if ch a n g e s i n spee d a re n ot obj ect i on a bl e .

5 C om pli ca
. t e d ch a n g es s h ou ld n ot be a t t e m pt e d e xce p t by pe rs ons
of som e e xpe r i e n ce a n d s h ou l d be h a n dl ed w i t h ca u t i on .

6 If t h e pe ri ph era
. l s pe ed of t h e rot or (w h i ch e qu a l s rot or di a m e te r
i n fee t X X rpm ) e xceeds 7
. 000 fee t pe r m i nu t e on a n y proposed

ch a ng e , t h e m a ker of t h e m ot or sh ou l d be consul ted before m a kin g t h e

ch a ng e .

7 I n ca
. se of a n y dou bt on a n y poi n t , re fe r t o t h e m a n uf a ct u re r of t h e

m a ch i n e .

Di a
g r a
m s f or Difi e r e n t C h a
n g e s of C onn e ct i on s Two —

ki n ds of di a gr ams a re mo s t us e d to i n di cate t h e co n n e cti ons

to be m a de i n i n ducti o n m otors T hes e a r e s hown i n Fi gs
.
-
.

17 4 a nd 1 7 5 Th e di a gra
. m of Fi g 1 7 4 i s athree pha
. s e four -
,

pole wi n di n g conn e cted i n sta r on a 3 6-s lot core I t re pres e n ts .

t h e coi l s as th e y would look i f r e move d fr om t h e m a chin e a nd

la i d on at a ble wi th t h e actu al con n ecti ons ma de Th e di a .

gra m Of Fi g 1 75 i s acon ve n ti on a
. l s ketch for t h e win di n g of
Fi g 1 7 4 s howi n g t h e pol a
. r groups Th e l a tter di a
. gra m is
mu ch us e d .
 R E -C ON N E C TI N G I N D U C TI ON M OTORS

In t he te d si n ce there a
wi n di n g i ll us tra re three ti m e s four or ,

1 2 pol a r gr oups a n d 3 6 coi ls there a re thre e co i ls co n n e cte d ,

i n s e ri es to form apola r ph a
- se g rou p I t sh ould be born e i n .

M l l n oc n yn u n t coil s lo t q g s o! cl ot s .

W a l k )“ ce ll s In W ot -
l ot s

FI G . 174 .
—
C om p l e t e aa
wi n di n g di g r m for a3 -p h se , 4-p ol e m a ot or ha
vi n g
3 6 s l ot s . a
n d con n e c t e d i n se ri e s-s t a
r .

mi n d tha t the re a re n ot a ctu a lly 1 2 ma gn et i c poles i n t h e

ma chi n e for t h e re a, s o n th a t th ree con s e cuti ve pol a r pha se -

g r oup s u n i te to fo rm o n e m a g n e t i c p o l e by v i r tu e of t h e ph a se

difie re n ce of t h e curre n ts i n t h e th ree ph a s es T he r e a r e two .

m a gn e ti c n orth a n d two m a gn eti c south poles formed by thi s

wi n di n g a t a n y i n s ta nt a n d th es e pole s a ,
r e e qu a lly s p a ce d

a r oun d t h e a ir g a p li k e -fou r m e c h a n i c a lly p r oj e ct i n g po l e .

p i e ce s e x c i t e d by fou r co i l s c ar r y i n g d i re ct c u r r e n t S ome .

t hi n g of thi s co n ce pti o n i s ga i n ed
i f on e i ma gi n es t h e a rm a ture of
adi rect curre n t ge n erator he ld
-

s ta t i on a ry a nd t he field poles
r ot a te d a r oun d i t At a n y g i ve n
.

i n s ta n t t h e ma gn e ti c fie ld ca n

be con ce i ve d to be t h e s a me a s

t h e fie ld whi ch i s form e d by
t h e wi n di n g s hown i n Fi g 1 7 4 . .

T h e coi ls i n s lots 3 6 9 1 2 , , , ,

et c .are s hown by he a
, vy li n e s
t o i n di ca te tha t t h e i n s ula ti on
on th ese coi ls i s he a vi e r to F O 1 75 di ag m a
I f t h r or e

h w m F g 17
wi thsta in a
4
n d t h e g re a t e r s tr a
o u c nnec o ns S o “ l ' °

t
t h e poi n ts wh ere t h e w i n d i n g cr os se s or li e s a dj a ce n t to co i l s

d i ff e ri n g g rea tly i n pot en ti a l Thi s i s ca lle d pha . s e i ns u l a

“

ti on
”
a,
nd m a y b e p u t on t h e fir s t coi l i n e a c h g r oup or it
 2 64 A R M A TU R E WI N DI N G A N D M OTOR R E P A I R

m a y b e put o n t h e fi rs t a n d l as t c o i l of ea c h g r oup wh e r e th e r e

a r e al a rg e n umbe r of coi ls i n t h e group Thi s i s on e of t h e .

rea s o n s why am a chi n e m a y n o t a t t i m e s b e r e c o nn e c t e d

for a n oth e r n um be r of pol es or ph a ses I f s uch re co n n e cti o ns
.

were m a de t h e ma xi mum di ff e re n ce s i n pote n ti a l mi ght occur

be tween two a dj a ce n t coil s u n prot e ct e d by thi s ext ra i n s ula
ti o n a nd a brea k d own res ult
- .

Th e co n ve n t i o n a l di a gra m of Fi g 1 75 re pres en ts t h e s a . me
co n n e cti o n s a s F i g 17 4 ex ce pt th a t ea ch pole ph a g r oup - -
.
, s
e
as n u mb e re d 1 2 3 e t c i n Fi g 1 7
, , , 4 i s s hown by as hort a
.
,
.
,
re

i n Fi g 1 7 . 5 T h e n umb e rs on t h e groups a
. re i d en ti ca l wi th
Fi g 1 7
. 4 a n d t h e gr oup co n n e cti o n s
, The a r rows a . re s how n

s i mply to i n d i ca te ame thod of checki n g up t o i n s ure t h e proper

pha s e re l a ti ons The re i s co n si der a
. ble d a n ge r i n athr ee ,

ph a s e co n n ecti o n of ge tt i n g a60 d e gre e re l a

, ti o n be t wee n t h e
-

pha ses i n s te a d of a1 20d e gre e rela ti on or a

-
s i t mi ght be e x ,

press e d on t h e di a gr am th ere i s d a ,
n ge r th a t t h e wr on g e n d of
t h e B ph a s e f or e xa
,
mple m a y b e c o n,
n e ct e d to t h e s t a r po i n t .

A s ach eck a ga i n s t thi s wh e n t h e di a ,

gr a m i s com ple te d t h e ,

curre n t i s a s s um e d a s goi n g i n a t a l l three l e a d s towa rd t h e

Y po i n t A rr ows a
. re put on e a ch pol e ph a s e gr oup a s s hown
- -
,

a n d wh e n a l l th r e e pha se s a r e tra ce d thr ough t h e wi n di n g i s ,

co rre ct if t h e a rr ows on co n s ecuti ve gr oups r u n a lte rn a te ly

clockwi s e a n d cou n t e r clo ckwi s e -
It m a y b e .a r gu e d th a t th i s

is a n a rti fi ci a la s s umpt i o n a n d th a ta t n o i n sta n t i s t h e curre n t

flowi n g towa rd t h e s t a r in a ll th re e ph a s es It m a y a l s o b. e

a rgue d th a t i n acorre ct wi n di n g if t h e curre n t be a ,

ss um e d a s

flowi n g towa r d t h e s ta r i n two ph a s es a nd a lwa ys from i t i n

t h e thi rd t h e a ,
rrow s wi ll f a ll i n s u cce ss i ve se ts of three i n t h e
sa m e di re ct i o n a n d th e n th re e I n t h e re ve rs e d i re cti o n T hese .

sta te m e n ts a re t r ue but a ,
li ttle ex pe ri m en ti n g wi ll s how tha t
a n i n corre ctly co n n e ct e d or 60 d e gr e e wi n di n g ca - n i n th i s w a y
be shown to gi ve s u cce ssi ve s e ts of thre e a rr ows a n d s t i ll be

wron g There i s but on e e x ce pti on to t h e corre ctn ess of t he

.

ch e ck a s s hown i n Fi g 17 5 wh e re t h e curr e n t i s a
. s s um e d as

flowi n g towa rd t h e s ta r in a ll th re e ph a
s es a nd the a r rows

altern a te i n di re cti on Thi s ex ce pti on to t h e rul e i s t h e ca

. se

where t h e wi n di n g fo rm s con s e quen t poles or pa s s e s thr ough

al l t h e pol e ph a s e gr oup s i n
- — a n orth dir e cti o n i ns tea d of
 2 66 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

i n p r ll e laaI f ag i ven m a
. chi ne were con nect ed , a s s h own i n

Fi g 1 75 , for an orm a
. l voltag e of 440, i t coul d re a
dil y b e re co n
n ect ed a
ccordi n g to a n d woul d the n be sui t a
Fi g . 176, ble for
opera ti on on 220 volt s h a vi n g t h e s a me performa n ce i n a ll t e
s pe ct s ex ce pt th a t i t woul d dra w from t h e 220 volt li n e twi ce -

a s ma ny a mpe res un de r agi ve n loa da s i t p re vi ous ly dre w from

t h e 440 volt lin e - S i mi l arly if i t h a

. d four poles or amul ti ple
, ,

of four poles i t coul d still be p a , ra ll eled a a

g n or pu t i n 4
i ,

pa ra llel s ta r a s sh o wn i n Fi g 1 7
, 7a n d ope ra t ed on 1 1 0 volts
.
, ,

a n d woul d s til l ha ve t h e s a me p erforma n ce a t acorres pon d

i n g l y i n crea s e d curr en t a t t h e sa m e loa d .

Fi g 1 7 . 8 re pres e n ts ava ri ati on i n conn ecti on from t h e fore

goi n g whi ch i s possi ble onl y wi th three pha
, se m a ch i n es - .

Thi s is t h e so ca ll ed del taor m e sh co nn e cti on I f am a

- chi n e .

co n n ect ed a s i n Fi g 17 4 for 440 vol t s be re co nn e cted a

. s in

Fi g 1 7. 8 i t would be s ui t a ble for Ope ra ti on on aci rcui t ha vi n g

avolta g e of 44 0 or 2 54 volt s .

C OM PA R I S ON or M OTOB V oL TA G E s WI T H V A B I ou s C oN N E C TI ON s

If am ot or con n e ct e d ori g in a ll y a s s h own i n an y h ori z on t a l col u m n ha d

an orm a l v ol t a
g e of 1 00 i t s v ol t a g e w h en r econ n ec t ed as i n d i cat e d i n a
n y
v e rt i ca
l col u m n i s s h own a t t h e in t e rsect i on of t h e t wo col u m n s .

3—P h a
sc Se ri es S t a r

3-P h asc 2 Pa ra
- l l el S t a
r .

3-P ha s e 3 -Pa ral l el S t a

r .

3 -Ph ase 4 Pa ra
— l l el S t a
r .

3 -Ph ase 5-Pa ral l el S tar .

3-Ph a se S e ri es D e l t a .

3 -P h a
se 2 P a r De l t a
- . .

3—P ha sc 3-P a r De l t a
. .

3-Ph a s e 4-P a r D el t a
. .

3 Ph a
-
s e 5-P a r .

2 P ha
-
sc S eri es
2 Ph a
-
s e 2 Pa ra
- l l el s
2 Ph a s e 3 -P a ral l cl s
21 t 4-Pa ral l el s
2 Ph a
-
s e 5-Pa ral l els .
 RE - C ON N E C TI N G I N D U C TI ON M OTORS

U se of Ta
bl e of C onn e ct i on s —
Difi erent o
re c n n ec ti o ns or
o ve rsi o n s a
c n re s hown i n t h e T a ble on p a ge 2 66 whe re t h e
p r oble m j us t s hown m a y b e wo r k e d out by s el e ct i n g Three pha se -

S eri es S ta r i n t h e ho ri zo n t a l
colu mn ( firs t li n e ) a n d r ea di n g
acr oss t o t h e verti ca l colum n
h ea de d S er i es Deltawhe re t h e
figure 58 a ppea rs Thi s m e a . ns

th a t if 1 00 volts wa s n o rm a l on
th e s eri es s ta r co n n e ct i o n a nd a

ch a n ge i s m a d e to se ri e s d e lt a
t h e co rr es po n di n g volta ge i s 5 8 .

B y m ulti pli ca ti o n if 440 wa s

,

t h e se ri e s s t a r volta ge t h e se ri es ,

d e ltavolta ge would be X 58
2 54 a s n ote d a
, bove Fi gs . .

17 9 a nd 1 30 S how a P a ra llel F m 1 80 C t i g di a g a m —
onn e c n r

a 4 pa ra llel delta 0 o e c
. .

nd - n n f a 1
3 p ha 4 p l 4orp a al l l - se . - o e. - r e

d l t am dm g
ti o n res pe cti vely a
.

be a
e n
nd
‘

, r
,

t h e sa m e re l a ti o n to Fi g 1 7 8 th a t Fi g s 1 76 a
. nd 1 7 7do to Fi g . .

17 5 .

Two ph a s e Di a
-
g r am s I n F i g 1 8 1.a —
d e v e lopm e n t. of a two
p h a s e w i n di n g i s s how n s im i l a r to F i g 1 7 4 e x ce pt f o r t h e di.fl e r ,

e n ce i n t h e n umbe r of ph a s es A n i n s pe cti o n of t h e co i ls
.

re pre se n te d i n h ea vy li nes a n d acomp a ris o n wi th t h e coi ls i n

Ful l h u ropron a
t coll c l n t ou ol d ob , m m m h bott om c ol s l oh

FI G . 1 81 .
—
C wi n di n g d i a
om p l e t e g r am f or a 2- h se
p , 4- ol e m o t or s e ri e s
p a
c n n ect e d
o T h e co
. il s f r o m x to y f or m on e pol e -
p h as e -
g r ou p .

Fi g . 17 at o n ce wh a
4 i n d i ca
tes t i s me a
n t by t h e ph a s e co i ls

or ph a te d coi ls be i n g di ff eren tly si tu a

s e i n s ula ted Thi s a l so .

i n s one of t h e good rea

e x pl a s o n s why two pha s e moto rs s houl d -
268 A R M A TU R E WI N DI N G A N D M OTOR R E P A I R

n ot be t d
rec n n e c e tho phase or vi ce ver sa wi thout
for ree - , ,

chan gi n g t h e posi ti o n of the s e pha s e coi ls .

Fi g 1 82 g i ves t h e co n ven ti on a
. la ti c eq ui va
n d s ch e m a len t of

FI G 1 82 di a
C g ra
on n e ct i n g
m for FI G 1 83 C o n n e ct i n g di a g ra
m for
— —
. . . .

a2-p h a se 4-p ol e wi n di n g w i t h se ri es
. a2-p h a
se , 4- p ol e w i n di n g w i t h p ara
ll e l
co nn ect i on s . con n e ct i on s .

Fi g 1 8 1
. .a rr ows s hown i n t h e th
Th e ph a se d i a gra ms a re ree -

omi tte d here for t h e rea s o n th a

, t t h e two pha s es a r e n ot i n te r

con n e ct ed a n d t h e o n ly e ff e ct ,

of re ve rs i n g on e pha s e i s to

r e ve rs e t h e di re ct i o n of rot a ti o n
of t h e motor Thi s i s re a di ly .

co rr e ct e d by r e ve rs i n g t h e two

l ea d s of on e pha se a t t h e mo t o r
te r m i n a ls Fi gs 1 83 a
'

n d 1 84 . .

gi ve p a ra lle l a n d 4 pa ra ll e l two —
,

ph a s e co n n ecti o n s a n d b ea r the

sa m e re l a ti o n to t h e se ri e s con
n e ct i on a s t h e th ree ph a s e s ta r -

a n d d e lt a di a g r am s F r om th es e .

F I G.1 84 C t i g di a
.
—
g a m
2 p ar
on n e c a ll en
l a n dr
4 p ar a-
ll e l c o n n e c —

f
or a2 p h a 4 p l w i di g wi t h ti o n s i t m a be rea
-
se , - o e n n
d i l y s e e n th a t
4 p aa
y
ll l ti
wh ere t h e n umb er of pole s i s a
- r e con n e c on s .

multi ple of three a s 6 1 2 1 8 et c there i s apos s i ble a

, , , ,
na
. logous
,

3 pa
- ra lle l con n ecti o n ; a ls o where t h e n umb e r of poles is a
mul ti ple of fi ve su ch a s 1 0 2 0 et c
, there i s acorres pon di n g
, , .
,
270 A RM A T U R E WI N DI NG A N D M OTOR R E P A I R

or in o ther words i f there we re e i ght s lo t s be twee n t h e t wo

,

s lot s i n whi ch t h e t w o si des of a n y coi l we re lo ca te d S uch a .

coi l would s p a n 1 80 ele ctri ca l d egrees Ha lf of 1 80 de grees is

.

90 de g rees a n d t h e s i n e of 90 d e grees i s 1 ; th e re fo re t h e e ff ect

of t h e turn s i n s u ch acoil i s on e S uppose i ns te a . d t h e coi l li es

i n s lots 1 a nd 8 . I t would the n s pa n 1 40 d e gree s e l e c

t ri ca l l y si n ce 7
,
2 8 9 s lots re pres e n t s 1 80 d e grees a nd ,

on e s lot therefo re re pre s en ts 2 0 d e gree s Th e si n e of h a

. lf of
1 40 d e grees or 7 , 0 de grees i s , I t follows th a t t h e eff ect
of t h e turns i n this coi l is les s tha n th a t of t h e full pi tch coi l
by t h e r a ti o of to 1 This i s of i n teres t i n t h e prese nt
.

p roblem b e ca ,
use i t is often possi ble i n ma ki n g ch a n ges t o

ch a n ge a t t h e sa m e ti m e t h e s pa n of t h e coi ls by on e s lot ,

more or less by s pri n gin g t h e coi l me cha

,
ni ca lly a n d so i m ,

prove t h e pe rform a n ce of t h e m a chi n e u n d e r t h e n e w con

di t i on s
. Th e poi n t be comes of vi ta l i mporta n ce i mm e di a te ly
, ,

whe n cha n gi n g t h e n umb e r of pol e s wi thout ch a n gi n g t h e

throw of t h e coi ls R eferri g a . n ga to t h e 7 s lot motor

i n 2 -
,

a s s um e th a t t h e coi ls a re wou n d i n s lo t s 1 a nd 8 For .

a n e i ght pol e co n n ecti o n th e se coi ls wi ll h a

-
ve t h e effe ct of
a s C x pl a i n ed a bove I f t h e co n necti o n s a
. r e cha n ge d

for si x poles t h e eff e ct i s e n ti re ly di ff e re n t 72 .6 12 a nd

1 80 12 1 5 or e a
, ch s lot re pres e n ts 1 5 e le ct ri ca l de gree s .

A throw of 1 a nd 8 cove rs se ve n comple te slots or ,

7X 1 5 1 05 d e grees ; t h e si n e of ha l f of 1 05 or d eg rees
whi ch me a ns tha t whe n con n ecte d for six poles
t h e coi ls ha ve a n e ff e ct of onl y as a ga i ns t when
co nn e cte d for e i ght poles I t is poss i ble to a
. voi d us i n g t h e
s i n e of ha lf t h e a n gle a n d s e cure a fa cto r wh i ch is sufli ci e n t l y

a ccur a t e pr a cti ca lly by us i n g t h e ex pressi on

‘

( N umb e r of s lotspole ) pe r2 ( N umbe r Of s lot s d r oppe d )

2 ’

( N umb e r O f s lot s pe r pol e ) ”

me ei ght pole exa

U si n g t h e s a m m e a
-
bove t h e n umbe r of ,

s lots pe r pol e i s 72 8 9 a n d t h e pol e pi t ch i s 1 a nd 1 0 .

Wh e n t h e coil is wou n d 1 a n d 8 i t s pa n s s e v e n s lots a

n d th e re

a re 9 7 2 s lots droppe d Th e ex pr ess i on th en becomes

.
 R E -C ON N E C TI N G I N D U C TI ON M OTORS

n d si m i la
a rly for t h e s x pol e ,
i -

2
12

whi ch a grees roughly wi th t h e othe r me thod A coi l s houl d i n .

n o ca s e be chor de d mo re t h a n ha lf of t h e pole pi t ch a s s e co n d ,

a ry dis turb a n ces of t h e m a gn e ti c field a re occa si o n e d by cho rd

i n g whi ch b ecom e pr ohi b i ti ve a t th a t poin t Th e ex press i on .

,
“
s i n s of h a lf t h e a n gle s p a n n e d by t h e coil
”
i s gi ven t h e n a, me
ch ord fa ct or a n d i t should be co n s i d ere d i n t h e wo rk of re con
,
-

n ect i n g . For exa mple if t h e pOl es a

,
re ch a n ge d from 8 to 6 ,

a s i n t h e exa mple a bove a n d t h e chor d f a

,
ctor ch a n ges f rom

to t h e n e w li n e volt a ge should be
t i m es t h e old n e gle cti n g t h e efle ct of other cha n ges whi ch a
'

,
re

be i n g m a de I f n othi n g e lse wa
. s u n d e rgoi n g ch a n ge a nd t he

n orm a l volta ge wa s 440 i n t h e firs t pl a ce i t s hould be 3 7 , 0a fte r

t h e ch a n ge i s m a de or express i n g i t a
,
n oth er wa y i f i t w as s t i ll ,

Ope ra te d a t 440 volts a fte r t h e ch a n ge t h e motor s hould be

,

thought of a s Ope ra ti n g a t a bout 1 8 pe r cen t over volt a ge . .

P ha s e I ns ul a t i on .
—
I t i s t h e pr a cti ce of m a ny m a n uf a c

t urers to put hea vi er i ns ul a ti on on t h e coi ls a t t h e e n ds of t h e

pol a r gr oups whi ch a re m e cha n i ca lly a dj a ce n t to on e a n oth e r

a nd a re a ls o s ubj ecte d t o t h e volta g e b e tw ee n ph a s e s wh i c h ,

ma y b e t h e m a x im um volt a g e be tw ee n s upply l i n es S u c h .

coi ls a re i llus t r a te d a t N os 9 1 2 1 5 e t c i n Fi g 1 7
.
, , ,
4 .
,
. .

B y compa ri n g thi s di a gra m wi th Fi g 1 8 1 for two pha . se -

co n n ecti o n ,
it a ppe a rs at o n ce th a t both t h e n umber
a lo a
n d c t i o n of thes e so ca - lle d pha s e coi l s
”
s hould be

ch a n ge d a t t h e ti m e t h e m a chi n e i s re co n n e cte d from two to

- ~

th r ee - pha s e or vi ce ver sa a
, s s umin g tha
,
t t h e volta ge ca n be

ch a n ge d so tha t a pha s e cha n ge i s pe rmi ssi ble Al s o i n .

cha n gi n g t h e n umb e r of pol es t h e n umb er a ,

n d lo ca ti on of t h e
ph a se coil s mus t a lso be cha n ge d I n fa ct wh a
. t e ve r t e ,

conn e cti o n i s a tte mpte d t h e pha se coi ls s hould be ch e ck e d

a n d re a - rra n ge d s i n ce thi s is comp a

, ra ti ve ly e a sy a nd a dds
co ns i d e r a bly to t h e prote cti o n of t h e ma chin e fr om bre a k
downs of i ns ula ti o n .
27
2 AR M A T U R E WI N DI N G A N D M OTOR R E P A I R

RE -C ONN E C TI N G M OTOR S TO M E E T NE W OP E RA TI N G
C OND I TI ON S

R e conn e ct i on s
- Fre qu e nt l y M a
de —
Th e followi n g ch a n ges

a
re ma
de on a
ccou n t of cha
n ges in operati n g co n di ti ons or t h e
s ervi ce c n o di ti o ns on t he ci r c ui ts from whi ch t he motors a
re

p a
o erte d .

1 . C ha
n g es t o ope rt e on adifiere n t v ol t a
a ge .

2 . C ha
n g e for Ope rat i on on adifi e ren t ph as ed ci rcu i t , t h ree t o t wo
ph a
s e ,
e t c .

3 C ha n g es t o opera t e on adifl e ren t fre qu en cy

'

. .

4 C ha
. n g e i n n um be r of pol es of t h e m ot or .

In ac se of ch a n g e N o 4 t h e re conn ect i on m a
.
, y be i n depe n den t of all
ot h e r ch a n g es t o secu re a fas t er or sl ow e r s peed or i t m ay foll ow as a
'

te

su l t of ch a ng e N o 3 i n ord e r t o k e ep t h e sa
. m e s pe e d on adri v en
ma ch i n e w h e n t h e m ot or is ope ra t ed on t h e n e w fre qu en cy .

P roce dur e wh e n C onsi de ri nga Wi nding s

R e conne ct i on of
- .

Th e pro ce dure i n che cki n g up am a chi n e to s ee whe the r or

n ot i t ca n be r e co nn ect e d i s a
- s follows : Fi rs t a s ce rt ai n t h e ex ,

i s t i n g co nn ecti on a n d t h e thr ow of t h e co i l s i n o rd e r to k n ow -

wh a t t h e poss i bili ti es are i n t h e wa y of n u mb e r of tu rn s an d

throw S e con d i f i t i s apha
.
, s e or volt a ge cha n ge fin d di ,

r ect l y f rom t h e Ta ble on pa ge 266 wha t co n n e cti ons wi ll gi ve

a pproxi m a te ly t h e prope r n e w volta ge a n d ne w ph a se If .

a n y on e of th es e co n n e cti o n s i s po ssi ble wi th t h e n umb e r of

poles i n t h e ma chi n e s el e ct i t a
, s t h e n e w co nn e cti o n a nd a r

ra n ge t he ph a s e coi l s prop e rly a t t h e b e gi n n i n g or en di n g of

t h e groups or a , t ea ch e n d of t h e groups if the r e a re e n ough of

the m i n t h e old wi n di n g S i n ce t h e s pe e d h a
. s n ot cha n ge d t h e ,

horse power s hould r ema in a ppr oxi ma tely t h e sa me a nd t h e ,

curre n t i n t h e co i ls the ms elves wi ll r e m a i n som e wh ere n ea r the

ori gi n a l I f t h e frequen cy i s to be cha

. n g e d ei th e r i n de pe n d

e n tly or i n co n j u n ct i o n wi th a pha s e or avolta ge cha n ge t h e ,

a ppli ed volta ge s hould be cha n ge d i n t h e s a m e di re cti on a nd

by t h e s a me propor ti on a la moun t a s t h e fre qu en cy i s ch a n g ed

'

or i f t h e volt a ge i s to re ma i n un cha n ge d t h e n u mb er of turn s i n

s eri es in t he oi ls s hould be ch a
c n g ed i n t h e oppo si t e di r ecti on

to t h e frequ en cy a n d by t h e s a me a mount For ex a mpl e i f a .

,

2 5 cycl e moto r i s to be r u n on 3 0 cy cle s i t s hould h a

— ve t h e volt
,

a g e i n cr e a
s e d 2 0 p e r ce n t o r e l s e h ave t h
. e g
,
r oup s r e co n ne ct e d —
27
4 A R M A TU RE WI N DI N G A N D M OTOR R E P A I R

fur the r than full pi t ch s i n ce 72 6 , 1 2 s lots pe r pole a nd

1 to 1 3 would be exa ct p i t ch Th r owi n g t h e coil ove r pi t ch

.

has t h e sam e effe ct a

s thr owi n g i t u n d er pi t ch s o t h e n e w chord

fa
ctor on s i x poles or s i n e of on e

ha lf of 1 50 de gree s Ta ki n g i n to a ccou n t t h e chang es

i n ph a s e pol e s fr e qu e n cy a
, ,
n d chor d i n g t h e n e w a
ppli e d volt ,

880 4 60
a
g e p pha
s e s hould be X X X 305 volts
(m
e r
T 6 46
.

Th e pl ana
ex ti on of thi s ex p res si on by terms is : Th e first
term (880 3 ) comes from t h e ch a
, n g e i n ph a s e fr om 2 to 3 .

S i n ce t h e ori gi n a l con n e cti o n wa s i n pa ra ll el a n d wa s for two

ph a s e t h e volt a
, ge a cross on e ph a s e i n se ri es wo u ld be 2 X 2 20

440 a n d t h e volta
, ge a cro ss both ph a s es i n s e ri es wo u ld be

2 X 440 880 volts I f t h e wi n di n g is di vi d ed i n to th ree

.

s e pa ra te ph a s es n ot i n ter co n n e ct e d t he a ppli e d volta

, ge on
ea ch ph a s e would be (880 T h e n ext te rm (4 6) is ,

du e to t h e ch a n ge i n pol es A motor wi th s ix pole s would run

.

s lowe r on t h e s a m e fre quen cy tha n a motor wi th four poles a nd

woul d gen e ra te les s cou n t er em f C on s e que n tly th e a

. ppli ed ,

v olta ge s hould be de cre a s ed i n t h e s a m e p ropo rti o n T his .

s hould n ot be co n fu s e d wi th t h e f a ct th a t t h e frequ en cy is
bei n g ch a n ge d i n thi s ca se a n d t h e S p ee d k e pt t h e s a me be
ca use ase p a ra te fa cto r i s i n tr od u ce d to t a ke ca re of t h e fre

quen ey Th e pole cha

. n g e s h ould be co n s i d e red a s a n i te m

s e pa ra te from t h e fre que n cy ch a n ge Th e n ex t term ( 60

.
,

40) i s d u e t o t h e ch a n ge i n f r e qu e n cy a nd is t h e a ppli ca ti on
of t h e rule to cha n ge t h e a ppli ed volta ge di rectly a s t h e fre

quene y i s ch a n g ed T h e la s t te rm
'

.
,
i s due t o t h e
difleren ce i n cho rd fa cto r Wi th athrow of 1 t o 1 5 t h e coi ls
'

,
.

a re mo re eff e cti v e t o ge n e r a te coun ter e m f on t h e si x pole .

-

t ha n on t h e four pol e co nn ect i o n by t h e ra

- ti o of t h e chord
fa cto rs to h e n ce t h e a ppli ed volta ge s houl d be ra i s ed
wi th t h e cou n ter em f .

Th e va lue of 305 volts m ea n s th a t if t h e wi n di n g wa s di vi de d

i n to th r e e s e p a ra te pha se s n ot i n t e r co n n e cte d i n a n y wa y he t ,

volta ge should be 305 volts a cr oss e a ch ph a se I f t h e thre e .

~

pha s es a r e con n e ct ed i n s e ri es s t a r a s i n Fi g 17
,
5 the a .ppli ed ,

volt a g e s ho ul d b e X 3 0 5 5 3 0 volt s S i n ce t hi.s i s o n l y

 R E —C ON N E C TI N G I N D U C TI ON M OTOR S

a
bout pe r ce t 05 from t h e 550 volts whi ch i s to be us ed
n .
,

t h e moto r wil l oper a t e sa tis f acto ri ly Thi s ca l cul a ti on for .

volt a g e s o fa r n egl ects t h e diff er e n ce i n t h e so ca l l ed di st ri

“
-

bu t i on fa cto r bet ween three pha se a n d two ph a

- s e but this is
-
,

i mm a t eri al Thi s fa
. cto r a cts t h e sa me wa y as t h e cho r d
fa ct o r a
,
n d is a bout for a n y n o rm a l three pha s e wi n d i n gs -

a nd for a n y n o rm a l two pha s e wi n di n g so th a t the a

-
p ,

pl i ed volt a
ge s hould re a
lly be 5 30X
gig?)
—
560 volts ,

whi ch i s a lmos t exa ctly wh a t is required Thi s motor could .

th en ha ve i t s pha s e coil s r e-a rra n ged for s ix pol es a n d be

co nn ect ed s e ri e s s t a r a n d would be sa ti s f a
cto ry for t h e n ew

co n di ti o n s . Th e cha n g es i n volv ed do n ot m a teri a

l ly eff ect
t h e s li p so tha
,
t n o cha n g e i s r e qui r ed i n t h e roto r wi n d i n g .

T hi s exa mpl e ill us tra t arough ca l cula ti on tha t can be ma de

to see wha t t h e possi bil i ti es of re con n ecti on a re - .

C ha ng e s i n Vol t a
g e O n l y w i t h a
l l Ot h e r C on di t i ons R e

mai ni ng t h e S ame —
Thi s i s t h e si mples t ch a
. n ge whi ch ca n be

ma de i n a n i n du cti o n moto r wi n d i n g a - n d i n pri n ci pl e i s t h e

sa me a s th a t of atra ns fo rm e r co i l i n whi ch t h e n u mb e r of turn s

of wi re i n seri es mus t be va ri e d i n e x act pr opo rti o n to t h e vol

ta ge a ppli e d P ra . ct i ca ll y a ll commerci a l motors a re a rra n ge d

s o th a t the y ca n be co nn e ct e d for two volta g es s a y 1 1 0 a n d ,

2 20 or 220a
, n d 440 Thi s is a ccomplis h ed by putti n g t h e pol a
. r

g r oup s i n s e ri e s a s i n F
,
i g s 1 75 a n d 1 82 fo. r t h e h i gh e r volt
, a g e ,

a n d i n pa ra l le l a s i n Fi gs 1 7
, 6 a n d 1 83 for t h e l owe r volt a
.
, ge .

A ssu me aca s e i n whi ch t h e moto r a s i t st a n ds i s co nn e cte d

for 2200 volts a n d i s con n e cte d i n se ri e s s t a r a s i n Fi g 1 7 5 . .

I t is desi red to r e co nn e ct i t for 440 volts for t h e s a

- me hors e
power pha ,
se cy cl es a
,
n d s p ee d Four hu n dre d a . n d fo rty

volts i s 20 pe r cen t of 2 200 R efer to t h e Ta . . ble on p a ge 266

a n d us e t h e hori zo n t a l column ma r k e d 3 P ha se S er i es S ta —
r , .

S in ce are co n n e cti o n i s d es i r ed to gi ve 2 0 pe r ce n t of t h e
-
.

Ori gi n al volta ge r e a ,
da lo n g t h e hori zo n ta l li n e un ti l t h e figure
20 o ccurs Th i s i s foun d firs t u n d er t h e v erti ca l colu mn
ma rk ed 3 P ha — se 5 Pa ra
, l l els Thi s i s obvi ous of course
- .
, ,

be ca us e if t h e n u mb e r of pol es i n t h e m a chi ne i s di vi si bl e by

five i t could be r e co n n e cte d i n five p a

,
- ra ll els a n d Ope r a te d on
2 200 5 440 volts B ut suppos e t h e num b er of pol es
.
276 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

is di vi si ble by five L ook sti l l further a

n ot . lo n g t h e hor i
z on t a l li n e a n d t h e figure 1 9 a ppe a rs u n d e r t h e v e rt i ca l
column h e a de d 3 P h a
- se 3 P a ra l l el Del ta I n oth e r wo rds if
,
-
.
,

t h e n u mb er of pole s i n t h e ma chi n e i s di vi s i bl e by th re e i t ca n

be put i n three pa ra l le l del taa

- n d o p e ra te d on 2 200 (3 X
424 volts whi ch i s n ea ,
r en ough to 440 t o gi ve

perfe ctly sa ti s f a ctory ope ra ti o n .

I f t h e n umb er of pole s on t h e m a chi n e is n ot di vi si bl e by five

or by th r ee i t i s evi d e n t f rom t h e t a
,
ble th a t i t i s n ot pos si ble
by a n y or d i n a ry thr e e ph a s e co n n e cti o n to a
- ppr oa ch clos e r tha n

550volt s wi th a fou r p a ra l le l s t a
- r co n n e cti o n or 33 0volts us i n g ,

afou r pa ra -llel d eltaco n n e cti o n Th e rel a ti o n b e twe e n 550volt s

.

a n d 3 3 0 volt s a s j us t gi ve n i s n ot qui t e t h e th e o re ti ca l
whi ch would be ex pe cte d but thi s i s du e to t h e ta ,
ble b ei n g
ma d e up to t h e n ea re s t i n te gr a l figure wi thout us i n g fra c

ti on s Th e e rror i n thi s i nsta

. n ce i s thr ee pe r ce n t whi ch i s .

i m ma teri a l .

A poi n t whi ch i s brought out by t he ex a mpl e j us t ci te d i s

th a t s o fa
,
r a s i n s ul a ti on i s co n cern e d am otor m a y a lw a y
,
s b e

r e co n n e ct e d for alowe r volta

-
ge for i n s ta n ce a2 200 volt
—
,
-

motor m a y b e r e c o n n e c t e d
- f or 44 0 volt s but o n t h e c o n t r a—
ry , ,

amotor ori gi n a lly desi gn ed for 440volts m a y n o t be ru n o n 2 2 0 0 ,

e ve n i f t h e re co n n ecti o n i s pos si ble s o fa r a s n umb er of turns is

co n cern e d b e ca ,
us e t h e i n sul a ti o n wi ll n ot s ta n d t h e d i e l e ct ri c

s tra in It m a
.
y b e s t a t e d g e n e r a lly th a t p r ac t i ca lly a l l m a n u
fa ct ure rs u s e two cl a s s es of i n s ul a
.
ti o n up to 2 500 v olts on e ,

cl a ss good up to 5 50 volts a n d t h e se co n d good fr om 600vol t s to

2 500 Thi s s hould be ca

. re fully co n s i d e r e d a nd a motor n e ver
r e co nn e ct e d fr om t h e low er i n to t h e h i gh e r cla
-
ss a lthough ,

t h e ch a n g e fr om t h e h i gh e r to t h e lower i s p ermi s s i bl e fr om

t h e i n sul a t i o n s ta n dpoi n t .

C ha n g e of P h a s e Onl y Th e mos t commo n probl em whi ch

.
—

pres en ts i ts elf i s t h e cha n g e from t wo t o t h r e e ph a

- se a nd ,

vi ce ver s a T h e ore t i ca lly for t h e s a me volta ge there s hould

'

.
,

be a bout 25 per cen t more tota . l turn s i n atwo pha s e wi n di n g -

th a n in a three ph a s e wi n d i n g
- T h e n if athr e e ph a . s e motor
,
-

be re co nn e ct e d f or two ph a
-
se a t t h e sa
-
m e volta ge a n d wi th t h e

sa m e coi ls i t wi ll exhi bi t a
,
l l t h e s ymptoms of amotor ope ra ti n g
a t 2 5 per cent over volta .
g e a n d u s u all y w o u ld o v e r h ea t to a
27
8 A R M A TUR E WI N DI N G A N D M OTOR RE P A I R

hi gh er tha n on n o rm a
the l th ph a s e wi n di n g
re e— Th is .

s hows th a t ch ag g f om two pha

n i n r - s e to t h re e ph a
- se a nd ,

vi ce vers a i s a ,
t bes t very un s a ti sfa ctory I t i s be tte r to re
.

w d w th n o m a
i n i r l three pha- s e coil s a nd a v oi d t h e tr oubles

whi ch m a y follow .

On e ess en ti a l in a n y pha s e re-co n n e cti o n is t o go ove r t he

wi n di n g a n d re a rr a n ge t h e pha s e coi l s or coi l s ha vi ng

”
,

h ea vi er i n s ul a ti on s o tha ,
t the y wi ll come prope rly a t t h e en ds
of t h e g roup s wh e re t h e vol t a ge i s hi ghes t Thi s i s i llus tra . t ed
i n Fi gs 1 7
. 4 a nd 1 81 .

On e ca s e of volt a ge a n d ph a s e cha n ge whi ch wor ks out v ery

well i s t h e cha n ge f r om th re e ph a se 550 volts to two ph a

- se -

440 volts or vi ce vers a Thi s uses a

, . l l t h e turn s in t h e wi n di n g
for ei ther co nn e cti o n si n ce t h e two ph a , s e volt a ge s hould be
-

a bout 80pe r ce n t of t h e thre e pha . se a n d s i n ce t h e h i ghe r volt

-
,

a g e O u t h e th r e e ph as e- c ut s dow n t h e cu r re n t whi ch would ,

other wis e be hi gh er tha n t h e two ph a s e ci r cui t

- I f t h e ph a se .

coi ls a re r e a rr a n ged th er e i s p ra cti ca l ly n o obj ecti o n to s u ch a

,

re co n n e cti on a
- n d t h e motor wi ll gi ve esse n t i a lly t h e s a m e per
form a n ce on e i the r co n n e cti o n .

Th e ta ble on pa ge 2 66 s hows t h e poss i bi li ti es of i n te r ph a se

co nn ecti o ns a,s we ll a s t h e d iffer en t volta g e ch a n ges For .

ex a mple i n t h e ca
, s e j us t ci t e d follow t h e hori z o n ta
,
l li n e
ma rk e d 2 P h a- s e S eri es to t h e firs t ve rti ca l column he a de d 3
P ha s e S eri es Th e figur e i s 1 2 5
. Thi s m ea . n s th a t amotor
ori gi n a l ly co nn e cte d two ph a s e s e ri es- if re co n n e cte d th ree
,
—

pha s e s eri e s s houl d be ope r a

,
te d on 1 2 5 pe r ce n t of t h e ori gi n a l .

volta ge Or if t h e two ph a
.
, s e vol t a
- ge w a s 44 0 t h e th ree ph a se -

wou ld be X 440 550 volts Th e co n v e n i e n ce of t h e

.

ta ble i s de mo ns tr a te d for ph a s e ch a n g es a s w e ll a s volta ge

"

ch a n g e s or f or comb i n a
, t i o ns of both .

C ha n g e s i n Fr e que n cy Th e o cca . s io n oft e n a

—
ri s es f or ch a ng

i n g 25 cycl e motors to 60 cy cl e a
-
n d 60 t o 2 5
- T h e re i s a ls o .

som e ch a n gi n g do n e from 60 cy cl e s to 50a n d 50 to 60 Occa .

s i on a l l y 40 cycle motors a
-
r e ch a n g ed to 60 but th es e ch a n ges
,

a r e i nf re qu en t .

In a ll ca s es of ch a n ge d fre qu e n cy t h e ques ti o n th a t firs t

a ri s es i s : H ow i s t h e r e s ulti n g ch a n g e i n s p ee d to be ta ken
ca r e of ? Th e sy n ch r o n ous s pe ed of a n y moto r ( wh i ch i s o n ly
 R E -C ON N E C TI N G I N D U C TI ON M OTORS

afew per cen t tha n . full lo a

hi gher d s pee d) i s gi ven by t h e
t he -

A lte r n a ti o n s pe r M i n ute
gen er a
l ex press i o n Thi s would be
N umbe r of P ole s

et c . then t h e fre que n cy is cha

If n g ed a n d t h e n umbe r of

poles left t h e s a me t h e res ulti n g rpm wil l va

,
r y di re ctly a
. s

t h e frequ e n cy T his i mm e d i a
. te ly bri n gs up two ques ti ons :
Fi rs t i s t h e me ch a
,
n i ca l d es i g n of t h e rota ti n g p a rt a d e qua te
to a ll ow s u ch acha n ge i n s pee d ? S e co n d ca n t h e s pee d of
,

t h e dri v en ma chi n e be a dj us te d to su i t t h e n e w spee d on t h e

motor ?
C ons i der firs t t h e ca s e whe re t h e fr eque n cy i s ch a n ged a nd

t h e n u mb er of poles r e m a i n t h e sa me Th e res ulti n g cha

. n ge

i n s pe e d i n thi s ca s e i s ta ken ca re of ei the r by a pplyi n g t h e

motor to an e w lo a d or by cha n gi n g t h e pul le ys on t h e ol d loa d
so a s to k ee p t h e sa me r pm on t h e dri ve n m a . chi n e Th e
.

n ext thi n g tha t mus t be co ns i de re d i s t h e n e cessa ry cha n ge

i n t h e volta ge a ppli e d to corres pon d t o t h e cha n ge i n fre que n cy ,

or t h e other w a y a bout i f t h e n e,
w c i r cu i t a t t h e n e w f r e qu e n cy
ha s t h e sa m e volta ge a s wa s us e d wi th t h e ori gi n a l fre qu en cy ,

how ca n t h e co ls i i n t e mo t o be e conn ecte d so a

h r r - s t o g et t h e

proper volt a g e o n e a ch c o i l ?
Th e ea s i es t rul e to r e m e mbe r i s to va ry the a pp l i ed v ol t ag e

on the m otor i n ex a ctl y the s a m e wa y a s th e f q

r e u e n c y i s va r i ed .

I f this be do n e t h e m a g n e t i c fie ld i n t h e i r o n w i l l r e m ai n t h e

sa me a n d t h e curre n t i n t h e s t a tor a n d r otor coi ls wil l re ma in

t h e sa me if t h e motor is worki n g a
, ga i n st t h e sa m e torque .

Thi s i s a n othe r wa y of s a y i n g th a t i f t h e fr e q u e n c y a n d vol t a g e

a re v a ri e d t oge ther t h e moto r wil l de ve lop t h e sa

, m e t orque a t
a ll tim es a n d ha v e flowi n g i n i t a pprox i m a te ly t h e s a m e cur
r en t . I f t h e to rqu e re m a i n s t h e sa me t h e hors epower de ,

ve l oped wi ll va r y d i re ctly a s the a ppli ed frequen cy For .

e xa mple a60 cycle 50 h p motor ope ra

,
-
,
- . te d on 2 5 cycles a t
p e r c e n t of i t.s o ri g i n a l volt ag e would d e ve lop t h e s a m e

n o rm a l full lo a d tor que whi ch would be

-
,
hp .

C ha ng i n g fr om 2 5 to 60 cycl e s A cha n g e fr om 2 5 cycl e s t o

—

60 cycles ca n oft e n be m a
, de by i mpres si n g twi ce t h e volta ge
on t h e coi ls on 60 cy cles a s on 2 5 cy cl es A 220 volt 2 5 cy cle
.
-
,
-
 28 0 A R M A TU R E WI N DI N G A N D M OTOR R E P A I R

motor op era te d on 440 volts 60 cycles wi ll h a , ve a ,bout double

t h e ho rs e powe r Th e o re ti ca
. l ly thi s s hould be 60
,
25
ti mes t h e volt a g e i ns t e a d of twi ce a
,
n d t h e r e s ul ti n g hors e
,

power would be ti mes I n thi s ca . s e s uppo s e t h e moto r

wa s co n n e ct e d i n s e ri e s s ta r f or 440 volts on 2 5 cy cl es a n d i t is

d es i red to run i t on 440 volts 60 cy cles I t s hou ld the n be, .

co n n e ct e d i n p a ra lle l s ta r a n d ru n on 440 volts wh i ch wo ul d ,

ha ve t h e s a me eff e ct a s i mp r e s s i n g 880 volts on t h e o r i gi n a l

s e ri e s co n n e cti o n On 60 cycl es t h e motor would th e n ru n
.

t i m es a s fa st a n d de ve lop a bout twi ce t h e hors e powe r .

S i x ty cycle M otors on 50 cycl e C i rcu i ts

- - S i x ty cy cle moto rs
.
— -

a r e ofte n r u n on 5 0 cy cl e s wi thout ch a n ge Fr om t h e r u le .

a bove th a
, t t h e volta ge mus t va r y wi th t h e f re qu e n cy to k ee p

t he sa me m a g n eti c d e n s i ti e s i t wil l be n ote d tha

, t t h e d e ns i
ti es on 50 cy cles a t t h e sa me volta ge wi ll be s i x fif t h s of t h e -

60 cycl es d e n s i ti es Th e moto r wi ll th e n op er a
. te a s i f i t ha d
1 20 pe r ce n t of n orm a . l volta ge i mpress e d Thi s wil l res ult i n .

i n crea s e d i ro n los s e s wh i ch m a ,
kes t h e motor hotte r a nd t he ,

de cre a s e d s pe e d on 50 cy cl e s wi th t h e s a m e n umbe r of poles

a l so m a k e s t h e ve n t i l a ti o n poorer s o tha t t h e output of t h e
,

m oto r i n ho rs e powe r s hould be r e du ce d to k ee p do wn t h e cop

p e r lo ss e s .

A n othe r po i n t th a t s hould be wa t che d i n cha n gi n g f r e qu e n cy

i f t h e moto r h a s a s qui rr e l ca ge rotor i s to m a

- ke s ure tha
,
t the
r oto r w i n d i n g h a s e n ough re s i s t a n e to g i v e t h e pr ope r s t a rti n g

to rque A s t h e fr e que n cy i s r a
. i se d t h e r e s i s ta n ce of t h e s ho r t

ci r cu i t i n g r i n gs a t t h e e n d s of t h e r oto r wi n di n g s hould
be i n cre a s e d to k e e p t h e s a me r el a t i ve v a lue of s ta r ti n g to r que

to full loa
- d torque A s lo n g a . s t h e m otor s t a r ts i t s lo a d sa ti s
fa ct oril y n o ch a n ge i s n e ce s s a ry but i f t r oubl e i s e x p e ri e n ce d
, ,

t h e s hort ci r cui ti n g ri n gs m a
-
y h a v e to b e c h a n g e d f o r o n es of
hi gher re s i s ta n ce C o n ve rs ely wh e n d e cre a
.
,
s i n g t h e f r e que n cy

t h e r es i s ta n ce ca n be r e du ce d to a dva n ta ge ther eby cutti n g ,

down t h e rotor C opper loss a n d t h e h ea ti n g .

C ha n g e i n Frequ en cy wi th S a m e S peed I n thi s ca se t h e

.
-

n umb e r of pol e s mus t be ch a n ge d i n t h e s a me r a ti o a s the

fre que n cy or a , s n ea r ly s o a s po s s i bl e For e x a mpl e i f a

.
,

motor h a s four pole s a n d i s op e r a te d on 2 5 cycles i t wi ll ,

ha ve asyn chr o n ous s pe e d of 3 000 4 750 rpm I f t h e .

28 2 A R M A TU R E WI N DI N G A N D M OTOR R E P A I R

I t is ea
si er to re- wi n d t ma
or re c n n e c o
chi n es for 60 25-cycle
cy cl e s th a n i t i s to r e co n n e ct 60 cy cl e m a
- chi n es for 2 5 cy cles
.
-
.

Thi s follows logi ca lly from t h e physi ca l fa ct th a t the re is more

coppe r a n d mor e i r o n i n 2 5 cy cl e m a ch i n es f or t h e s a
-
m e ho rs e
power volta ,
ge a n d r pm tha n i n 60 cy cl e m a
. ch i n e s I t is
-
.

a lwa ys e a s i e r to m a ke cha n ge s wh e r e th e re i s al a rg e r s upply

of ma la
te ri a va i la ble A n other con di ti o n th a
. t is aga i n s t ch a ng

i n g t h e n umb er of poles on as qui rre l ca ge motor i s t h e cur -

r e n t i n t h e s hor t ci r cu i ti n g ri n gs of t h e r oto r wi n di n g
- T h es e .

ri n gs a re i n n e a rly t h e s ame re l a ti o n a s re ga r d s cu rre n t th a t

t h e p ri m a ry core is a s r e ga rds m a g n e ti c flux Tha t is t h e .
,

tot a l se con d a ry a mperes whi ch r e m a i n nea

,
rly t h e s a m e if
t h e r e co n n e cti o n i s do n e pr op e rly a
- re d i vi de d i n to a s ma
,
n y ci r

cu i t s a s th e r e a r e poles a n d i t fo l lows a
, t o n ce th a t t h e s ma ller
t h e n um b e r of pole s t h e l a r ge r mus t be t h e cr o ss s e ct i o n of t h e -

s ho rt ci r cui ti n g ri n gs a lthough t h e tota l s eco n da ry a

'
-
,
mpe res
re m a i n ne a rly t h e sa me A ltoge th e r t h e pos si b i li ty of re con
.
-
,

n ect i n g for d i ff e r e n t n umb e rs of pol es wh e n ch a n gi n g freq ue n cy

i s u s ua lly ama tte r for t h e de si gn i n g e n gi n eer t o i n ve sti ga te .

C ha
ng e s i n t h e N um be r of P ol e s , a
ll Ot h e r C on di t i on s

R em a
i n i ng t h e S a m e Th e . d for s u ch cha
—
n ges com e s
n ee

from t h e de s i re to s pe e d up or s low do wn t h e d ri v e n m a ch i n e

to mee t n e w re qui re m en ts I t m i ght be b roa . dly s ta te d th a t

the re a re m a n y ca s e s whe re ach a n ge of two pol es i s pe rmi s

s i ble a
, s for e x a mple cha n gi n g fr om fou r pol es t o s ix or fr om
, ,

t e n to ei ght a n d t h e li k e ; T h e ch a n ges woul d co n s i s t i n re

a r ran gi n g t h e ph a s e coi ls to a gree wi th t h e n e w groupi n g a nd

ch e ck i n g t h e cho r d f a cto r to n ot e i t s e fle ct on t h e volt a

,
ge .

I t i s ofte n po ss i bl e to g e t afa i r Ope r a ti n g h a lf s pe e d by con

n e ct i n g f or twi ce t h e n umbe r of pole s P ra cti ca lly a ll re .

co n n e cti o n s i n volvi n g pol e ch a n ges gi ve o nl y a fa i r o pe r a ti n g

pe rform a n ce .

Te st in g a R e -conn e ct e d M ot or A fte r amo t o r h a . s b ee n re

—

co n n e cte d or a f ter a n y ch a n ge i s m a de i n t h e wi n di n g i t s ho u ld ,

be s t a r te d up s lowly a n d t h e lo a d g ra du a lly thrown on oh ,

s e rvi n g ca re fully to s e e if th e r e a re a n y s i g n s of di s tre ss s uc h a s ,

s udd e n h e a ti n g n oi s e or m e cha
,
n i ca l vi b r a ti on I f t h e motor .

s e e ms to ope r a t e n or m a lly re a d t he a mpe re s i n e a ch ph a se

a n d t h e volt a ge a cr o s s e ach ph a s e to s e e th a t they a re ba la n ced

 RE -C ON N E C TI N G I N D U C TI ON M OTORS

a nd a r e re a s on a ble i n a moun t Th e fnil loa d curren t for th ree

.
-

pha s e 550 volts i s som e wh ere n e a r on e a mpere pe r horse

powe r for n orma l motors of mode ra te s pe e d s b e twee n fiv e a nd

2 00 ho rse power A t oth e r volt a

. ges thi s wi ll be i n ve rs e ly a s

t h e volta ge tha t is a t 440 volts three pha

, se a bout
,
-em ,

pe res per horse powe r On two pha . s e t h e cu rre n t pe r ph a

-
se

is a bout 87per cen t of t h e co rre s pon di n g three ph a

. s e va lu e -
.

I f t h e re a di n g s a s a bove look re a s on a ble athermome te r s hould

be pl a ce d on t h e s t a tor i r on a nd a n oth e r on t h e s t a tor coi ls a nd
‘

re a d a t 1 5 mi n ute i n ter va
- ls for a n hour a nd a t ha lf hour i n ,
-

te rva lathere a fter un ti l t h e te m pe ra

,
ture i s co ns ta nt Th e .

s p e e d should be ch e cke d a t i n te rva ls I f t h e rpm s hows a . .

te n de n cy to de crea se r a pi dly or fa ll below 90pe r ce n t of syn .

ch r on ons s pee d i t m a y , b e s u s p e c t e d th a t t h e r oto r h a s too

mu ch res i s t a n ce a n d i s ge tti n g hot B y ma ki n g a l l thes e
.

che ck s re a s on a
, ble a ss ura n ce m a y b e h a d th a t t h e r e c o n n e c

ti o n i s s a ti sf actory .

E fi ect s of Hi g h a n d L ow V ol ta g e on M o t or O p e r a ti o n .

A ll ch a n ges i n a lte rn a ti n g curre n t motors whether of ph a

- se ,

volt a ge poles or fre que n cy m a

, y b e co,
ns i d e re d a s vol t a g e

ch a n ges a n d re du ce d to s u ch te rm s I n ma ki n g s uch ca . lcul a

t i o ns a n d compa ri n g t h e res ul ts i t i s a dvi s a ble not to a
,
pply a
volt a g e th a t d ifl e rs f r om t h e r a t e d volt ag e by mo r e th a n plu s

or m i n us 1 0 per ce n t Th e ge n e ra .l efle ct of hi gh a n d low

v olta g e m a y b e e x p r esse d b r i e fly as follow s

= I n crea
s s es a g n e t i c den s i t y
m .

-
é , se s m a
I n cre a g n e t i z i n g cu rre n t .

s De crea l ea ka a a a
”
s es
“
g e c u rren t ( l e k g e re ct i v e c om p o n en t ) .

g I n crea s es sta r t i n g t o r qu e a nd m a x i m u m t or qu e .

aDecrea s es s l i p or ch a n g e in s pe e d from n o l oa d t o ful l l oa d .

fi D eases se con da ry coppe r l os s

a
ec r .

c I n cre s e s i ron l oss .

y U sua ll y decrea s e s p owe r-fa ct or .

i Ma.
y i n cr eas e or d e creas e e ffi ci e n cy an d h ea t i n g , de pe n d i n g u pon

t h e proport i on s of p ri m a ry coppe r l oss a n d i ron l oss i n t h e n orm a l

ma ch i n e and a l so t h e deg re e of s a t u rat i on i n t h e i ron .

j L ow V ol ta
'

E ect o f g e

0 Decreas es
. ma
g n e t i c d e ns i t y .

b Decre a
. se s ma
g n e t i z i n g cu rren t .
2 84 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

c . I n cre a ka
se s l e a ge cu rre n t .

d De cre a
. s es st a
rt in g a
nd m a
xi m u m tor qu e .

e . I n cre a
se s sl i p .

f . I n cre a
s es s e con d a
ry coppe r l oss .

9 De c
.r e a
s e s i ron l oss .

It . ll y i n crea
U su a s s po
e w e r- fact or .

i . Ma y i ncrea se or de cre a s e e ffici en cy n d h ea

a t i ng , de pen d in g u pon

t h e propor t i on s o f pr i m a r y cop pe r l os s an d ir on l oss in t h e n orm a

l
m a chi n e a
nd a l s o t h e d e g r ee of s at u rat i on i n t h e i r on .

Opera t i n g S ta n a
d r d A l tem afi n g -c urr e n t M o t o r s o n Difl e r

e nt V ol ta g e s an d F r e qu e n ci e s —
W h e n a moto r i s to be op e r

a
te d adifferen t volt a
on ge or freque n cy th a n t h e moto r wa s

d esi gne d for there s houl d be acorre s po n di n g cha

, n ge m a de i n
ci rcu i t to whi ch t h e moto r wi ll be co n n e cte d Th a t is i f th ere .
,

i s to be a n i n cre a s e i n fr e qu e n cy or volt a ge a n e qu a l d e cre a

,
se

i n volt a ge or fre que n cy of t h e ci rcui t wi ll bri n g a bout n o r m a l

re s ults P res e n t da
.
y d e s i g n -
s of moto rs c a n b e u s e d i n most
ca s es wi thout ex ce s s i ve h e a ti n g whe n t h e va ri a ti o n e i ther up
or dow n of fr e que n cy or volt a ge i s n ot more th a n 1 0 pe r ce n t .

For a n i n du cti o n motor t h e followi n g co n d i ti o ns re s ul t wi th

ach a n ge of freq u e n cy or volt a ge

1 P ull out to rque a
.
-
n d s ta r ti n g to r qu e v a ry a s t h e s qu a re

of t h e volta ge a n d i n ver se ly a s t h e s qu a r e of t h e f r e qu e n cy .

2 Th e C oppe r los s i n t h e pri m a

. ry v a ri e s a s t h e s qu a r e of

t h e curr e n t Th e cu rr e n t v a
. ri e s i n ve rs e ly a s t h e volt a ge but ,

i s n ot a ff e cte d by ach a n ge i n fr e qu e n cy e x ce pt to t h e s li ght ,

e x te n t pr odu ce d by ch a n ge s i n m a gn e ti z i n g curre n t Th e .

s e co n d ary copp e r lo s s a n d s li p t e n d to v a ry i n ve rs e ly a s

t h e s qu a re of t h e volt a ge but thi s t e n d e n cy i s modi fi e d by

,

t h e ch a n ge s i n pri m a r y I R d r op a n d ma g n e ti c l e a ka g e Th e .

s e co n d ar y copp er los s a n d s li p r e m a i n co nst a n t wi th ch a n ge

i n fre qu en cy .

3 Th e i r o n lo ss i s compo se d of hys tere s i s a

. n d e ddy cu rr e n t

loss es Th e hys teresi s los s va

. ri e s a s the power ofthe flux ;
t h e e ddy curr e n t lo ss v a ri e s wi th t h e s qu a r e of t h e flu x ; a nd

t h e flux v a ri e s di re ctly a s t h e volt a g e an d i n v e rs e ly w i th t h e

fre quen cy Th e m a .
g n e t i z i n g cu r r e n t v ar i e s d i re c tly w i t h
t h e flux ex ce pt for modi fi ca ti o ns produ ce d by s a tura ti o n of t h e
ma gn eti c ci r cui t .

4 Th e powe r f a
. cto r i s us ua
- lly d e cre a s e d by a n i n cre a se i n
28 6 A R M A TU R E WI N DI NG A N D M OTOR R E PA I R
E FFE C T ON SP EED A N D HOR S E P OWE R W HEN M or o ns A R E OPE R A TE D

O N D I F F ERE NT V OL T A GE S A N D FR E Q U E N C I E S

2 20 vol t s , 25 cy cl es 2 50 v ol t s . 33 cy cl es I n creas ed 3 3 t o 25 I n crea se d 33 t o 2 5

4 40 v ol t s , 25 cy cl es 500 v ol t s , 33 cy cl e s I n crease d 3 3 t o 2 5 I n cre a

se d 33 t o 2 5

(a
) 440 v ol t s . 60 cy cl e s 2 20 vol t s , 2 5 cy cl es R ed u ced 60 t o 2 5 R e d u ced 60 t o 2 5
440 v ol t s , 60 cy cl es 2 2 0 v ol t s , 33 cy cl es R ed u ced 60 t o 3 3 R ed u ced 60 t o 33
( b) 2 20 v ol t s 60 cy cl es 2 2 0 v ol t s 50 cy cl es R ed u ced 60 t o 50 R e d u ced 60
, . t o 50

( ) W h e re
0 g ood pow er -f ct ors a
a re a l it m a y be a
e ss e n t id vi s abl e t o u se 5 50 v ol t 60 -
,

cy cl e m ot or or a 2 20 v ol t 2 5—cy cl e ci r cu i t a
-
. n d r e du ce t h e r at i ng a ccordi n g t o t h e h e at i ng
be t w ee n 3 5 t o 45 per ce n t of t h e r a . t i ng a t 60 cy cl es :
( )
b S t an d a r d 60 c y c l
-
e m ot o rs of l i b e r a
l r at i n g can b e us e d o n a 50 -c cl e ci r cu i t wi t h
y
t h e sam e ra t i ng B es t r es u l ts a
. r e se cu r ed h ow e v e r w h e n 2 20 4 40 a
, n d 550-v ol t

m ot ors a re Op e ra t e d on 200 400 a n d 500-v ol t ci r cui t s a t 50 cy cl es .

Fa
ct or s whi ch Li m i t aC h a n g e i n N um ber of P ol e s of a n

I n du cti on M ot or Th e pri n ci p a l fa
. cto rs l i m i t i n g ach a
—
n ge i n

t h e n umb e r of poles of as qui rre l ca ge i n du cti on motor a re -

gi v e n a s follows by awri t e r i n t h e Gen era l E lectri c R evi ew

(a) Th e nu m be r of t u rns i s e i es per ph ase Th es e m us t rem a
n in t h e
r .

s a
me s i n ce the a pp l i e d v ol t a
g e is t o be u n ch a
n g ed .

( b) Th e i ns u l at i on be t w ee n t he con du ct o rs ofdi fierent ph a s es Of .

t h i s t h e re m ust be su ffici e n t to n ot r e du ce the ct or of s a

fa fe t y a gai ns t
bre ak dow n s a ft e r t h e re g rou p i n g of the con d u ct ors ha
s bee n a
c rri ed ou t .

( 0) Th e sa t u ra t i on of t h e i r on . I t is oft en dv is a
in a bl e t o u se am a
g
net ic de n s i t y m u ch h i g h er t h a
n n orm a
l .

B e ca
us e t h e d e si gn s of i n du cti o n motors va ry wi d e ly wi th

di ff ere n t m a n uf a ctur e r s a nd a ls o i n t h e produ ct of e a ch m a ke r

(for t h e purpos e of s upplyi n g motors for v a ri ou s typ es of

s e r vi ce ) i t wi ll be i mposs i bl e to m a
, ke other tha n v e ry g e n e r a l
s ta t e m e n ts r e ga r d i n g t h e e x p e ct e d ch a n ge i n ch a ra ct e ri s t i cs

of t h e moto r wh e n ru n n i n g a t t h e hi gh e r s p ee d Furth e r mo re .
,

t h e followi n g s t a te men t s mus t n ot be e x pecte d t o hold true

whe n t h e n umb er of poles h a s b ee n d e cr ea s e d s u ffi ci en tly to

ra i s e t h e n orm a l s pe e d more th a n sa y 2 5 p e r ce n t .

A ft er t h e recon n e cti on ,

a
( ) Th e n or m al s p ee d w i l l be e q u a
l t o app r ox i m at el y t h e o r i g a
i n l
n orm a
l spe ed t im es the or i g i n a
l n u m ber of pol es di vi ded by t h e n ew

nu m be r ofpol es .

( b) Th ere wi l l be as om ewh a t h i g h e r t orqu e pe r pol e exe rt ed du e t o ,

t h e s l i g h t l y i n cre a s ed flu x pe r p ol e t h a t a ri s e s f rom t h e s h or t e n ed pol e

p i t ch s
, o t h a
t t h e t o t a
l m ot or t or qu e m i g h t b e ex p ect e d t o be d e crease d
bu t li t t l e by t h e ch a ng e .
 R E -C ON N E C TI N G I N D U C TI ON M OTORS
' ’

(c ) Th e runn i n g -li g h t cu rre n t w i ll b e s li g h t l y l o w ere d .

( d ) Th e s t a rt i n g t o r q u e w il l p r o b a b l y b e s l i g h t l y d e c re as ed .

( )
e Th e p o w e r -fa c t o r m i g h t b e e x p ec t e d t o b e s om e w h a t h i g h e r .

(f ) W h e n t h e p ow e r -fa c t o r is h i g h e r t h e r a t i n g of t h e m o t or can be

i n cre a sed abou t in proport i on t o t h e s qu a re r oot of a

t h e in cre se i n s peed

w it h t h e sam e h ea t ing .

( 9) Th e e mci en cy w i l l be pra ll y t h e sa
ct i ca me a
s be fore the ch a
ng e .

S i ng l -
e c ir cui t Del t aa
nd Doubl e cir cui t
- S ta
r C onn e ct i on s .

Th e use of a i-
on e c rc de lt aa n d adoubl e or two
ui t ir cui t -c

s ta r wi n d i n g for a three pha s e moto r a -

s po i n te d out by He n r y ,

S ch e r il (E l ect ri ca l R ecor d M a r ch 1 9 1 9 ) d e p e n d s upo n Ope r a

, ,
t
i n g co n d i ti o n s or de s i g n t o mee t cert a i n re qui re m e n ts On e .

of t h e b es t i llus tr a ti o n s i s offe re d i n t h e wi n di n g of aph a se

wou n d rotor of t h e i n du cti on motor S uppo s e tha t t h e rotor

ha s b e e n woun d wi th a t wo ci r cui t s t a r wi n d i n g a
- n d t h e volt a ge
b e twe e n ri n gs on ope n ci rcui t i s 220 volts L e t u s a s s um e th a. t
t h e full lo a-
d curre n t i n t h e rotor i s 200 a mper es S i n ce t h e .

wi n di n g h a s adouble ci r cu i t ea ch ci r cu i t wi ll ta
,
ke ca re of

1 00 a mpe res Th e volt a

. ge per ph a s e wi ll be 1 2 7volts .

Ma n ufa ctur e rs i n ge n e ra
,
l s ta n da r d i z e t h e b ru s h ri ggi n g
,

use d i n con n e cti o n wi th m a chi n e s u s i n g a ce rt a i n n umb e r of

,

br us hes per ri n g I f i t i s foun d for i n s ta

. n ce th a ,
t 200a mpe re s , ,

a s i n thi s e x a mple bri n gs t h e curre n t d e n si ty i n t h e brus h to

,

too hi gh av a lue i t would me a

,
n th a t t h e n umbe r of b rus hes pe r
ri n g mus t be i n cr e a se d S i n ce thi s i s n ot p r a
. ct i ca l n or e co
n om i ca l ach a
,
n g e i n t h e co n n e cti o n s of t h e wi n d i n g m a y b r i n g
a bout t h e d esi re d r es ults th a t i s re duce t h e curre n t d e n si ty
, ,

i n t h e br us h to wi thi n t h e a llowa ble v a lue .

I f t h e wi n di n g we re th e n re co nn e cte d fr om two ci r cui t s t a r -

to si n gle ci r cui t de lta the n t h e volta

-
,
ge b e twee n te rm i n a ls
wi ll be i n cre a s e d from 2 2 0 volt s to 2 54 volts a n d t h e cu r r e n t

p e r ri n g would be r e du c e d f r om 2 0 0 a mp e r e s to 1 7 3 amp e r e s -
,

or are du cti o n of p e r c e n t T h i s r e du c t i o.n m a y j u s t b e

s u fi ci e n t to d e cre a s e t h e b ru s h d e n s i ty to t h e d e s i r e d v a lue .

S i n ce co n t rollers u s e d i n t h e r oto r ci r cu i t a re m a d e to ta ke ca re

of volta ges of re a s on a ble va ri ati o n s a n i n cre a s e i n volt a,

ge
from 220 volts to 2 54 volts wi ll n ot re qui re ach a n ge i n t h e

co n tr oll er a n d th e r e for e t h e 2 2 0 volts co n tr oll e r ca n be us e d

on t h e 2 54 v o lt ci r cui t
-
.
2 88 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

C u t ti ng ou t C oi l s of a
a coils
n I n du ct i on M ot or .
—
In c se

burn out i n a n i n du cti o n moto r th e y ca n be cu t out a nd t he ,

motor ope ra te d for ati me or u n ti l i t ca n be r e p a i r ed I t is .

advi s a ble to cut t h e e n ti re coi l a n d ta pe up t h e two e n ds so

tha t the y ca n n ot com e toge th er The re is ali mi t to t h e .

n umbe r of coi l s th a t ca n be cu t out a s thi s i s e q ui v a le n t to

rai s i n g t h e volt a ge on t h e motor whi ch wi ll ca use he a ti n g .

Whe re more tha n t w o coi l s mu s t be cu t out t h e moto r s hould

be re pa i re d at on ce or t h e s am e n umb e r of coi ls i n e a ch pha se

ou t out e v e nl y d i s tri bute d a

,
rou n d t h e s t a
tor .

P R OC E DUR E WHE N C ON N E C TI N G TH E C OIL S OF AN

I N DU C TI ON -M OTOR WI N DI N G

A t t he of thi s ch a
en d pte r typi ca l di a gr a ms for co n n e ct i n g
t h e wi n di n gs of polyph a se a ltern a tin g curre n t motors a re -

shown a s p re p a r ed by A M Dudl e y Whe n a n a rm a ture

1
. . . .

wi n d e r or re p a i rm a n k n ows t h e n umb e r of pol e s a n d ph a se s

for t h e wi n di n g a nd h a s b ee n s uppli e d wi th t h e n e ce s s a
,
ry

coi ls of t h e p rope r thr ow t h e pr obl e m of i n s e rt i n g t h e co i ls

,

a n d th e n co n n e cti n g th e m up ca n be e a s i ly u n d ers tood for

ea ch of t h e di a gr a ms refe rr e d to if t h e fu n d a me n ta l pro ce dure

for a n y on e i s u n d e rs tood T h i s pr o ce dure i s ex pl a . i n e d by
t he a utho r of t h e di a gra ms a s follows :

Th e di a gra ms a re n ot d e pe n d e n t on t h e tot a l n umber of

s lot s i n t h e m a ch i n e n or upo n t h e n umb e r of co i l s pe r gr oup ,

n or upo n t h e thr ow or p i t ch of t h e coi ls but a r e ge n e r a l for ,

a ll m a chi n e s of t h e s a me n um b er of pha s es a n d pol e s E a ch .

on e of t h e s m a ll a r cs i n e ach d i a gr a
m re pre s e n ts t h e e n ds of
t h e coi ls i n asi n gle pole ph a s e gr oup i n t h e wi n di n g T h is i s
'

- - .

il lus tr at ed i n Fi gs 1 8 7a n d 1 88 s ho wi n g a
. sta tor i n thr e e s ta ges
of b ei n g con n ected I n Fi g 1 87(A ) am a . chi n e i s s hown in
.

whi ch t h e coil s h a v e s i mply b e en pl a ce d i n th e s lot s by t h e

1
Th e di a g r a
m s s h own ha
v e be e n s e l e ct e d from as eri es of e ig h t y-on e

de vi se d by A . M . Du dl ey , E n g ineer i n dus t r i a
l di v i s i on Wes t in g
of the
h ou se E l e ct ri c M fg . C o .
, t o be in corpora t ed in a n e x ce l l e n t book by

( M c Gra
“ ”
hi m on C on n e ct i n g I n d u ct i on M ot ors .w Hil l B ook C o - .
,

N ew York M D d i a a i i h - ol e w i n di n s a d
)
’
. r u
. d l e y s g r m s b e g n w t t w o p g n

g i v e p ract i cal l y a l l p oss i bl e co m b i n a

t i on s for t w o a n d t h re e-
ph as e , st ar

and del t aa
nd se ri es-p r aa
l l el conn e ct i on s .
2 90 A R M A T UR E WI N DI N G A N D M OTOR RE P A I R

protrud e ra di a l ly towa rd a nd a wa y from t h e cen t er of t h e

ma chi n e fo rm t h e b e gi n ni n g a
,
n d t h e en d of ea ch pol e pha se -

group .

C onn e cti ng P ol e ph a
- s e g r oups of a Wi n di ng Th e oper a
- —

ti on whi ch h a s b ee n pe rfo r m e d b e twee n Fi g 1 87(A ) a n d Fi g

. .

1 8 7( B ) ca n be d e s cri b e d i n th i s w ay : S uppo se f or e x ampl e th at , ,

the re a re 96 tot a l coi ls i n t h e wi n di n g an d th at i t i s to be con

n e ct e d for th r ee ph a s es a n d four pole s There wi ll the n be 3 X
.

Fro 1 88
. .
—
Sta t or of a 1 00-h p , 3 -p h a -
. l
s e , 8 po .e 2 2 0-vol t . fill -c cl e
y . 1
20
coil , 1 2 0-s l ot , i n du ct i on m ot or com p l e t el y w ou n d wi t h pol e -p h a s e -g rou ps

p ro p e rl y cr os s con n ec t e d.

4 12 pole ph a oups a
- -
se g r n d 96 + 1 2 , 8 coi ls i n e a ch gr oup .

S ta rt i n g a t any a rbi t r a
ry po i n t t h e wi n d e r co n n e cts t h e firs t
,

e i ght coi ls i n s e ri e s by co nn e ct i n g t h e e n d of co i l N o 1 to t h e .

be g i n n i n g of coi l N o 2 a n d t h e e n d of co i l N o 2 to t h e b e gi n
.
,
.

ni n g of co i l N o 3 e t c
.
,
un ti l e i ght coi ls a
.
,
re i n s e ri es Th e .

be gi n ni n g of coi l N o 1 i s the n b e n t outwa

. rd a n d l e ft lo n g and

t h e e n d of coi l N o 8 i s b e n t i n w a
. rd a n d l e ft lo n g B e twee n .
 R E -C ON N E C TI N G I N D U C TI ON M OTORS

thes e two a r e s e ve n s ho r t s tubs or co i l to co i l co nn e ct i o n s - -

,

whi ch a re s hown t a pe d up i n Fi g 1 87( B ) Th e wi n de r the n . .

p r o cee ds t o co nn e ct coi ls N o 9 to N o 1 6 i n se ri e s i n t h e s a
’

. me .

m a nn er t o fo r m pol e ph a s e group N o 2 a un d so on a rou n d t h e

- .
,

ma chi n e u n ti l h e h a s comple t e d 1 2 pol e ph a s e g r oup s a nd - —

us e d a ll t h e co i ls Th e wi n d i n g th e n look s a
. s s how n i n Fi g .

1 8 7( B ) .

a t h e wi n d i n g h a
In c se i n co i ls pr ovi d e d wi th h e a
s ce r t a vi e r
i n s ul a
ti o n on t h e e n d tu rn s to t ake t h e s t rai n of t h e full volt a
ge
A B

Fro . 1 89 .

FI G . 1 90 .

F ro . 1 91 .

FIG . 1 92 .

Fro . 1 93 .

Fro . 1 94 .

FI G 1 89 .
T hi r t y -t w o
.
—
c o i l s co n n e c t e d i n t o 8 p o l e -
p h a se — r ou
g p s f o r a
2 -p h a se wi n d i n g .

FI G 1 9. 0 —
S am e a
. s F i g 1 8 9 w i. t h p o l e -
p h a s e -
g r o u p s c o n n e c t e d a c c o r d i ng

t o d i r ect i on of a rr ow s .

FI G 1 9 1 —
S am e a s F i g 1 9 0 w.i t h B -
ph a s e r e v e rs e d .

r a
. .

FI G 1 9. 2 —
F o y
r t - e
. i g h t c o i l s c o n n e c t e d i n t o 1 2 p o l e -
p h a s e -
g r o u p s f o

3-p h a s e wi n di n g .

FI G 1 93 Sa m e a s Fi g 19 2 w i t h o l e - h a s e - r o u p s c o n n e ct e d a c c or d i n g
.
—
. .
p p g
t o d i re ct i o n of a r ro w s .

FI G 1 9 4 Sa a F i 1 9 3 t l a d a b h t t f m d i ff nt
’

m e e e s r e r o u g o u r o e r e
x c p
—
. e . s g .

g r ou p s .

of t h e ma chi n e whe re di ff er e n t ph a s es a re a dj a ce n t t h e op e r a ,

ti on i s sli ghtly di ff e re n t I n thi s ca s e t h e n umb e r of co i l s pe r

.

pole pha -
se g roup mu s t b e -d e t e r m i n e d b e fo r e t h e co i ls a r e

t d
i ns e r e i n t h e s lot s a n d t h e s p e ci a,
l ly i n s ul a t e d p h a s e co i l s

pla ce d on both e n d s of e a c h g r oup I n th i s c a s e t h e lo c

. at i o n
292 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

of t h e pol ph a g roups is de fin i te ly de te rm i ne d by t h e wi n de r
e- se -

b efore h e sta rts co n n e cti n g t h e co i ls toge the r .

Th e n ext s te p i s t o m a r k t h e pol e ph a s e gr oups A B C A - - e — —

B C et c a
—
, r ou n d t h e m a
.
,
chi n e an d th e n to co n n e ct a ll the
groups toge ther i n t h e prope r m a n n e r t o form athr ee ph a se -

wi n di n g as i n di cate d by t h e di a gr a m of co nn e cti ons Th e .

compl e t e d wi n di n g wi ll the n a ppe a r a s s how n i n Fi g 1 88 . .

G e n e ra
l Th e ory on w hi ch C onn ecti on Di g r m aas a
re C on
s t ru ct e d . fi me thods by whi ch a
S i m pl e n y wi n d i n g m a y b e

ch e ck e d f or ph a s e pol a ri ty a re s how n i n Fi gs 1 8 9 to 1 94 i n .
,

elus i ve .I n Fi g 1 89 awi n di n g cho s e n a

. t ra n dom i s s hown

s tubb e d i n to pole pha s e g r oups f or a two pha s e co n n e ct i o n

“
- - -
,

a n d i n Fi g 1 9 2 s tubb e d f or a
. thre e pha s e co n n e cti o n -
To de .

te rmi n e t h e proper co n n e cti o ns for t h e pole ph a s e g r oups i n a - —

two pha -
se wi n di n g t h e r ul e i s to m a
,
rk on t h e gr oups a rr ows

a lte rn a ti n g i n di r e cti o n i n p a i rs Th a t i s on two s u cce ss i ve

.
,

groups t h e a rr ows a re clo ckwi s e a n d on t h e two im m e d i a tely

a dj a ce n t t he a
,
rr ows a r e cou n t er clo ck wi s e S u ch a rr ows
-
.
,

for e x a mple a r e s how n i n Fi g

,
1 89 j us t a bove t h e wi n d i n gs
. .

I f n ow on e e n d of a n y gr o up i n aph a s e i s cho s e n a s a le a
”
d “

a nd a l l t h e g r oups a r e followe d th r ough a n d co nn e cte d a s i n di

ca t e d by t h e a rr ows t h e co n n e cti o n wi l l be co rr e ct
,
S u ch a .

co n n e cti o n i s s how n i n Fi g 1 90 Howe ve r s uppose t h e a

. . r r ows ,

ha d a lte rn a te d i n p a i rs but s t a rt e d wi th a
,
di ff ere n t g roup a s ,

s how n j us t b e low t h e wi n d i n gs i n Fi g 1 90 Th e re s ul t i s s hown . .

i n Fi g 1 9 1 whi ch i s jus t a
.
, s co rr e ct a s Fi g 1 90 e x ce pt th a t the .
,

motor would ru n wi th t h e Oppos i te di re cti o n of rot a ti o n .

S i n ce t h e r ot a ti o n ca n be ch a n ge d by r e v e rs i n g t h e two l e a ds
of e i ther pha s e out s i d e of t h e motor i t i s e vi d en t th a t t h e rule
,

usi n g t h e a rr ows a lte rn a ti n g i n p a i rs i s co rre ct i n a ll ca s es .

I t s hould a ls o be n ote d th a t i t ma ke s n o d iff ere n ce from wha t

group t h e le a d i s ta ke n provi de d a l l t h e g r oups a
, r e followe d

through wi th t h e a rr ows .

I n t h e three ph a s e ma -
chi n e t h e m e thod i s e v e n mo re s i mpl e .

Th e r ul e i n th a t ca s e i s to put a rr ows on t h e gr oups a ltern a ti ng

i n d i r e cti on fr om g roup to gr oup a s s how n i n Fi g 1 92 , A ny . .

group m a y th e n be cho s e n a s a l e a d g r oup o r a “

s t a r

g r oup s o lo n g a s the a rr ows a re followe d i n p a ss i n g fr om t h e

le a d to t h e s t a r i n ea ch ph a se Fi g ure 1 93 s hows on e a
. rr a n ge
294 A R M A T URE WI N DI N G A N D M OTOR RE P A I R

corr e ct nu m be r of poles is proba bly t h e ne xt lowe r e ven

n umbe r whi ch wi ll a ga i n be 8
. Thi s i s n ot a n i n va ri a
bly
corre ct ru le . A furthe r check i s a s follows : Di vi de t he
n umb er of s lots by t h e n um b e r of ph a ses
. I f th i s n u mber
i s d i vi s i bl e by t h e n u m be r of poles ob t ai ne d as a bove i t m a
, y
be sa fe ly a s s u me d th at t h e correct num ber of pol es h a s been

de termi n ed .

Typi ca aa
l C i rcl e Di g r m s f or C onnect i ng I nduct i on M ot ors .

On t h e foll owi n g p age s , 295 to 300 typ i cal wi n d i n g di a g r a

m s

ar e s how n by whi ch i n du cti o n moto rs m a y be c o nn ec t e d for

ava
ri e ty of op er a
t i n g co n di ti o n s .
3 02 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

hot from t h e poor brus h co n ta ct a fiorde d th a t t h e s olde r

,

wi ll be me lte d a n d th rown out re s ulti n g i n s ho rt ci r cu i ts

,
-

be twee n b a rs a n d ope n ci r cui t s du e to t h e a

- rm a tu re le a ds
be comi n g di sconn e cte d A bout t h e o nly perm a
. ne n t re li e f fo r

s pa r ki n g a t b ru s h e s du e to h i gh mi cai s u n d e rcutti n g t h e mi ca .

Thi s re me dy i s recomm e n de d whe n i t i s rea s on a bly cert a i n tha t

t h e h i gh m i cai s ca us e d by t h e n a tura l con di ti on of t h e coppe r
or m i ca I f i t i s n ot
. the n t h e re a
,
l ca us e mus t be foun d ,

otherwi s e un d e r cutti n g t h e mi cawould p rob a

,
bly i m p rove
t h e run n i n g co n d i t i o n s om e wh a t but would fa ,
i l t o re move t h e
ca u se .

Th e mi cas hould n ot be cu t too d ee ply ad e pth of % 2 to % 6 ,

i n ch b e low t h e s urfa ce of t h e copp e r b e i n g s uffi ci en t Ca re .

must be exe rci s e d to remove t h e mi cat h e full wi dth of t h e

s e gm en t for a,
n y thi n s li ve r s l e ft flu s h w i th t h e s urfa ce wi ll

ofte n d e fe a t t h e purpos e of t h e un d e r cutti n g (For deta i ls

.

for u n d e r cutti n g m i ca s e e p a ,
ge T hi s m e thod h a s

co rr ecte d s om e s tubbo rn ca s es of s p a r ki n g a n d i f t h e job i s

prope rly don e a l l th a

,
t wi ll be ne ces s a ry to p re s e rve S p a r kl e s s

commut a ti on i s to ke e p t h e s lots cle a n a n d we ll be low t h e

s urfa ce of t h e copp e r .

R e m e dy f or Hi g h or L ow B a rs A ne w or re pa
.
-
i red motor
ma h a v a ommut a to th at i ttl d h a t i h
“
y e c r s n o t s e e T s .t e ,

cla mpi n g ri n g h a s n ot b e e n d ra wn up a s t i ghtly a s i t s hould be .

Wh en t h e mi caen d ri n gs a r e cu t th e y a re o n ly s li ghtly fl exi ble

du e t ot h e sh el l a c i n th e m a n d ca nn ot be m a de to fit pe rfe ctly
wh en cold Wh e n t h e commut a
. tor i s hot t h e s hell a c in the
, .

mi cawi ll s often a nd a llow i t to move un de r t h e s tra i n of t h e

ce n t ri fuga l force of t h e b a rs wh en t h e m a chi n e i s ru n ni n g .

Thi s move m en t of t h e mi caa llows t h e b a rs to move a nd is

fre quently t h e ca use of hi gh or low b a rs To re m e dy thi s

.

troubl e t h e ma
, ch i n e s hould be ru n un t i l i t s n o rm a l op era ti n g
t e mpe ra ture i s a tta i n ed a n d th en s hut down Th e cl a mp .

i n g ri n g ca n th e n be t i ght e n e d Thi s p ro ces s m a

.
y b e n ec e s

sa ry s e vera l ti mes or un ti l t h e commuta

,
tor i s p e rfe ctly soli d .

Ca re mu s t be t a ke n n ot to ti ghte n t h e bolts too mu ch whi le

t h e commuta tor i s wa rm .

I n t h e ca s e of a hi gh ba r i t s hould be t a
,
ppe d down un ti l it
res t s fi rmly a gai n s t t h e mi caen d ri n gs I t ca n th e n be fil e d
.
 C OM M U TA TOR R E P A I RS

eve n wi th t h e t of t h e ba
res rs A low ba r ca
. n be ra i se d by
pryi n g up a n d i n s e rti n g an a
,
rr ow s t ri p of mi cab en e a th i t ,

but i n t h e m a j ori ty of ca s es thi s m a kes apoor j ob Us u a l ly .

t h e o n ly a lte rn ati ve i s t o turn t h e commuta tor down t o t h e

l e ve l of t h e low ba r .

B urn ou t B e t we e n B a
- rs P r ob a
. bly t h e mos t fre que n t com
—

m ut a to r trouble i s abu m o ut be twee n ba

- rs I t o ccurs ofte n
.

on t h e co rn e r of t h e b a rs a n d i s n ot i n fre qu en tly ca
,
use d by

2 22 . M i case g m e n t s t a
—
ke n from da m a g e d m ot ors s h o w i n g t h e e fle c t s
of s h ort ci r cui t s i n t h e com m u t at or T w o t ool s a
. re a
l s o s h ow n m a d e fr om
ha ck s a w bl a d es for u se i n pl u g g i n g acom m u t a t or .

oi l worki n g a lon g t h e s ha ft from t h e be ari n g a n d up on t o t h e

co m mut a tor Thi s oi l colle cts dus t a

. n d di rt a n d fin a l ly
ca us es curre n t t o le a k from on e ba r to t h e oth e r Th e mi ca .

then be come s ca rbo n i z e d a n d as ho rt ci r cui t re s ult s

,
- Thi s .

i s on e of t h e ca uses of burn e d o u t a rma tu re coi l s S ome ti m es

- .

t h e s hort ci r cui t wi ll burn i ts e lf cl e a

- r a n d n o ha ,
r m w i ll be

ca us e d ex ce pt to burn ahole i n t h e mi ca H owe ve r i t m a .

y ,
3 04 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

o ti nue to a
c n re a cro ss a n d b urn agood s i z ed h o le i n t h e b a rs

a ls o .

P l ug g i ng aC om m uta t or Whe n m i cas e gme n ts a

.
—
re burn e d

but n ot t oo de e p t h e holes ca ,
n be cl ea n ed wi th athi n kn i fe

bla de a n d plugge d wi th s ome ki n d of fil li n g I f agood fil li n g

.

compou n d i s us e d a n d t h e commuta
,
t o r ke pt free fr om oi l i t ,

wi ll hold for ayea r or poss i bly lon ge r I t is a

. lwa ys a dvi s a ble
to sa ve t h e w e a ri n g s u rf a ce i n thi s m a n n e r whe n e ver i t ca n be

do n e for e ve ry ti me acommuta
,
tor i s turn ed down i n ala the
on a n a vera ge of three ye a rs of i t s us e ful li fe i s lo s t .

A good fill i n g compou n d for commuta tors ca n be m a de a s

follows : Two pa rts pl a s t e r of p a -

ri s ; on e p a
-
r t powd e re d m i ca ;
a nd e n ough glu e to m a ke athi ck pa s te Thi s wh e n a ppli ed
a
.
, ,

wi ll dry qui ckly a nd a

,
s s um e a bout t h e s me deg ree of ha rd

n es s a s t h e mi cas e gm e n ts .

Wh en as e gmen t b e comes burn e d de e p down i n to t h e com

muta tor an e w on e mus t be i ns erte d B efo re a
,
. tte mpti n g to
do thi s t h e a
,
rma tu re s hould be thoroughly blown out wi th com
p re s s e d a i r i n o r d e r to re move a ll du s t th a t ma h a v a u
a
y e cc

m ul a t ed .Thi s i s e ss e n ti a l for i t i s a
,
n e sy ma tter for s ma ll
pa rt i cl e s of fo re i gn m a tter t o work in un der t h e ba ck e n d be

twe e n t h e ba rs a n d t h e s le e ve wh e n t h e commut a tor i s loose .

De t e rmi n e j us t wh i ch mi cas e gme n t s mus t be ta ken out a nd ,

n umb e r t h e b a rs a t ea ch bu m out s i n ce t h e b a
-
,
rs m a y h av e to
be re move d a ls o i n o rde r to g e t t h e mi case gm e n ts ou t If .

t h e s e gm e n ts w e re n ot s h ell a ce d wh e n t h e commut a tor w a s

bui lt t h e ch a
, n ce s a re th e y ca n be li ft e d out w i thout di s turb

i n g t h e ba rs Oth e rwi s e t h e ba
. rs wi ll h a ve to be ta ken out
,

wi th t h e se gm en ts .

R e m ovi n g B a rs a n d M i ca S e g m e nt s for R e pa i rs R e move —

.

t h e bolts th a t hold t h e cla mpi n g ri n g i n pla ce Ma rk t h e

.

ri n g s o th a t it m a y b e put b a c k ju s t a s i t w a s t a k en o ff T a p .

t h e e n d of t h e ri n g li ghtly wi th ah a mme r I f t h e mi cari n g

.

doe s n ot loos e n from t h e commuta tor i t wi ll ha

,
ve to be hea te d ,

a s t h e ri n g i s p rob a bly s tu ck fa s t wi th s h e lla c He a t the .

commut a t o r w i th ato r ch t o a n e v e n t e mp e ra ture a ll a r oun d .

Thi s wi ll e x p a n d t h e copp e r a n d ca us e i t to bulg e out from t h e

e n d ri n g Ta.
p t h e r i n g a g ai n l i ghtly a n d i t,
w i ll be fou n d t o

work loos e The n i t ca . n be pull e d out .

3 06 A RM A TUR E WI N DI N G A N D M OTOR R E P A I R

aba r wi th a burn e d pla ce a n d ( B ) t h e m e thod of re pa ir In .

thi s ca s e t h e bar wa s cu t down e n ough to re move t h e bu rn ,

a n d api e ce of copp e r s t r i p ca re fully s qua re d a

\

n d s old er e d i n

t h e cu t I t wa
. s th e n ri v e te d wi th as m a ll coppe r ri ve t t h e ,

lo ca ti on of whi ch i s s hown a t (X ) Th e ri ve t w a
. s u se d t o

p rev e n t t h e p a t ch from flyi n g out s hould t h e commuta tor for

a n y re a s o n b e com e hot e n ough to m e lt t h e s old e r . S u ch a
pa t ch s houl d be fil e d down to t h e di me n s i on s of t h e ba r . Th e
cu t for ap a t ch of thi s ki fid ca n be qu i ckly m a d e i f ami lli n g
ma ch i n e or s h a p e r i s h a n dy oth
, e r w i s e a good s h ar p fi l e wi ll s e rv e
t h e pur po se .

R e pl a ci n g aR e pa i r e d C om m u ta t or B a B e fo re re pla ci n g
‘

—
n

acommu ta tor ba r th a t ha s be e n r e p a i re d a n i n s p e cti o n s hould

,

be m a de of t h e b a ck mi ca r i n g to be s u re th a
,
t n o dus t or s older
ha s lodge d th e r e . Th e mi cas e g m e n ts s ho ul d be re pl a ce d

firs t a,
n d th e n t h e ba r pus h e d i n .S ha pe t h e com m ut a tor
a s n ea rly a s pos s i bl e i n to aci r cul a r fo r m a n d re pl a ce t h e e n d

ri n g . Ti ght e n t h e cla mpi n g n uts a s mu ch a s po ss i bl e wh i le

t h e commut a tor i s cold I t i s agood pl a

. n to p a i nt t h e en d
of t h e commuta to r wi th s h ell a c i n o r d e r to fill up a
,
n y cra cks

tha t ma y e x i s t b e tw e e n t h e b a r s a n d t h e r i n g .

Ti g h t e ni n g up aR e pa i r e d C om m u ta t or Wh en acom m u
.
—

ta tor h a s be e n t a ken down i n are pa i r s hop a nd a ss e mbl e d

a ga in a l l l ook n uts a
,
n d s cre ws s hould be fir st s e t up h a rd

a nd t h e commut a tor b a ke d i n a n oven . Th e n t h e lo ck n uts

a n d s cre ws ca n be ti ght e n e d up a ga i n s i n ce t h e h e a ti n g ca us e s
t h e copp e r to e x p a nd a n d put p re s s u re on t h e m i cawh i ch ,

comb i n e d wi th t h e h ea t d ri ves out a

,
l l t ra ces of s h e ll a c in the

mi ca Th e n a
. s t h e commut a tor cools a n d t h e coppe r b e com es

n o rm a l t h e bolts ca n be t a k en up Thi s pro ces s s hou ld be

.

re pe a te d a n d fin a lly t h e commuta tor coole d qui ckly by afa n

,

a n d t h e n uts t ri e d a ga in. I f th e y s e e m ti ght t h e commut a tor

i s re a dy f or a s s e mbly on t h e a
. rm a ture s ha ft I t re qui re s s ome
.

ex p eri e n ce to d e t e rm i n e jus t how t i ght t h e bolts ca n be d ra wn

on acommut a tor wi thout i nj uri n g t h e m i cae n d ri n gs Th e .

on e p r e ca uti on i s n ot to d ra w up t h e bolts fin a lly u n ti l t h e

commut a tor h a s cool e d . Th e commut a tor s urfa ce ca n n ow

be tu rn e d dow n i n al a th e A fte r do i n g thi s as hort ci rcui t

.
-

t es t s ho ul d be m a d e wi th ates t la mp from ba r to ba r . Fa i lure

3 08 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

of t h e la mp to li ght i n di ca tes tha t t h e commuta tor i s free from

s hor t ci r cui ts
-
S ee a . lso C h a pte r V pa ge s 1 2 3 1 2 6 a ,
n d 1 35 , .

A t es t for g roun d s s hould a lso be m a de at thi s ti m e (s e e pa ges

1 31 a nd

Ba ki ng C om m u ta t or wi t h E l e ctri c H e a t I n thos e ca s es
.
—

wh ere a n ov en i s n ot a va i labl e for b a kin g ar ebui lt commuta tor

a n d i t i s too l a r g e to h ea t wi th ato rch t h e el ectri ca l m ethod
,

s ho wn i n Fi g 2 26 h a s b e en s u cce
. s s ful ly us ed ( A lb ert Kra us e ,

E l ect r i cal Wor l d J ul y 26 1 9 1 9 pa

, g e 1 90) A s a
, , ctor y h e a
t i sf a t
i n g el em en t ca n be m a d e up by usi n g al a yer of H G l n a sbe s tos -
.

pa per a r o un d t h e commut a tor a n d wi n d i n g ov er thi s a bout

FI G . 226 .
—
t ur e p r od u ce d by h e a
U n i for m t e m pe r a ti ng el em en t w ou n d a
rou n d

com m u t at or .

90 ft of N o 2 2 N i chrom e r es i st a
. . n ce wi re By a pplyi ng .

2 50 volts to t h e t erm i n a l s of thi s r es i st an ce wi r e au n i form

h ea t i n t h e commuta tor ca n be p r odu ced to p er m i t e v eni n g up

t h e i n s ul ati n g s egm en ts a n d cl a
mpi n g t h e en d ri n gs Ordi .

na ril y i t wo ul d be a dvi s a bl e to ha ve ava ri abl e res i sta n ce i n

s e ri es wi th t h e h ea ti n g elem en t so i t s t emp era ture ca n be k e pt

a t ad es i r a bl e va lu e B y coverin g t h e a
. rm a ture a ft er t h e
commut a tor i s h ea t ed i n thi s ma n n e r va rn i s h m a y b e a ppli ed
th ereto a n d ba k ed i n by t h e h ea t con duct ed to t h e a rm a ture
through t h e l ea ds from t h e commut a tor .

R e m ovi n g a n d R e pa i ri n g Groun d s i n aC om m u ta t or Th e .
—
31 0 A RM A T UR E WI N DI N G A N D M OTOR R E P A I R

Sp raki n g a n d bu rn i n g a t t h e poi n t of t h e cutti n g tool due

to i t s s hort ci rcui ti n g t h e b a
- rs wh e n i t cr o ss es t h e m i ca Th e .

tool h a s to be s h a r p e n e d f re qu e n tly a nd a j ob i s seldom good

e v e n w h e r e t h e gr e ate s t ca r e i s e x e r ci se d .

For th e s e re a s on s i t i s a lwa ys prefe ra ble to be lt t h e m achi n e

to as e pa ra te motor a n d turn down t h e commut a tor wi th

t h e fie lds u n e x ci t e d I n co n n e cti n g up amoto r for d ri vi n g
.

t he a r ma ture t h e s peed s hould be m a de a s low a s pos s i bl e ,

pr e f e r a
bly n ot ove r 75 revoluti on s pe r mi n ute .

Te m pora ry C ove r f or U s e Wh e n Turn i n g D own a Gom m u

ta t or . I n ca
—
s es wh e r e i t i s n e ce s s ary to turn dow n t h e com m u

ta tor of adi rect cu rre n t m a ch i n e w i thout re movi n g i t f rom

-

1 Fi rs t C or d C ove r
ve r Le a
on
Z r C ove r S t r e tc he d O d
'

u
p s .

aLa t T s i e on C ove r 4. La
st E nd Pul l e d un d e r

C o rd Wind ing .

FI G . 228 S teps in a
—
p p l y i n g acot t on cov e r ov e r t h e e n d of n a
a rm a
t ure
be fore t u r ni n g d ow n t h e com m u t a t or t o p r e ve n t cop p e r chi p s fa
lli n g be hi n d
t h e bars t o ca u se s h or t ci r cui t s .

the a
fr m e H S R i ch h a ,
s ma
. d e u se of amus li n cove r (E l ec
.

tri ca l R ecord De ce mb e r 1 9 1 8) t i e d ove r t h e op e n l e a

, ,
ds s o tha t
copp e r ch i ps ca n n ot fin d a wa y dow n b e h i n d t h e b a rs to c au s e

as ho rt ci rcui t Thi s cover i s m a

- . de a nd a ppli e d a s foll ow s :

C u t as tri p of mus li n wi d e e n ough to re a ch a cr o s s t h e com m u

ta tor a n d w e ll p ast t h e le ads a n d lo n g e n ough to go a ,

r ou n d

on e a n d on e h a lf ti m e s Ti e thi s ve ry s e curely wi th fin e
-
.

s t ro n g co r d wi th t h e m u s l i n l a
,
i d ov er t h e b a rs a s s hown i n

Fi g 2 28
. .

Dra w the overi n g a n d s t r et ch al i ttl e a

c t ati m e all a roun d .

an d up ove r t h e op e n l e a ds fa r e n ough b a ck to allow of a t lea st

two se p a
ra te cords to be ti ghtly woun d a roun d an d v e ry s e
 C OM M U TA TOR R E P A I RS

c ure ly ti e d on t h e core body Turn t h e a . rm a tur e s lowly to

se e th a t t h e coveri n g does n ot i n te rfe re wi th a n y b ru s h hold e r .

I f s o t h e hold e r s hould be s hi fte d

, Th e s ur plus e dgi n g a
. ll ,

loose s tr i n gs an d thre a ds s hould now be tri mme d off a ll a r ou n d .

B y turni n g b a ck t h e mu s li n over t h e le a ds t h e firs t cord

ti e d a roun d t h e b a rs i s cove re d n e a tly Th e cords woun d .

a r ou n d t h e co r e body ca n be s e cur e d wi thout kn ots by wi n d

i n g ov er t h e firs t e n d afe w tu rn s a n d th e n by wi n d i n g ove r

,

as hort e xtraloop t h e l a ,
s t e n d ca n be j e r k e d un d er a ll the
turn s a n d cu t s ho rt s o th a t akn ot i s n ot n e eded For a
p erm a n en t a rm a tur e coveri n g sh ella ,
c s ho ul d be a ppli ed a ll
ove r i t whi ch s ea ls t h e cords a n d s t ifl en s t h e mus li n .

R e fil l i ng aC om m u ta t or.
—
Wh en acommuta tor i s to be
re fil l e d di s con n e ct t h e a
, rm a ture lea ds a n d re mov e t h e com

muta tor A si mple d e vi ce for a

. ccompli s hi n g thi s i s s hown

i n Fi g 229. .Tw o lo n g bolt rod s a r e s cre w e d i n to hol e s t a pped

i n to t h e s l ee ve ri n g a n d aba
,
r of h e a vy i ron pl a ce d a cro s s t h e

e n d of t h e s h a ft wi th bolt rod s co m i n g through a

,
s s hown ,
.

B y ti ght e ni n g t h e n ut s e ve n ly t h e commut a
, tor ca n be pull e d

off . N e xt coun t t h e n u mbe r of b a rs ca r e ful ly a n d e n te r ,

thi s i n an ote book for future refere n ce R e move t h e s l ee ve .

a n d i f po ss i bl e s a ve t h e m i cari n gs I f these a . r e i n goo d

co n di ti o n th e y ca n be u s e d a ga in Ca re fully ca
. li p er t h e
di a m eter of thes e ri n gs a n d e n t e r thi s i n t h e n ote book a ls o ,

a s t h e n e w commut a tor wi ll h a ve to be bore d to fit th es e ri n gs .

Wi th am i crometer ca li p e r ,

me a s ur e t h e th i ck a n d thi n

e dg e s of on e of t h e b a rs i n

thous a n d s of a n i n ch ; a lso t h e
thi ckn e s s of t h e mi cas e gmen t .
F m 2 29 D i f m i g
—
e v ce or re ov n

I t is a dvi s a
. .

ble to or der t h e a m m t at o f om a am at
co u r r n r u re

ha
rs a
ft
ba n d mi case gm e n t s from
S ‘

t h e moto r m a n ufa ctu re r s a we d to t h e p rope r s i ze a s in a ll ,

p rob a bi li ty thi s ca n be do n e ch e a pe r th a n in a n o r di n a ry r e p a ir
s hop n ot e qui pp e d for thi s wo r k Wh e n o rd eri n g n e w ba
. rs

a deta i l e d d ra wi n g s hould be s en t gi vi n g a l l n e ce ss a
,
ry

di me n s i on s of t h e old ba r for bo ri n g a n d tu rn i n g pu r po s es .

Ha r d dra wn coppe r i s us u a lly us ed a s i t we a rs a t a bout t h e

sa m e ra te a s t h e mi case gm e n t s ( s e e p a ge
31 2 A RM A TURE WI N DI N G A N D M OTOR R E P A I R

Ucc f a Coom m u t ato r C la mp When a sse mbli n g t h e com

.
—

muta tor a cla mp wi ll be n e ces s a

, r y to hold t h e ba rs to

gether whi l e bori n g S e ve ra .l ma kes hi ft m ethods a re a va i la ble ,

but i t wi ll pa y a n y r e p ai r s hop to h a
v e s ui t abl e c a s t i r on -

cla mps s u ch a ,
s s hown i n Fi g 2 3 0 Th e cl a . mp sh ould be
.

s ma ller th an t h e di a me ter of t h e commuta tor so tha t when ,

i t i s dra wn ti ght th ere wi ll be as pa

, ce of a bout i n ch be twe en
t h e se cti o n s Whe n us i n g thi s cla
. mp a s s hown i n Fi g 2 30 .

a t t h e ri ght wood en blo cks ( C ) ca

,
n be employe d to hold t h e

cla mp a bout mi dwa y of t h e commuta tor D i s a n i r o n fa .ce

pla te Th e cla
. mp (B ) s hould firs t be pla ce d on t h e pl a te a s

s ho wn a n d t h e ba
, rs a n d m i case gm e n t s s ta ck ed i n aci r cul a r

form wi thi n i t C a re m us t be exer ci sed to ma

. ke s ure tha t a

FI G . 2 3 0— A t t h e l e ft ,
. acl a
m p for h ol di n g com m u t a t or ba rs t og e t h e r w h e n
be i n g a
s se m bl e d . A t t h e r i g h t t h e u se of t hi s cl a
, m p i s s h ow n .

mi case gmen t i s pl a ce d b e tw e e n ea ch cop pe r ba r C oun t .

t h e ba rs ca re fu ll y s o th a ,
t thei r n umbe r corres pon ds wi th t h e
n umb er of b a rs i n t h e o ri gi n a l commut a tor .

Ta ke s e v e r a l pi e ces of copper wi re (a bout N o 9 B dz S . . .

ga uge) a n d r e move t h e i n s ul a ti on P l a ce th es e a. r oun d t h e

commut a tor n e a r t h e top a n d low e r e n ds to a ct a s ba n d wi r es ,

a n d twi s t th e m t i ght Th e cl a . mp m a y th e n be r e mov e d ,

a nd t h e commut a tor s tra i ghte n e d B ri n g out t h e mi ca

.

s e gm e n t s e ve n w i th t h e s ur f a ce of t h e b a rs by holdi n g t h e

fin ge rs a ga i n s t t h e i n si d e e dge of t h e s e gmen t s a n d ta ppi n g

t h e ba rs on t h e out s i d e w i t h a s ma ll m a ll et P la ce as qu a re.

or s t e e l s ca l e on t h e fa ce pl a te a nd t a p t h e b ar s on t h e out s i d e

wi th as m a ll ma lle t P la ce t h e s qu a
. r e or s te e l s ca le on t h e
fa ce pl a te a n d s ee th a t t h e ba rs l i n e up p e r p e n d i cul a rl y wi th

on e e dge of t h e s qu a re I f th e y do n ot agen tl e pres s ure on e

.
,
31 4 A RM A TUR E WI N DI N G A N D M OTOR R E P A I R

up on t he are fil li n g j ob whe n t h e old mi ca

en d nu t . On ,

ri n gs a r e use d agai n cra ck s m a y b e fou n

, d b e tw ee n t h e b an d
ri n g a n d t h e commuta tor coppe r du e to t h e i rre gula ri ty of

t h e mi cari n g ca us e d by t h e s ha pe of t h e old commuta tor .

Th e se crh cks ca n be fill e d by pu s hi n g i n thi n s h ee ts of mi ca .

S h e llac s hould be u s e d l i b e r ally on t h e e n ds .

Ba ke t h e commut a tor i n a n ov en for a bout on e hour un ti l

i t be com es tho roughly hot a n d t i ght en t h e n u t s ,
R e duce .

t h e hea t s ome wha t a n d ba ke a t alow h e a

,
t un ti l t h e sh ella c

1 11
FI G . 23 1 .
—
I s h ow s ta
per of com m at or ba
ut rs II . is at e m p l at e for l a
yi n g
ou t m i cae n d ri n g s . III s h ow s as ch e m e for l ayi n g ou t t h e t ap er E ,of t h e
t em pl a t e s h ow n i n I I .

b e com es h a rd Ti ght en t h e n ut s a
. ga in a nd a llow t h e com
mut a tor to cool Wh e n cold gi ve t h e nuts afin a
. l s e tti n g up .

Th e cl a mp ca n n ow be r e mov e d .

I n o rd er to fin i s h t h e commut a tor u s e am a n d re l to fit ,

t h e bo r e of t h e s l ee ve a n d ta k e t h e fin a l fini s hi n g cuts A fter

, .

fin i s hi n g aba, r to ba r t e s t wi th t h e te s t l a mp outfit s hould

be m a de to be s ure th ere a r e n o s ho r t ci r cui ts b e twe e n b a rs - .

A t es t for groun ds s h ould a ls o be m a de by holdi n g on e wi re

of t h e te s t l amp on t h e i ron s leeve a n d pa s s i n g t h e oth e r fr om

ba r to ba r a rou n d t h e commuta tor A hi gh volt a ge tes t for .

-

g r ou n d s should be m a de a ls o l a te r .
 C OM M U TA TOR R E P A I R S

Th e lot s for ta
s ki n g t h e a rm a tur e l ea ds m us t n ext be cu t .

I t i s we ll to cu t th e m ali ttl e wi d er th a n t h e di a m e te r of t h e
l ea d wi res Th ese s lots should be m a
. de i n am i lli n g ma ch i n e

i f on e i s a t ha n d oth e r wi s e ah a
, ck s a w ca n be us e d S om e .

ti me s two bla des fa s te n e d t oge th e r wi ll gi ve t h e r e qu i re d

wi dth oi s lot Th e comm ut a. tor ca n n ow be pl a ce d on t h e

a rm a ture s ha ft .

M i caU s e d i n C om m u ta t or s Th e s el ecti on of m i cafor t h e

.
—

i n s ul ati on of commut a tor ba rs a n d for V ri n gs i s us u a

- lly b as ed

upon t h e typ e of moto r b ei n g r e p a i red but bui lt u p mi cah a

,
-
s

been foun d to be t h e mos t sa ti s f acto ry I n di am i cai s g en er

.

a l ly t oo h a rd a n d dom es ti c mi ca t oo bri t t l e for us e bet ween

FI G 2 3 2
. M i cas e g m e n t (B ) cu t f r o m s h e e t u s i n g ba
.
—
r (A ) a s pa t te r n.

S u ch ase g m e n t i s cu t l a
rg e a t t 0p a nd a t e n d s so a s t o t ur n dow n e v e n l y
wi t h copp er ba rs w h e n com m u t a t or i s fi n a
l l y su r fa
ce d .

ba rs . Dom es ti c m i caa lso h a s cra ck s a n d fis s u res w hi ch fil l

up wi th di rt a n d ca us e s hort ci rcui ts A mb er m i cagi v e s

.

good s er vi ce but i t com es i n s u ch odd s i z es th a t i t i s too

wa s t ef ul for t h e a ve r ag e r ep a i r j ob Ha rd b a
. k ed built u p
- -

m i cai s foun d b es t to be u s ed b etw e en b a rs an d t h e un b a k ed

b es t for bui ldi n g up t h e V ri n gs Th e un ba -
. k e d mi ca i s
us ua lly obta i n ed i n s h e ets i n ch a nd i n ch t hi ck .

Hea vi er m i cawo ul d be di ffi cul t to b en d a n d to cu t i n s h a pe .

Th e s a m e si z es of ha rd b a k ed mi ca wi th t h e a
-
ddi ti on of
i n ch and i n ch h a ve b e en foun d s uffi ci en t s to ck to
fill a lmost a n y s i z e of commut a tor I n cutti n g up t h e u n
.

ba ked mi cafor t h e V ri n g i n s ul a - ti o n i t i s s afer fi rs t to fit a

pi ece of pa p er a roun d t h e ri n g a n d th e n u s e t hi s a s a t empl a te .
 31 6 A R M A T U RE WI N DI N G A N D M OTOR R E P A I R

a
S h pi ng M i caE n d Rin g s Whe n i t i s i mpo ss i bl e to sa.
—
ve
t h e old m i cae n d ri n gs , n e w on e s must be m a d e The s e ca n .

be m a d e of fl e xi bl e mi caus ua lly i n ch th i ck I t is .

bes t to m a ke t h e ri n gs i n three pi e ce s to t h e l a yer on s ma ll

commut a tors ; three l a ye rs co n s ti tut i n g ari n g Wh e n h e a te d .

s li ghtly th i s m i ca
,
ca n be b e n t a r ou n d t h e s l e e v e to t h e d e s i re d

sha pe Tri m t h e e dges s qua

. r e on e a ch p i e ce a n d fit th em

ti ghtly i n t h e bore of t h e commuta to r Th e ta p e r r i n gs .

s hould be fitt e d i n t h e s a me ma n n e r wi th a s li ght s p a ce b e i n g

l eft be twe e n a but t i n g e n d s .

Tem pl e t f or M ak in g M i ca E nd R i ng s A good sh 0p m e thod —

for m a ki n g atempla te to l a y o ff m i ca e n d r i n g s i s as follow s:

FI G . 2 33 .
—
Pa
rt s of am e di u m si z e d com m u t at or .

(a
) .
a
nd ( c) M i cae n d r i n g s ( b) I r o n cl a
. m p i n g V —r i n g ( d) M i cabu s h i n g s l ee v e
.

f or i n s i d e o f co m m u t at or ( e) C o m m u t a
. t or ba rs a n d m i ca s e g m e n t s ass e m bl e d .

Sam p l e bars an d m i cas e g m ent s a

re s h ow n at ( f ) an d (a
) .

Ma
r k off api ece of ca
on r dbo a rd a n a r c of a ci r cl e t h e r a di us of ,

whi ch i s e qua l to t h e di a me t e r A i n Fi g S t ri k e a n othe r .

a r c f r om t h e s a m e ce n t e r w i th t h e ra d i us of t h e d i vi d e rs m a de
s ma l l e r by t h e d i s t a
n ce C Th i s wi ll gi ve at e mpl e t for t h e
.

ba nd D .

A t e mpl e t for t h e t a pe r E ca n be p re p a re d a s i llus t r a te d i n

t h e fol l owi n g e x ampl e : A s s um e t h e d i a m e te r B to e qua l s e ven
i n ch e s .Th e n i n Fi g 2 3 1 l a y o ff o n e h
. alf th i s d i a m e t e r o r -
,

3 % i n ch e s f r om A on t h e e dge A B a s s how n a t 0 I f the .

 A RM A TU R E WI N DI N G A N D M OTOR R E P A I R

re s ults a re obta i n ed by ti ghte ni n g up t h e commuta tor gra du

a lly a fter ba ki n g a s i t cools gi vi n g a ,
fin a l ti ghten in g wh en n e a rly

cold Ma
. n y of t h e t roubl e s m e t wi th i n commut a tors i s du e
to ex cess i ve ti ghte n i n g I n a . rch bou n d commut a - tors i t i s ,

i mpo rta n t th a t the a ss e mbl ed s e g m e n t s a r e n ot ti ght e n e d too

ha rd i n t h e a r ch b e fo re t h e V p a rt s a re turn e d a s t h e re s ult
,

i n g s tre s s e s fr om t h e e x pa n d i n g copp e r d i s to r t t h e p a ,
rt s a nd

ofte n a re t h e m a i n ca use of hi gh b a rs S i mi la r ca
. re s hould be

ta k en n ot to e xe rt more pres s ure tha n n e cess a ry on t h e e n d

ri n g s a n d wh e n e ve r pos s i ble m e a n s s hould be p rovi d e d to

mea s ur e t h e p re ss ure . Ca se s h a ve b e e n kn own wh ere t h e

a n gl e s of t h e cl a mp ri ngs i n sma ll commuta tors h a ve b een
ch a n g ed by e xce s s i v e p re s s u r e A ppr ox i m a
. te ly 1 500 lb per .

s q i n on t h e p r oj e ct e d a
. . r ea of t h e in s i d e con e or ta pe r ri n gs
i s as a t i s fa cto ry m e d i um p r e ss ure .

Ma ki n g M i ca ni t e E n d R i n g s I t i s ofte n n e ce ss a
—
r y for

t h e commuta to r bui lde r p a r t i cul a

,
r ly t h e r e p a ir m a n to m a ke ,

up h i s ow n ri n gs For tha . t purpo s e adiff e re n t ki n d of pla te

k n own a s No 1 m i ca
. n i t e or mo u ld i n g pl a te i s furn i s h e d by
t h e M i ca I n s ul a to r C omp a ny T hi s pl a
. te i s m a de from whi te
m i cas ele ct e d w i th s a m e ca re a s for m i ca n i te commut a to r s e g
me n t pla te a n d co n ta i n s t h e p r ope r p roporti on of ce m e n t to
pr odu ce sa ti s fa cto r y mould i n g ch a ra ct e r i s ti cs M i ca ni t e i s
.

n ot du ct i l e a n d w i ll n ot s t r e t ch u n i fo rmly l i k e s h e e t m e t a l It .

i s th e re fore n e ce s s a
, , r y to cu t t h e p a tte rn for mi ca n i t e com

muta tor ri n gs i n to t h e e x a ct d e v e lopm e n t of t h e r i n g b e fo r e

mouldi n g Th e pa . tte rn should be lon g e n ough to a llow for a

ta p e r e d s pli ce a t t h e e n ds For ce m e n ti n g t h e s pl i ce u s e ahi gh
.
,

gra de s he lla c of a bout 2 lb to t h e ga . llon of s olve n t Whe n t h e .

N o 1 m i ca
. n i t e i s pl a ce d on as te a m ta bl e or me ta l pla te
hea te d to a bout 1 40 C i t be com es pl a s ti c a n d ca
°
. n

be mould e d re a di ly i n to t h e d e si re d s ha pe Th e m i ca . n i te

s hould n ot r e m a i n on t h e hot pl a te a n y lo n ge r th a n n e ce s s a ry

a s t h e ce m en t m i ght s e t m a ,
ki n g i t le ss pli a bl e I t i s a dvi s a
. ble
to turn t h e m i ca n i te ove r s o a s to h e a t u n i fo rmly from both
si d e s A ft er pl a
. ci n g t h e m i ca n i t e i n t h e mould or i n t h e com

muta tor i t sh ould be un de r press ur e whi le cooli n g

,
.

Ca u s e s of E xce s s i ve C om m u t a t or W e e n Wa rre n C
—
Ka lb .

ha s po i n t e d out (P ow er Ma ,
r ch 1 8 1 9 1 9) th a,
t commut a tor
 C OM M U TA TOR R E P A I R S

we a r m a y b e c a u s e d by t h e u s e of ab r as i v e b r u s h e s I t m a y .

a ls o re s ult from t h e s a me me cha n i ca l or el e ctri ca l ca uses

tha t produ ce brus h we a r . M e cha n i ca l con di ti on s of t h i s
na tu re a re : R ough commut a to r du e t o poorly p re pa re d

s u rf a ce ; r ough commut a tor ca used by burni n g ; vi b ra ti on from

a n y s ou r ce s u ch a s t h e poun d of ad i r e ct con n e ct e d e n gi n e -
,

b e lt la ci n g i mp rope r moun t i n g loose be a

, ,
r i n g s or commuta tor
out of true ; hi gh pe ri phe ra l s pee d ca us i n g brus h e s t o ch a
,
tte r
or cre a ti n g a n e x ce s s i ve t e mpe ra ture a t t h e b r u s h fa ce s du e

to fri cti on ; type of brush holde r or a - n gl e of op e ra t i on re s ulti n g ,

i n t h e cha tteri n g of t h e brus hes .

C oppe r U s e d t o M a k e C om m u ta t or B a rs Th e b a r s for
.
-

commuta t o rs ca n be ma de from drop forge d cold roll ed , ,

ha r d d ra wn or ca s t cop pe r b a rs Th e d r op fo r ge d coppe r i s
.

us u a lly con si d e re d t h e best a n d ca s t copp e r t h e wo rs t for ba rs .

P r ob a bly most commut a tors a re m a d e of cold rolle d or ha rd

d ra wn coppe r C a . s t coppe r i s poo r on a ccou n t of t h e m a ny

p i n hol e s a n d l a r g e r th a t a r e l i abl e t o b e i n t h e s t ru c tu r e of
t h e ba r . Th es e s how up a t e ve ry tu rn i n g a n d req ui r e fil l i n g

to pre ve n t ca r bo n du s t fr om a ccum ul a ti n g I f th e y a re n ea
. r

t h e e dge of t h e b a rs t h e ca r bo n i s l i a ble to b ri dge t h e mi ca

b e twee n t h e b a rs a n d ca us e as ho rt ci r cui t a n d burn ahole
-

i n two ba rs . Thi s ca lls for apa t ch i n g of t h e b a rs a nd the

i ns ula ti on whi ch a dd s awea k s pot t o t h e commuta to r a nd

s i mply h a s te n s t h e t i m e wh e n i t m u s t be re bu i lt A good .

gra de of coppe r for b a rs i s e co n om i ca l from poi n ts of serv i ce

a n d r e du cti o n of r e p a i r co s t s .

H ow e v e r wh e n h a
,
rd roll e d or d ro p fo rg e d copp e r i s n ot
-
,
-

a va ila bl e for t h e re pa ir m a n ca ,
s t C opp e r m a k es agood s u bs t i
tut e I f t h e ca
. s t i n gs a r e s oft th e y h a v e ami n i mum con du e
t i vi t y of 60 pe r ce n t a . nd a r e mo r e f r e e f rom blow hol es ; a ls o ,

th e y wea r fr om 7 5 per ce n t to 9 0 per cen t a

. s lon g a s t h e ha
. rd

d ra wn or d rop forged copp e r ba

-
rs Th e ca s ti n gs a r e s oft but

tough a ,
n d t h e low co n du cti vi ty i s du e to t h e flux es us e d i n

melti n g t h e coppe r A redu cti on i n t h e a

. moun t of flu x us e d
i n cr ea s es t h e co n du ct i vi ty of t h e copp e r but i t a ls o t e n d s to
,

ma k e t h e m eta l mor e b ri ttl e mo re porous a,

n d li a bl e to h a ve
blow hol es b elow t h e s u rf a ce Th e 60 p e r cen t s oft copp e r
. .
-

ca s ti n gs do n ot n e e d filli n g or m a chi n i n g on t h e s i d e s Th e y .
3 20 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

c na be ea s i ly s t ra i ght en e d a nd a n y proj ecti o n fl a tten ed out on

as urfa ce pl a t e by t h e a id of as t eel fla t t en e r a n d ah a mm e r .

Te s t f or Oil s a t ura t e d M i cai n aC om m u ta t or Whe n t h e .

—

mi cab e t wee n commuta tor ba rs a ppea rs to be s a t ur ate d wi th

oil t h e followi n g t es t ca n be a ppli ed Wet ara g o
. r p i e ce

of wa s t e wi th g a s ol i n e a n d w i p e t h e s u rfa ce of t h e commut a tor

dry .Th en wi th ator ch h ea t t h e commuta tor a t t h e poi n t
wh ere t h e mi caa pp ea rs to be s a tura ted I f oi l h a s wo rk ed
.

down b etwee n t h e m i caa n d t h e ba r i t wi ll ooz e out i n s m a ll

bubbles I n s uch aca . s e n e w m i ca s e gm en t s m us t be i n se rt e d .

Bla ck e ni n g of aC om m u t a t or a t E qua l l y S pa ce d P oi n t s .

Th i s i s u s ua lly ca u s ed by a n op e n ci r cu i t i n t h e a rm a ture
wi n d i n g Th e op en ci r cui t m a
.
y b e a t t h e commut a to r n ec k s

or a t t h e re a r e n d co n n e ct i o n s of t h e w i n d i n g wh e n two p i ece
—

co i l s a r e us e d Wh en th e se s pots a
. re n ot i ce d on a commut a tor
i t s hould be t es t e d out for ope n ci r cui ts a t o n ce b e fore furth er
commut a to r trouble s de ve lop .

U N DE R C U TTI N G M I C A OF C OM M U TA TOR S

Th e obj e ct of u n d ercutti n g t h e mi caof commut a tors i s to

n out t h e m i ca
cl e a b etwe e n t h e copp e r s e gm en ts to ad e pth of
a bout to % 2 i n ch s o th a t t h e coppe r ba r s w i ll we a r e ven ly

free from t h e poo r commuta t i on tha t oft en res ults whe n t h e

mi cai s ha rd a n d do e s n ot w e a r down e ve n ly w i th t h e coppe r

s e gm e n t s Th e und e r cutt i n g op e ra
. ti on s hould be don e a fter
the a rm a tu re h as b e e n re woun d s old er e d a n d ba nded
,
Th e .

commut a tor s hould a ls o be tr ued up a nd a l l e x ces s s old e r

re mov e d fr om t h e n e ck a n d fa ce .

Tool s f or U n de rcut t in g M i ca S pe ci a l mot or d ri ve n or

.
— -

b elt-dri ven sa ws a re a va i la bl e for doi n g thi s work wh i ch ca n be

FI G . 2 34 .
—
Ha
n d t ool for i cat h a
u n de r cu t t i n g m t ca n be conn e ct e d to asm a
ll
by afle x i bl e s h a
’

m ot o r ft .

u se d wh e n t h e arm ature i s cen tered i n al a th e Th e sa ws .

are u s u a
lly cl a
mp e d on an a rbo r wh i ch i s mou n t e d on ah e a
d
3 22 A RM A TU R E WI N DI N G A N D M OTOR R E P A I R

tools a r e us e d th e y s hould be d r a wn towa rd t h e ope r a t or ,

i n or d e r to p rop er ly g ui d e t h e t ool .

I t is a dvi s able to ha ve ajet of compres s ed a i r or afa n so

lo ca te d t h a t t h e pa r t i cl es of m i caa n d copp er wi ll be blown

a wa y from t h e a rma ture to pr e ven t thi s ma teri a l falli n g i n

be hi n d th e commuta to r a nd a t t h e sa me t i m e m a ke i t e a sy

for t h e ope ra tor to see t h e s lot wh en t h e sa w i s th r owi n g t h e

pa rt i cl es tow a rd h i m on t h e fa ce of t h e c om m ut a tor .

Fin i s h i n g S l ot s a
nd C om m u ta
t or S urfa
ce a
ft e r U n de rcut
ting —
A ft er t h e lots a
s re s awe d i t i s a dvi s a ble to go over th e m
wi th as h a rp h a n d tool to re move re m a i n in g p a rti cl e s of m i ca

a n d th i n s tr i p s a lon g t h e e dges of t h e s lot Thi s ca

. n be don e

wi th as ha r p kn i fe or V s h a
,
-
pe d tool whi ch ca ,
n a ls o be us e d to
s li ghtly b e v e l t h e s ha r p e dge s of e a ch ba r a n d r em ov e a ll
burrs S eve ra
. l ha n d tools th a t ca n be us e d for u n d e r cutt i n g

mi cawh en moto r ope ra te d tools a re n ow a va i labl e a re d es cr i b e d

i n t h e followi n g p a ra g ra ph s .

A fte r t h e un d e rcutt i n g ope ra ti o n h a s b e e n comple t e d t h e

commut a tor s hould be s to n e d a n d poli s h e d w i th fin e s a n dp a p er

to remove a l l bur r s of copp e r .

B ru s h e s for U s e on U n d e rcu t C om m u ta t or s.
—
Th e re mova l
of mi cap ermi ts t h e u se of brus h e s wi thout a b ra s i v e qu a li ti es
a nd ha s r e s u lt e d i n t h e d e v elopm en t of ver y low fr i cti on

b ru sh es I n fa
. ct s om e of t h e v e ry low e s t fr i cti o n b r u s h e s

ma n ufa ctu re d a re h a rd a n d do n ot co n ta in a n y gr a ph i te .

S u ch bru s h e s gi ve to as lotte d commuta tor t h e br own glos s

tha t s hows p e rfe ct ope ra ti on Th e li fe of aha
. r d n on a -
b ra
si ve b r us h i s s ev e ra l ti m es tha t of agra phi te b ru s h S om e
.

cr i ti ci s m h a s b ee n m a d e of s lotte d commut a tors wh i ch h a s

b e e n t ra ce d to t h e fa ct th a t t h e b rush e s us e d were n ot s ui ta ble .

Oft en wh e n t h e s a m e b ru s h e s a r e u se d on a n u n d e r cut com

muta tor th a t w e re us e d b efor e t h e commuta

,
tor wi ll be ri dge d
a n d worn r a p i dly a n d t h e s lot s fill e d w i t h copp e r du s t wi th

s hor t ci r cu i t s a
-
n d bur n e d out co i l s t h e re sul t . Th e fa ult i n
s u ch ca s e s i s i n t h e b r u s h n ot i n t h e u n d e r cutti n g p r o ce s s .

I t s hould a ls o be rem emb e re d tha t t h e b r u s h t e n s i o n on '

a n u n d er cut commut a tor ca n oft e n be mu ch low e r th a n be fo r e .

B ru s h a utho ri ti es r e comm en d 1 % to 2% pou n ds per s qua re

i n ch of cro s s s e cti o n on s t a
- ti o n ar y m oto rs from 3 to 5 po un d s
,
'
 C OM M U TA TOR R E P A I R S

p e r s qua r e i n ch for cr a n e moto r s a n d f rom 4 to 8 pou n d s pe r

s qu a r e i n ch on ra i lwa y moto rs wh en t h e commuta tors a re

un d er cut .

A n oth e r fa cto r i n good op e r a ti on of un d e rcut comm uta to rs

i s cle a n in g a t r e gula r i n ter va ls I f t h e motor i s oper a
. te d i n a
pla ce wh e r e t h e a ccumul a t e d dus t a n d di r t i s dry i t ca n be re ,

move d wi th abla s t of comp r e ss e d a ir E ve n i n s u ch ca s es .

t h e s lots s hould be s cr a pe d o cca si on ally A lub ri ca n t s hould .

n e ve r be u s e d on a n u n d e rcut commut a tor n or a n y oth e r wh e n ,

opera ti n g con di ti on s a r e co rr e ct .

Ha n d Tool s f or U n de r cu t ti n g M i caof C om m u ta t or s An —

ea s il y m a de ha n d tool for un d e r cutti n g t h e m i caof com

Seal l o0 -

X X '

FI G . 2 36 .
—
S h or t s aw bl a
de cl a
m pe d i n av u l ca n i z e d fi be r h ol de r f o r u se in
u n de r cu t t i n g m i ca .

m ut a
t ors i s s hown i n Fi g a s d e v i s e d by Wi lli a
. 236 m H Wa ts on .

(P ow e r O ct ,
1 T h
. e s lot
,
i n t h e hold er i s m a d e a s d ee p
or d e e p er th an t h e wi dth of t h e h a cks a w bl a de wi th s m a ll bolts ,

to cla mp t h e bla de s a t ea ch e n d A n y d e pth of cu t d e s i re d ca

. n

be m a d e by a djus ti n g t h e bl a de i n t h e holde r but th ere s el ,

dom is o cca s i o n to mov e t h e bl a d e Th e h a n dl e p a rt i s cu t

.

a wa y j ust e n ough to a llow t h e fin gers to pa ss ove r t h e com m u

ta tor wi thout rubbi n g I n un d er cutti n g commuta . tor s ca re

mus t be ta ken th a t n o r ough e dges a r e l e ft a ft er t h e mi cai s

cu t but i t i s s om e ti m e s h a
,
r d to a voi d th i s e s p e ci a lly i f i t i s a n ,

old commut a tor Thes e rough corn ers ca . n be s mooth e d a fter ,

3 24 A RM A TURE WI N DI N G A N D M OTOR R E P A I R

the mi cah a
s bu d ut wi th aV h a
ee n n e rc ped tool ma
, d e of
-s

ha r dwood or v ul ca n i z ed fib e r run be tw ee n t h e s eg m e n ts a
, s

s hown a t A a n d i t does n ot s po i l t h e ba
, r Th e fron t corn er .

of t h e un de rcutte r whi ch i s ma , de of fi be r ca n be u sed to ,

s m ooth th es e r a w ed ges .

A n othe r h a n d tool recomm en d e d by T M S te rlin g (P ower

. .
,

N ov 5 1 9 1 8) for un d e rcutti n g mi caa

.
, nd a s us e f ul i n oth e r

wa ys by t h e re pa i rm a n is i llus trate d i n Fi g 23 7 I n t h e
,
. .

i llus t ra
ti on A re pres e n ts as tee l s tra i ght e d ge a bout M in ch -

thi ck a n d s l i ghtly lo n ge r th a n t h e le n gth of t h e comm uta tor

s e g men ts a n d s qu a re a t on e e n d to butt up a ga in s t t h e hea d of
t h e comm ut a tor B i s t h e un de r cutti n g tool a
. bout 1 2 i n ches ,

FI G . 237 .
—
Ha
n d t ool for u n de rcu t t i n g c om m u t a
t or m ic a
.

lon g m a
, d e from api e ce of % 6 h e xa gon a l tool s tee l for ged fla t
for a bout on e fourt h of i t s le n gth to athi ckn es s a
- t po i n t D
e qu a l to t h e thi ckn e ss of t h e mi cab e twee n t h e s e gm en ts Th e .

ha lf h e a rt sha p ed lob e C a ff or d s ab e a ri n g pla ce f or t h e

“
-

fin gers i n us i n g t h e tool .

Wh en us i n g thi s tool l a y t h e s t r ai ght-e d g e o n t h e c o m m u

ta tor wi th i t s e dge i n li n e wi th t h e mi cab e twe en t h e se g m e n ts

a nd t h e s qu are e n d a ga i n s t t h e he a d of t h e comm uta tor .

Hold i t firmly wi th t h e l eft h a nd Th en hold i n g tool B in

.
,

t h e r i ght h a n d d ra w t h e poi n t D a
,
lon g t h e mi cat h e s a me a s

d ra wi n g ap e n ci l a lon g arule r i n rul in g p a p e r Thi s ope r a t i on

.

wi ll s ta rt an i ce g roov e i n t h e mi caw i thout bur ri n g t h e e dges

of t h e copp e r on ei th e r s i d e A fte r on e or t wo pa
. s s e s t h e tool

ca n be tu r n e d e n dw i s e w i th po i n t D down a n d t h e mi ca ta k en
to a n y d esi r ed d e pth or a sa w bl a de m a y b e u s e d to fi n i s h t h e
 C HA P T E R XI I I

A DJU S TI N G B R U S HE S AN D C OR RE C TIN G B RU S H
TR OUB LE S

Ma
ny of t h e troubles wh i ch a re ch a r ge d to b rus h e s of m otors

a n d gene ra tors ca n be t ra ce d to i m m ope r a ppli ca ti on a nd

a djus tm en t or t o other d efe cts of t h e ma ch i n e th a t sh ow

up i n s p a r ki n g a t t h e commut a tor A ca . r e ful s e l ecti on of

b rus hes i s im por ta n t but n o mor e so th a n ca re fuln es s i n a d

jus tme n t a n d fr e qu e n t i n s p e cti o n i n Op e ra ti on for p roper
,

ca r e of b r us h es a n d b ru s h r i ggin g r es ult s in good commut a t i on

a n d pr olo n ge d l i fe of both b ru s h es a n d commu t a tor Th e
a
.

re p i rm a n should th e re fo r e gi v e du e con s i der a

, ,
ti on to brush
a dju s tm en t wh e n overh a uli n g am a ch i n e .

Fi t ti n g or Gri n di ng -in B ru s h e s (I n s tru cti on B ook Wes t i n g ,

hous e E le ctri c M fg ; —
Wh e n i t b e com e s n e cessa ry

to in s ta ll an ew set of b rus h es s a ,
n d pa pe r or ga rn e t p a per
m a y b e u s e d th a t i s lo n g e n ough to go a r ou n d t h e c ommut a to r .

I t s hould h a ve al a p of s e v e r al i n ch e s a n d b e s o mou n t e d o n t h e

commut a tor a s to p r e clud e t h e l a pp e d e n d butti n g a ga in s t t h e

b rush es whe n t h e m a chi n e i s r ot a te d for gri n di n g Wi th .

ma n y commut a to rs t h e fr i cti on b e tween t h e commuta to r ba rs

a n d sa n dp a pe r (i f t h e p a per i s ta ut ) wi ll s uffi ce to kee p t h e

pa per from s li ppi n g es pe ci a
,
lly if wh en s ta
,
rt i n g t h e p a
, pe r i s
gi ven apull i n t h e d i re ct i on of r ota ti on by t h e opera tor .

I f t h e pa pe r pe rs i st s i n sli ppi n g us e ali ttl e glue to s ti ck t h e

un d er e n d of t h e pa p er a t the la p to t h e c ommut a to r A l l
.

t ra ce s of t h e glu e mu s t be r emov e d fr om t h e b a rs b e fo re

putti n g t h e m a chi n e i n to s e rv i ce .

A s e co n d m e thod i s to r e move t h e mi ddl e bru s h on e a ch a rm

a n d bi n d t h e pa pe r to t h e commut a tor by runn i n g t a p e or

s t ri n g e n t i r e ly a r ou n d t h e p e r i ph e ry I f n e ce ss a
. ry a ,ls o b i n d
t h e pa pe r a t t h e i n n er a n d out e r e n d s of t h e commut a tor .

A f ter t h e p a p er i s a n chor e d t h e commut a tor m a y b e r ot a t e d

3 26
A DJ US TI N G B R US HE S A N D C OR R E C TI N G TR O U B L E S 3 27

by ha nd or i n a
,
n y co n ve n i e n t w a y G r e at ca re .mu s t b e

e x e r ci s e d i n gri n d i n g i n b rus h es i n thi s wa

“ ”
y a s t h e cutti n g ,

i s very r a pi d es p e ci a lly wi th s oft br us h es a

,
n d mu ch of t h e li f e
,

of t h e br us h m a y b e g r ou n d aw ay i n a v e ry f e w r e volu t i o n s .

If a fter t h e brush es ha ve be e n su rfa ce d i n t h e a bove m a nn er ,

FI G . 2 38 .
—
Gri n di n g i n bru sh e s
—
ofadi r e c t c u rr e n t
- a
g e n e r t or wi t h as t r i p of
sa
n dp ape r .

t he tr ail i n g e dge s hows apoor s ea t on a ccou n t of h avi n g h a d

to moun t t h e ri dge du e to t h e l a p i n t h e p ap e r afi n a
l s ur f aci n g ,

s hould be don e wi th v e ry fin e s a n dp aper by h a nd Th e .

fore goi n g me thod i s p a rly d es i r a

r t i cul a bl e wh e n am a ch i n e

ha s very ha r d b ru s h es or ala rge n umb er of s oft b ru s h es

, .
 3 28 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

t ti me-sa
I t i s agrea ver a
fte r t h e kn a
ck of a
pplyi n g a
nd a
n chor

i ng t h e pa per i s un d e rs tood .

Wi th s li p ri n gs if ca , r bo n or g ra p h i t e b r u s h es a r e u se d t,
h e

sa me gen e ra l s che me i s a ppli ca ble but i f me ta

, l gr a phi te
brushes a re us e d em e ry cloth or i t s e qui va
, , len t i s pr e fera, ble .

T he r e a re tho se who a dvoca te a n d those who pra cti ce

pulli n g t h e gri n di n g pa per in t h e di recti on of r ota t i on i n

order to more a ccura te ly s urfa ce t h e b ru sh Th i s see ms
.

log i ca l en ough on firs t thought but i n a , s mu ch a s t h e com

muta tor i s not in moti on when t h e b ru s h es a re s urfa ced i n

thi s m a n n er th ere i s n o a ss ur an ce tha t t h e bru s h wil l bea r

t h e sa m e rela ti on to i t s holde r (a n d th e re fo r e t o t h e com

muta tor) when t h e commuta tor i s rota ti n g a n d con s e qu e n tly

, ,

no a ss ur a n ce th a t t h e con ta ct wi ll r e ma i n fix ed Thi s pe rh a
. ps
e xpla i n s why b rus h es fr e qu en tly s how perfe ct co n ta ct whe n

i dle but poor co n ta

, ct wh e n i n se rvi ce Thi s m e t hod of
.

fitti n g t h e b rus he s there fore i s not n e cess a

, , ri ly mo re d e pe n d

a ble tha n oth er m e thod s though in s ome i n sta

,
n ce s i t ca n

be re comm e n d e d .

A ft er t h e bru s h es h a ve be en fitted a ll dus t s hould be ca re

fully blown out of t h e commuta tor by com press ed a ir .Th e

pres sure s hould be a bout 50 to 80 poun ds pe r s qua
,
r e i n ch u sed

wi th a i n ch n ozzle A hi gher press ure m a

-
.
y i n ju re i n s ul a
ti on a n d i s n ot n e cess a ry .

I t i s i m port a n t tha t t h e brushh ol ders whe ther for di re ct

,

or a lte rn a ti n g curre n t u se be n e i t her too close to n or t oo fa

-
,
r

from t h e commuta tor or s li p ri n gs A su i ta . ble dis t a n ce i s

from three si xteenth s to on e qu a

- rt e r of a
-
n i n ch .

I f t h e brush es a re copp e r co a te d t h e coa

-
, ti n g s hould be
n ot a ll owe d to com e i n con ta ct wi th t h e commut a tor or sli p
r i n gs . Thi s mea n s th a ta s t h e b rus h es wea r t h e coppe r coa ti ng
s hould be s cra ped ba ck a n d n ot a ll owed to exten d b elow t h e
bru sh h ol der box . Wi th prope r shun ts the re s hould be n o
n ee d for copp er co a ti n g from a n e le ctri ca l s ta n dpoi n t a lthough
,

for m ech a n i cal rea s ons i t m a y b e d e s i r a bl e a s a p ro t e c t i o n

for s oft or s tru ctur a lly we a k b rush es .

I f t h e t oe of t h e b rus h i s very s h a rp i t i s good pra cti ce t o

n o s e off t h e k n i fe e dge Th i s re du ce s brea

. ka ge a n d mi l i

ta tes a ga i n st gougi n g i n to t h e commuta t or .

33 0 A RM A T UR E WI N DI N G A N D M OTOR R E P A I R

s u rfa ce fo rm s on t h e b ru sh Drops ta. ke n duri n g thi s tim e m a y

n ot be t h e sa me a s d rops t a ken a fter t h e b rush is fa ce d up
“

a nd m a y p r ov e s e r i ou s ly m i s l e a d i n g D e fi n i te .o r r e a s o n a bly
pe rm a n e n t d r op v a lues a re a s arul e , to be h a d onl y a
,
fter
t h e b ru s h fa ces h a ve r e a ch e d a fix e d con di ti on .

From t h e for e g oi n g i t i s obvi ous tha t brus hes sh ould fit

s n ugly , but not ti ghtly in t h e hold ers ; a
,
ls o th a t the re a re

cer t a i n r ela ti ve di m en s i ons whi ch a re p refera ble b e twe en

t h e b ru s h e s a n d hold e r s a n d wh i ch mu s t n ot be i gn o re d i f t h e

be st res ults a re to be obt a i n ed For i n s t a

. n ce t h e s i d e of t h e ,

hold er i n t h e d i re ct i on of rota ti on s hould n ot ha ve l es s a r ea

tha n t h e la ggi n g s i de I n fa . ct t h e s i de a
,
ga i n s t whi ch t h e
b rus h press e s s hould ha ve pre fera bly agre a te r a r e a th a n

t h e oppo s i t e s i d e ce r t a i n ly n ot l es s a re a Wi th al i m i te d
—
.

a re a to Oppos e t h e b rus h move m en t of t h e b rus h i n t h e holder

,

du e to loos en e s s o s ci ll a
,
ti o n a n d i m pe r fec t re la ti on s be tween
t h e b ru s h a n d commut a tor a cce n tu a,
te s t h e cha n ge i n t h e

a n gl e of co n t a ct a n d re s ult s i n poo r commuta ti on a s w e ll a

a
,
s ,

i n m e ch ni ca la n d e l e ctr i ca l da m a ge to tha t pa r t of t h e b rush

i n co n ta ct wi th t h e hold e r .

I f abrus h i s th i n i t s l e n gth a
,
n d holder con t a ct s hould be

gre a te r th a n i f i t i s th i ck for t h e r e a ,
s o n th a t t h e thi n n e r t h e
con t a ct a r e aon t h e commut a tor t h e l es s sta ,
ble wi ll be t h e
b rus h on t h e commuta tor a n d t h e gr e a
,
t er wil l be t h e n eed
of s uppo rt fr om i t s hold e r To i llus tra . te I f t h e b rus h con
—

tact i s akn i fe e dge s e ri ous ch a,

tte ri n g m a y re s ult a n d th e re

m a y b e a m a x i mum of i n s t a b i l i ty but i f t h e,
k n i f e e dg e b e

gra du a lly remove d t h e b rus h wi ll be com e i n cre a s i n gly s t a ble

a s t h e th i ckn e s s of t h e b ru s h con t a ct i n cr e a s es a nd if t he ,

b ru s h a n gl e i s co r r e ct t h e m a xi mum s t a bi li ty wi ll be re a ch e d

wh en t h e brus h h a s i t s gr e a te st thi ckn e ss i n con t a ct w i th t h e

commut a tor I t s ta
. n d s to r e a s o n th e r e for e th a ,
t t h e g re a
, t er
the a r e adu e to th i ck n es s t h e mo re s t a ,
ble wi ll be t h e brus h
on t h e commut a tor re ga
,
r dl e ss of t h e hold e r a n d th a t a
,
s a

co n s e qu e n ce a hold er for athi ck b rus h mi ght n ot prove a t a ll

s ui t a ble for ath i n brus h t h e s pe ed s bei n g e qua
,
l I f howe ver .
, ,

th e re i s t h e s a me a moun t of los t moti on i n t h e holders for a

gi ve n len g t h of thi n brus h a n d th i ck b ru s h a n d t h e b rus h
,

a n g l e i s su ch th a t t h e thi ck brush moves i t s ma xim um i n t h e

A DJ US TI N G B R US HE S A N D C OR RE C TI N G TR OU B L E S 33 1

hold er then t h e thi ck bru s h wi ll sh ow ag rea

,
te r ch a n ge i n i t s

r e la ti on to t h e comm ut a to r tha n t h e th i n b rus h . Th e th i ck

brus h howe ver wi ll n ot be s o li ke ly to s hi ft i t s ma
, , xi mum on

a ccoun t of i t s b e a ri n g s u rfa ce be i n g gr e a te r th a n t h e bea ri n g

s ur f a ce of t h e th i n b rus h . I n oth er wo rds i t rest s on a

,

g re a t e r a re a .

Ca u s e s of R a p i d B ru sh W e a r . W-
a rr e n .C K a lb (P o w er,

Ma r ch 1 8 1 9 1 8) h a
, s fou n d th a t t h e followi n g e l e ct ri ca l con
di t i on s ca us e ra pi d b ru s h wea r : S pa rk i n g
,
from a n y ca use
wha te ve r ; glowi n g of b rus h es ; pi tti n g of b rush fa ces .

G lowi n g res ults from e x ce ss i ve curre n t d e n s i ty a nd m a y

be lo ca l or m a y cov e r t h e e n t i r e c o n t a c t e n d of t h e b r u s h.

C om mon ca uses a re un eq u a l colle cti on of curren t by di ffe ren t

brus h es of t h e sa me pola ri ty a n d very h e a vy s hort ci rcui t
-

cur r e n ts i n t h e co i ls u n d ergoi n g commut a ti on wh i ch a

, , dde d
to t h e loa d cu rren t bri n g t h e te mp era
,
tur e of t h e ca r bo n

a t t h e fa ce of t h e b rus h up to t h e glowi n g poi n t .

P i ttin g m a y re s ult fr om glow i n g i n s m a ll s po t s o n t h e b ru s h

fa ce . I t is a ls o ca us e d a t ti m e s by pa r ti cl e s of copp e r be com

ing a tta ch e d to t h e b ru s h f a ce . Th i s ca us e s ah ea vy curre n t

t o lo ca li ze i n asm a ll a r e a d i s i n t e gr a
,
ti n g t h e ca rbo n a nd

for mi n g as ma ll cra te r i n wh i ch t h e coppe r e mb e d s i ts elf .

Th e i n cr e a s e d b ru s h w e a r ca us e d by i n cre a s e i n cu rr e n t

d en s i ty i s du e t o t h e h i ghe r te mp e ra ture so cre a te d a t th e

b rus h fa ce a n d t h e co n s e qu e n t mo r e r a p i d d i s i n t e gr a ti on of
t h e ca r bo n a t th a t poi n t A n y fa
. cto r t e n d i n g to fur th e r

i n cr e a s e t h e t e mpe ra tur e a t t h e b r u s h fa ce w i ll a dd t o t h e
ra pi d i ty of we a r S om e of t h e th i n gs h a
. vi n g th i s effe ct a re :

Hi gh co e ffi ci en t of fri ct i on ; h i gh er co n t a ct d r op th a n i s n ee d ed

for commut a ti on es pe ci a ,
lly on m a ch i n e s of low volta ge a nd

hi gh cu rren t ca pa ci ty ; con t a ct d r op t oo low for s p a r ki n g

volt a ge pe rmi tti n g h e a

, vy curr e n t s to flow i n t h e s hort
ci r cu i t e d co i l ; l a ck of ca rryi n g ca pa ci ty or ve ry hi gh curre n t

de n s i ty .

Hi gh er curren t d en s i t i e s a r e p e rm i s s i bl e wh e r e th e re i s n o

s pa r ki n g volt a ge th a n wh e re th er e i s . Thi s i s b e ca us e t h e
he a ti n g e ffe ct of commut a ti on curre n t i s a bs en t a n d h i gh e r

loa d curren ts ca n be a ppli ed before t h e s a m e t empera ture

ri s e i s a tta i n ed .
332 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

A vera
ge volts pe r com muta tor se g m en t m a y b e a s h i gh a s

1 5 to 20 vol t s wi thout difficulty b e in g e n coun t e r e d Or .

t h e rea ct an cev ol t a g e m a y be th a t h i gh an d s t i ll be n e ut r a li z e d
by i n te r pole flux or fri n gi n g fie ld wi thi n s uffici en tly close
li mi ts to se cure good commuta t i on B u t t h e s p a r ki n g
.

volta ge tha t i s t h e res ul ta

—
n t b e tw e e n t h e re a
,
ct an ce volt a ge
a n d t h e oth e r e l e ctr omoti ve fo rce s ge n e ra te d wi th in t h e coi l
un d er goi n g commuta ti on s hould be l es s tha —
n t h e con t a ct

dr op of posi ti ve plus n e ga ti ve brus h to a tta i n pe r fe ct com

muta ti on I n a s mu ch a
. s 3 volts i s a bout t h e hi gh e s t br us h
con ta ct d rop obta inable i t wi ll be se en th a ,
t t h e s pa r ki n g

volt a ges m en ti on e d would n ot be n e utra li ze d wi thi n 1 2 to 1 7

volts S u ch avolta
. ge would se t up ex ce ss i ve curren ts i n t h e
s ho rt ci r cu i te d coi l s a
- n d res ult i n r a pi d burn i n g a wa y of t h e
bru s h fa ce s e ven wi th n o lo a d curren t wh a te ver ca
-
rri ed by

t h e ma ch i n e .

M e th od s f or Loca t in g t h e E l e ct ri ca l N e u tr a l i n S e t t i ng
B ru sh e s Th e followi n g m e thod s h a
.
—
ve bee n s ugges te d by

FI G . 239 .
—
P i l ot - bru s h m e t h o d of l oca
t i n g bru s h e s on t he e l e ct ri c l n e ut r a
a l
.

T . F . Ba
rt on (P ower ,
J uly 1 6 , 1 9 1 8) for se tti n g bru s hes on

the l t a l n e utra
e e c ri c l i n di re ct curr e n t m ach i n e s -
.

Wi th t h e m a ch i n e r u n n i n g at n o lo a d n o rm a l s pee d a
nd ,

volta g e s h i ft t h e b rus h es un ti l alow r e a

, di n g voltme te r s hows -

n o d e fl e cti o n wh e n con n e cte d to poi n ts j us t i n s i d e t h e h ee l

33 4 A RM A TUR E WI N DI N G A N D M OTOR RE P A I R

wh ether i t i s s mooth or un d ercut hot or c old i n good or poor , ,

m e cha ni ca l con di ti on Th e poo r m e cha

. n i cal co n d i ti on of t h e
com m ut a tor ca n be e lim i n a t e d by pr op e r a tte n ti on Th e .

other i n flu en ces a r e pe rma n e n t exce pt a s th e y m a y b e mod i fi e d

by fin di n g t h e mos t s ui t a ble brus h a n gl e .

C h e cki n g B ru s h S e t tin g To ch e ck t h e s pa
—
ci n g of b rus h es ,

pla ce a s tr i p of pa per com ple tely a r oun d t h e commut a tor u n der

t h e b ru s h es a n d ma rk t h e po s i t i o n of e a ch s e t Th e s tri p ca
. n

the n be remove d a n d t h e d i s ta n ce b e twe e n m a rk s m e a s u red .

I f t h e di s t a n ce v a ri es t h e b ru s h hold er s s hould be mov ed i n to

t h e pr op er pos i ti on . Th e d egr e e of a ccu ra cy wi th whi ch

b rus h es s hould be s et d e pen d upon t h e type of m a

.

ch in e .

Wi th i n t er pol e m a chi n es t h e s p a
,
ci n g s hould be mo re a ccur a te
tha n wi th oth e r typ es of m a chi n es Th e brus h es on a
. n y gi v e n

s tud s hould be s ta ggere d wi th re s pe ct to those on a dj a cen t

s tud s s o th a t t h e en ti re commuta tor wi ll be cove re d by t h e

brush es ex ce pt as li ght s pa ce a t ea ch e n d T hi s prev e n ts
.

grooves wea ri n g i n t h e commuta tor .

B ru sh P r e ss ure —
Th i s d e p e n d s upon t h e ch a ra ct e r of t h e

b rus h t h e commuta
,
tor s pe e d i n fee t per m i n ute a n d the ,

me ch a n i ca l con di ti on of t h e commuta tor I t va ri e s fr om two

.

to five pou n ds pe r squa r e i n ch t h e p res s ures ge n e ra

,
lly used
bei n g from to poun ds on com muta tors a n d fr om th r ee to

five poun ds on s li p ri n gs I f ther e i s at e n d en cy for t h e com

.

muta tor to burn thi s ca

,
n a t ti me s be co rrect e d by i n cre a sin g

t h e pre ss ur e a ,
n d th e re by i n cr e a sin g t h e a b ra s i ve e ff e ct of t h e

bru s h s ufli ci ent l y to s cou r out t h e burn i n g a

, nd m a i n ta in a
poli s he d s urfa ce. Wh en t h e mi cai s n ot un d e rcut t h e brush
s hould h a ve su ffi ci en t a b ra s i v e e ff e ct n ot o n ly to s cou r ou t

poss i ble burn i n g of t h e commuta to r b a rs but a l s o to we a r a nd

kee p t h e mi caflus h wi th t h e commut a to r ba rs .

C om m on B ru s h Te rm s Th e followi n g ter ms a
.
-
r e fre qu e n tly

us e d i n d es cri bi n g brush cha ra ct e ri s ti cs a n d th ei r p e r fo r m a n ce .

C on ta ct Drop —
T hi s r e fe rs to t h e d rop i n volt a ge b e tween
t h e b ru s h a n d t h e commuta tor I t d iff ers wi th d i ff erent
.

ma t er i als di ff eren t br us h pres s ur es a

, nd d i ff e r e n t loa d s b ei n g ,

b e twe e n on e a n d two volt s For agi v en ma

. t eri a la n d gi ve n

loa d t h e con ta ct d r op d e cre a s e s w i th i n cre a se d p r e s s ur e a nd

i n crea s e s w i th t h e lo a d I t va . r i es li ttl e wi th cha n ge s i n s p eed

A DJ U S TI N G B R U S H E S A N D C OR R E C TI N G TR O U B L E S 335
'

above 2 500 fee t per min ute a n d but li ttle wi th tempe ra

ture
n g es u n d er no rm a
ch a l co n di ti o ns .

B r us h Fr i cti on o —
Th e t of fri cti o n d e pe n ds upon
c e ffici e n

t h e brus h m a t e ri a l brus h a n gl e a
, n d co m m uta tor s pe ed Wi th .

agi ven ma teri a l a n d b ru s h a n gl e t h e c oe ffici e n t of fri ct i o n

,

i n cre a s es w i t h lo a da n d b r us h p r ss u re a n d i n ge n e r a l d e cre a
e s es

wi th i n cre a s e d commut a to r s pee d I n cre a se d t empe ra

. ture s i n ,

a ctu a l p ra ct i ce j us ti fy t h e co n clusi on tha

,
t t h e fri cti on co e f
fici en t i n crea s e s wi th i n cre a se d t e m pe ra tures .

S pecific R es i s ta n ce Th e ohm i c resi sta

—
n ce of acub e h a vi n g
on e i n ch s i des
- .

C urr en t Dens i ty or C a rryi ng C a p a c i ty T h i s i —

s b ase d o n t h e

ma x i mum co n t i n uous curre n t ca pa ci ty pe r s qua re i n ch w i th ,

out glowi n g hon ey combi n g un due h ea

, , ti n g or s pa r ki n g .

A b ru s h i s sa
”
Gl owi n g i d to glow wh e n i t b e com es re d or
—
“
.

i n ca n d e s ce n t i n s pot s i n p ro xi m i ty t o t h e commut a to r Thi s .

i s du e t o t h e s hort ci r cuiti n g curre n t un d e r t h e b ru s h or to t h e

-
,

s hort ci r cu i t i n g cu rre n t i n comb i n a

-
ti on wi th t h e wor ki n g or
lo a d curr en t I t m a .
y a l s o b e d u e to a l a ck of homog e n e i ty
of t h e bru sh (ha r d or s oft s pots of t h e s a me or d i ffe re n t ma te
ri a ls h a vi n g cha ra cteri s ti cs fo r e i g n to t h e ma te ri a l i n t h e body
of t h e brus h ) ; to i n corre ct brus h pos i ti o n ; to i mprope r brus h
s e l e cti o n ; to s e l e ct i ve commut a ti on ; t o t h e brus h coveri n g t oo
ma n y ba rs ; to h i gh m i ca ; to t h e m a ch i n e h a v i n g i n h e r e n tly
poor commuta ti n g cha ra ct er i s ti cs du e to i mp rop e rly s h a pe d
or s p a ce d m a i n pol e s or commuta ti n g poles ; to ba d com m u t a t
i n g pol e a djus tm e n ts or to apoo r di stri buti on of t h e a
,
rm a ture
Wi n d i n gs . I n t h e e v e n t t h e glowi n g ca n n ot be s toppe d by

corre cti n g s u ch of t h e b ru s h or m e ch a n i ca l trouble s a s m a y

e x i s t ; or by s h ift i n g t h e b ru s h e s or r e a djus ti n g t h e com m u t a
,
t
i n g poles or both ; abr u s h h a
,
vi n g hi ghe r curr en t d e n s i ty va lues
a n d l e ss s us ce pti bl e to t h e e ff e cts of h i gh volt a ges be twee n t h e
commuta tor b a rs s hould be i n s t a lle d I f as ui ta . ble b rus h
ca n n ot be h a d t h e d es i gn of t h e m a
,
ch i n e i ts el f m a y b e s ubj e c t
to modi fi ca ti o n .

H on eycom bi n g Whe n b ru s hes gra

.
—
dua lly burn a wa y form ,

i n g sma ll cra te rs i n th e i r fa ce s th e y a re s a
”
i d to ho n e y comb
“
.
,

T hi s i s du e to co n ti n uou s s p a r k i n g of amo r e or l e s s h i dd e n

na ture a nd m a y b e of e i th e r a s low o r r a p i d n a tu r e I.f t h e

336 A R M A TU R E WI N DI N G A N D M OTOR R E P A I R

g r owth is sl ow i t is s om et i m es poss i b t i t by i n crea

e t olc rre c s o
i n g t h e brus h press ure th ere by decre a , s i n g t h e con ta ct drop

a n d t h e co n ta ct a r ci n g a nd a t t h e sa
, m e ti m e i n cre a s in g t h e

a bra s i v e eff e ct of t h e b rus h a n d g ri n di n g a wa y t h e mi n ute

cra ters a s th e y form Hon e ycombi n g is du e t o t h e sa
. m e
ca uses on are du ced sca
, le a s glo wi n g a, nd a t ti m es both m a, y
ta ke pla ce s i m ul t a n e ous ly on t h e s a m e ma chi n e Hon ey .

combin g h a s bee n tra ced di re ctly t o hi gh m i cai n comb i n a ti on ,

wi th loose commuta tors ; a ls o to i mp rope rly s pa ced m a in

poles ; a n d un e qua l a i r ga ps ; a n d i n n on c ommut a ti n g pbl e - -

ma chi n es ,
to a n a b n orm a l s hi fti n g or di s torti n g of t h e m a g
n et i c flux . Th e t roubl e i s mos t freq ue n tly corr e cte d by su b
s t i t u t i n g amo re hi ghl y refra ctory brus h poss es s i ng a br a s i ve

ch a ra cte ri s ti cs .

Ha r dnes s . B rus h es h a
—
ve wi d e ly va r yi n g phys i ca l de ns i ti es
fi om e b e i n g ve ry h a r d oth e rs ve ry s oft , V ery h a r d bru s h es .

us ua ll y ca r ry a la r ge a moun t of a b ra s i ve a n d ha ve alow current

de ns i ty or ca rryi n g ca pa ci ty T h e s ofter brus h es a
. re mo re

hi ghly g ra ph i te ca rr y a ,
bra s i ve to ali mi t e d e xt en t on ly a nd

ha ve ahi gh curren t d ensi ty Th e ha rdn ess or s cl ero s co pe

.

rea di n g i s the re fore i n di ca

,
ti ve t o ali mi t e d d eg ree of t h e cha
,
r

a cte r of t h e b ru sh .

B r us h I n er tz a Th is h a s to do w i th t h e w e i ght of t h e b r u sh
'

-
. .

Th e li gh t e r t h e brus h t h e mo re re a ,
di ly wi ll i t foll ow t h e i rre g u
la ri t i es of t h e rota ti n g e l e m e n t a n d t h e mo re promptly wi ll
,

i t r es po n d t o agi ve n s pri n g p re ss u re A ga i n t h e w ea . r i n g of ,

t h e commuta tor m a y n o t p r ov e s o g r e a t I f a li ght a n d a .

he a vy bru s h prove eq ua ll y sa ti s fa cto ry e le ct ri ca ll y on am a

ble I f t h e ma t e ri a
,

chi n e t h e li ghte r brus h i s p re fe ra

, . l s fr om
whi ch bru s hes a re ma de a re h e a vy i t is a dvi sa ble to ha
, ve a n

i n crea se d n umbe r of s ma ll brush es ra th er tha n a

, li mi t e d n um
ber of l a rge bru s h e s ; a l s o t h e s pri n g pre ss ure sh o ul d be i n
e x ce ss of t h e p re ss ur e on li gh t e r brus h e s h a vi n g t h e s a me
di m e n s i o n s a , n d u se d for t h e s a me se r vi ce .

R efr a ctory A n y ma
—
t e ri a l whi ch r es is ts t h e o rdi n a r y m e th

ods of re du ct i o n i s s a i d to be re fra cto ry A bru sh th ere fore .

, ,

whi ch resi s ts wholly or to ama ,

r ke d d e g ree hi gh tem pera ,

ture s s u ch a
, s t h e he a t gen era te d by a n e l e ctri c a rc is sa i d to ,

be h i ghly re fra ctory .

 338 A R M A TU RE WI N DI N G A N D M OTOR R E P A I R

a n d i n cre a s es t h e cu rre n t d e n s i ty th r ough t h e b a la n ce of t h e

bru s h Th e ba
. d e ff e cts of t oo low b ru s h p re ss ure a re g re a tly
a gg ra va te d whe n t h e com m uta to r i s sli ghtly e lli pti ca l or run s
un b a lan ced .

Whe ther t h e pres s ure i s hi gh or low ca re s houl d be e x e r ,

ci s e d to g e t a ll t h e brus h e s on on e m a ch i n e a t aun i fo r m p res

su re ; I f t h e pre ss ure i s un eq ua l t h e brus hes wi th t h e hi gh es t
,

press ur e wil l ca rry t h e hi gh es t cu rre n t I n ma n y ca s es s om e

.

b rus hes on ama ch i n e m a y ca rr y th r ee o r fo u r t i m es as mu c h

curre n t a s other b r us h es du e to thi s va , ri a ti on i n press ure .

Thi s ex cess i ve curre n t m a y be e n ough to b u r n o ff t h e p i g ta il s ,

overh e a t t h e brus hes a n d ca us e glowi n g a

,
n d pi tti n g of t h e

brus h fa ce s Th e b es t va
. lue of b ru s h press ure s hould be de ter
mi ne d for a n y ma ch i n e by t r i al a s i t i s i n flu e n ce d g r e a
,
tly by
lo ca l con di ti ons A press ure of from
. t o 3 pou n ds pe r
s qua re i n ch of con ta ct s u rfa ce m a y b e us e d fo r moto r s a n d g e n

e ra t ors a n d f rom fou r to se v e n pou n d s pe r s qu a

, re i n ch for s u ch

ma ch i n es a s cr a n e motors a n d ra i lwa y motors where vi bra ti o n

i s comp a ra ti vely s e vere Howe ve r th es e va
. lu e s a re gi ve n o nl y
,

a s a n i n d i ca ti on of b es t a ve r a ge p ra ct i ce a nd a r e n ot a lwa ys ,

t h e b e s t to u s e S ee t a
. ble on p a g e 3 4 2 pa ra g ra ph 6 of h e a d
,

ing N o I . .

I n correct S pa ci n g Of B r us he s B y s paci n g of b r us h es , i s
.
—

m ea n t t h e d i s ta
n ce be tw e e n b ru s h e s on a
dj a ce n t s tud s m ea s

u re d a r ou n d commuta
the tor Thus .afour pole m a chi n e
,
in -

t h e b rus h es on e a ch s tud s hould be a t ad i s ta n ce e xa ctly on e

fourth t h e ci rcumferen ce fr om t h e brus h es on t h e a dj a ce n t

s tud s . Thi s m a y b e ch e ck e d up by cou n t i n g t h e t o t al n um b e r

of commuta tor b a rs th e n d i vi d i n g by t h e n umbe r of pol es a

,
nd ,

s e tti n g t h e b r us h e s th a t n umb er of b a rs a pa rt A b e tt e r wa y .
,

howe ver i s to obta ,

i n ap i e ce of wr a ppi n g pa pe r of t h e s a me
l e n gth a s t h e ci r cumfe re n ce of t h e commuta tor a n d of t h e

sa me wi dth a s t h e commut a tor M ea su r e off t h e co rr e ct

.

b r us h s p a ci n g s a n d d ra w li n es a cr o s s t h e wi dth of t h e p a per .

R e pla ce thi s on t h e commut a tor a n d w i th on e s e t of b r u s hes

,

se t s o a s to t oe on e m a r k s e t t h e b ru s hes on a
,
ll t h e oth er s tuds
ex a ctly on th e i r r e s p e ct i v e m a rk s I f th e n t h e s p a .r ki n g , ,

ca n n ot be e n t i re ly e l i mi n a
A
te d by s hi fti n g t h e b rus h yok e ei th er
forwa r d or b a ckwa rd e xa mi n e t h e fie ld coi ls a
, nd a i r ga ps .
A DJ US TI N G B R US H E S A N D C OR R E C TI N G TR OUB L E S 33 9

Def ecti ve Fi el ds Th e fie ld co i ls on t h e ma
—
ch i n e a re u s ua lly
t apa
con n e cte d i n se ri es s o th a r t of on e co i l m ay b e com e s ho r t
ci r c ui te d wi thout be comi n g a ppa re n t e x ce pt by t es t Ob t a in .

avoltm e te r wi th as ui tabl e s ca le a n d tes t t h e vol t a ge drop

a cr os s e a ch coi l Th e d rop s hould be t h e sa
. m e for ea ch fie ld .

I f on e co i l h a s hi gh e r d rop th a n t h e oth ers t h e co i l h a, s bee n

i n co rre ctly woun d I f on e co i l i s lowe r th a

. n t h e oth e r the ,

co i l i s e i th e r i n co rrectly woun d or apo r ti o n of i t h a s be com e

s ho r t ci r cui t e d
-
. E i th e r ca se wi l l r e qui r e a n e w co i l .

A n oth e r more common d e fe ct i n compoun d m a ch i n e s i s a

re ve rs a l of on e of t h e s e ri es fi e ld pole s For th i s tes t u se a

.

comp a ss a n d ch e ck t h e s hun t a s we l l a s t h e se r i e s coi l fi rs t .

pa s s curren t thr ough t h e s hu n t co i l s . N ex t bri n g t h e compa

, ss

n ea r on e co i l ; m a r k i t e i th er S outh or N o rth de pen di n g on

,

whi ch en d of t h e n ee dle i s a ttra ct e d t o t h e fi e ld pol e I f the .

bea r i n gs of t h e comp a ss a r e n ot p e rf ectly free u se ca , re n ot

to bri n g t h e n ee dl e s udde n ly too clos e to t h e pole a s it is ,

ea s y to re v ers e t h e m a g n e t i s m i n t h e n ee dl es of mod e r a t e

pri ce d c ompa
-
s s es A fter m a
. r k i n g on e pole p r o ce ed a
, r oun d t h e

ma ch i n e a n d tes t i n t h e s a me w a y e ac h pol e T h e
. n e e dl e

sh ould r e ve r s e d i r e cti on a t ea ch pol e . I f two a dj a cen t pole s

a r e fou n d to a ttra ct t h e sa me e n d of t h e n ee dle on e coi l i s ,

re ve rs ed .

Fi e ld coil s ca n a l s o be t es t e d for pol a ri ty by two o r di n a ry

i ron n a il s a s de s cri b ed on pa ge 1 36 .

A f t er a ll t h e s hu n t field s h a ve b een tes ted curren t from ,

s om e s ou r ce s hould be p a s s ed th rough t h e s e ri e s fields on ly ,

ca r e b ei n g ta k en t o s e e tha t thi s curre n t flows i n t h e s a me

di re cti o n a s wh e n t h e m a ch i n e i s i n op e r a ti o n N e a r ly a
. ll
compou n d m a ch i n e s a r e cumul a ti ve compoun d i n wh i ch ca , se

ea ch se r i es fie ld s ho ul d a ttra ct t h e s a m e en d of t h e n ee dle a s the

s hu n t fi e ld a ttra cts T h e di fle r en t i a
.
’
l compoun d wi n d i n g i s
us e d on ly wh e n i t i s de si re d to ha ve ari se of s p e e d wi th a n

i n cr ea s e of lo a d a ,
n d i s n ot i n e x t e ns i ve us e . I n s u ch m a ch i n es ,

howe ve r t h e s e ri e s fie ld s pr odu ce pole s of oppo si te pol a

, ri ty

t o t ho s e p rodu ce d by t h e s hu n t fi eld s .

Unequ a l A i r Ga p s U n e qu
—
al ai r g a p s m a y b e t h e c a u se

of se ri ous trouble pa r t i cul a rly i n la p a all l wou d

“ ” “ ”
, p o r r e n

ma ch i n e s . P oo r cen t er i n g of t h e a rm a ture wh en t h e m a ch i ne
3 40 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

w saa ss e mbl e d m a , y b e t h e c a u s e o r i t m a y re s ult la t e r f r om

worn be a r i n gs . Th e w ea r m a y b e e i th e r a t t h e b ottom of
t h e bea ri n g s du e to t h e we i ght of t h e a
, r ma ture or on abelt ,

co nn e ct e d m a chi n e a t t h e si d e of t h e ma
, chi n e due to t h e ,

pull of t h e be lt Thi s m a .
y b e c h e c k e d m e ch a n i ca lly by
me a s ure me n t wi th t hi n sh e e ts of m e ta l or fiber For l a p .

woun d ma chi n e s am or e a ccur a te m e thod howe ver i s to , ,

di s conn e ct t h e bus ba rs or l e a ds wh i ch con n e ct t h e s tud s of

t he sa me pola ri ty Th en wi thout a
.
,
n y lo a d on t h e ma ch i n e ,

ea ch s t ud wil l be i n d e pe n d en t a n d w i th alow r ea
, di n g volt -

m e te r a n y d i ff ere n ce b e tw ee n t h e volta ge g e n e r a te d un der

t h e va ri ous pol e s ca n be d e t ect e d Thi s i s va lua ble on al a
.
p
woun d ma ch i n e but on a
,
wa ve woun d m a chi n e t h e v a ri a t i on s
a re e qua l i ze d a n d t h e m e ch a n i ca l me thod i s more re li a ble .

A fte r h a vi n g corre ctly s pa ce d t h e b rus h es che ck e d t h e ,

drop a cr o ss t h e fie ld coi l s t h e pol a r i ty of t h e fi e ld pol e s a

,
nd

t h e un i fo r mi ty of t h e a i r ga ps i t s hould be poss i ble to s hi ft

,

t h e br us h e s to apo i n t wh e re n o s pa r ki n g wi ll a ppea r wi th

as te a dy loa d on t h e m a ch i n e I f t h e s pa rki n g r e a
. ppea rs

wi th ava ri a ti on i n loa d e i the r t h e brush es a

,
re of i n co rre ct

thi ckn ess or t h e n e utra l fie l d th a t i s t h e di s ta

—
n ce b e twe en
,

a dj a ce n t pol e ti ps i s t oo s m a
—
ll .

I ncorr ect Th i cknes s of B r us hes Th e b es t wa y to

—
i n v e s t i g at e

thi s s p a r ki n g i s wi th a voltm e t e r re a di n g a bout 5 volts .

Ta ke two or di n a ry l e a d pe n ci ls a n d t ri m down on e s i d e of

ea ch p e n ci l a s mu ch a s poss i bl e w i thout e x pos i n g t h e le a d .

N ea r t h e top of e a ch pe n ci l cu t agr oove d ee p e n ough to

e x po se t h e l e a d a nd a tta ch ap i e ce of la mp cord or other

flexi ble wi re to e a ch p e n ci l .
R e move on e b rus h a
. n d hold

the pe n ci ls i n t h e bru sh h ol der wi th t h e poi n ts on t h e com

muta tor a n d t h e fla t s i d e of on e pe n ci l a ga i n s t t h e fron t e dge
of t h e bru sh h ol de r a n d t h e fla t si d e of t h e oth er pe n ci l
a ga i n s t t h e ba ck e dge of t h e hold e r Thi s wi l l gi ve t h e volt
.

a g e g en e r at e d acr o ss t h e b r u s h o r i n oth e r wo r
,
d s t
,
h e ,
“
commut a ti o n volta ge N ow s hi ft t h e b rus h es to apoi n t
,

whe re the y do n ot s pa rk a n d re a d t h e commu t a ti on volta ge ”

.

I n cre a s e t h e lo a d un ti l t h e b r u s h e s s p a rk a nd a ga i n re a d t he
commut a ti on volta ge I f it h a s d e crea s e d t h e b r us h e s a
“
. re ,

too n a rr ow —
tha t i s t h e pe ri od of commuta
, ti on i s t oo bri ef .
3 42 A R M A TU R E WI N DI N G A N D M OTOR R E P A I R

B ru s hes tig ht i n br us h holders

5 . C l ea n t h e h ol d ers w i t h g a
s ol i n e a
nd .

i f brus h es a r e s t il l t i g h t , s a
n d pa
pe r t h e m d ow n o r fil e ou t t h e h ol de rs
ca re full y .

P re ssu re s h ou l d be 1 % t o 2 34 l b per s u a q
'

6 B rus h pres s ure too low

. re . .

t i on a
i n ch cross-sect i on for s t a ry m ot ors a n d g e n er a
t ors , 2 54 t o 4 l b for .

e lev t or a
a n d m i l l m ot ors , 3 t o 5 1b for . a
cr n e m ot ors , 4 to 71h . il w a
forra y
m ot ors .

TOO lo w conta
7 . ct drop of br us h C on su l t abru s h m a
n u fa ct u r e r . .

8 I ns ufli ci en t a
. br a s i ve a
cti on of brus hes U se acom m u t at o r s t on e . or

m or e a
bras i v e brus h es .

9 . Hi g h mic a . U se a
bra
s i ve bru s h es , acom m u t a
t or s t on e or u n de rcu t
t h e m ic a .

10 . C ha
tteri n g . S ee h ea
d i n g N o V I I for . r e m e di e s .

11 . P oor a
djus tm ent f
o i nt er pol es . C on s u l t t h e m a
n u fa
ct u r er of t he
m a
ch i n e .

12 Over loa
. ds U n dercu t t h e m i ca
.
, u s e l o w f ct i on bru s h es a
- ri
n d ch eck

up a l l ca u s es for s h or t -ci rcu i t cu rr e n t s (s ee h e a d i n g N 0 I V ) t o re du ce .

t e m pe ra t u res a s m u ch a s poss i bl e .

1 3 Open ci r cui t i n a
. rm a t u re coi l R ewi n d t h a t pa r t of t h e a rm a t u re . .

1 4 L oos e end conn ecti on

. S cra p e a n d r e so l d e r al l d e f ec t.i v e con n e c t i ons .

1 5 Worn bea
. r i ngs S hi m or r en e w t h e be a . ri n g s .

1 6 U nequ a
. l a i r ga ps S h i m t h e s h ort pol e s or g ri n d off t h e f a
. c es of
t h e l on g pol e s , or i f from worn be a ri n g s , s e e pa ra g a
r ph a bove .

1 7 S hort-ci r cu i t curr en t s be ween bru s h s tu ds ca

. us ed by u n ba la nced
‘

a rm a tur e wi ndi ng C onsu l t t h e m a nu f a. ct u re r of t h e m a ch i n e .

1 8 E ccen tr i c com m uta t or on hi g h-s peed m a 1\1 rn or g ri n d

’
. chi n e . .

1 9 P oor belt l a
. ci ng R e-l a ce or s t i l l be t t e r u s e acon t i n u ou s be l t
.
.

20 P oun d of r eci pr oca

.
ti ng en g i n e dri vi n g the m a
chi n e .

2 1 U ns ta
. bl e f ou n da
ti on .

22 . C r oss curr ents between g en era tors a

oper ted i n paral lel dri ven by
r eci pr oc a
ti n g en g i n es due to vari ati on i n ng ul a
a r s peed of en g i n es U se .

h ea
vi er fly wh eel .

II . C A U S E S A N D RE M E DIE S OF FL A T S P OTS O N
C O M M U TA TOR

1 . A n y f orm O f a
s p r ki n g .
S ee h e a
di n g N o 1 . .

Hig h ba t h e com m u t a t or bol t s a

nd t u rn or g rin d t h e
a
2 . r . Ti g h t e n
com m u t t or .

3 . L ow ba
r . Use com m u t a
t or s t on e or t u rn or g r i n d the com m u t a
t or .

4 . E ccen tr i c com m u t a
tor on hi g h-s peed m a
ch i ne a
c us i ng t h e bru s h to

j p f
um r om the com m ut a
t or a
t the hi g h s pots . I\1 rn
'
or g r i n d t he com

m u t t or a .

a n ta
i n s ta
5 .
f loa
S urges d O curr en t due to s hor t-ci r cu i t on the l i ne or n

neous h i g h pea k l oa d .

6 M echa
. n i ca l l y u nba la nced rm a
a t ure . P la
ce on la
ba n ci n g w a
ys a
nd

add wei g h t a t l i g h t es t poi n t .

I l l / d u o r [ n u D av o n n o an y b u n u u b r [ I VU 1 n u u u u n o

7 Dif erence
. i n ha
r dnes s O f com m ut a
t or ba
rs . U n de r cu t t h e m i caa
nd

u s e n on - bra
a sive bru s h e s .

8 . Di f er ence i n hardn es s f
o mic a. U n de rcu t t h e m ic aa
nd use n on

br a
a s i ve bru s h es .

I II . C A U S E S A N D RE M E DIE S FOR B L A C KE N I N G OF
C O M M U TA TOR

l . S pa
r ki n g S e e h ead i n g N o I for ca
. u ses an d r e m e d i es . .

2 . TOO m uch l ubr i cant C l ea

n com m u t at or w i t h g a
. s ol i n e .

IV . C A U S E S OF HE A TI N G I N A M OT OR OR GE NE R A TOR
W I TH RE M E DIE S

1 . S ever e s pa r ki ng S e e h ea
di n g N o I
. . .

2 . S har t-ci r cu i t cu rr en ts .

(a) B ru s h es ofl n eu t r a
l .

( b) Fau l t y bru s h a
s p ci n g .

(c ) T oo t h i ck brus h e s .

( d ) U n e q u a l a ir ga ps .

( e ) C r oo k e d br u s h s t u ds .

(f ) Too l ow con t r a ct dr op of brus h es .

(9) U n ba la n ce d a rm a t u re .

For re m e di e s of i t em s at o 9 s ee s a
m e ca
u se s h ea di n g N o 1
u n de r . .

3 . TOO hi g h -
or too low brus h pres s u r e . S ee par a
g r a
ph 6 u n d e r h e a
d i n g
No I . .

4 H i g h -f ri ct i on brus hes
. U n de rcu t m i caa n d u se l ow fr i ct i on bru s h
. .

5 C om m ut a
. tor too s m a ll C ons u l t m a nu f a ct u rer of m a
. ch i n e .

6 TOO hi g h ar a
. ti o Of br us h a r eato com m u ta t or s u rf a
ce U se f ew er .

bru s h es of h i g h er ca rry i n g ca p a c i y a n d l ow e r f r i c t i on .

7 Over l oa ds S e e pa ra g r
. a
p h 1 2 u n d e r h e a d i n g N o I . .

8 C ha .t ter i n g Of bru s hes S ee h e a d in g N o V I I

. . .

V . C A U S E S A N D RE M E DIE S FOR H O NE Y C O M B I N G OF
-

B R U S H FA C E S

S hor t-ci rcui t S e e pa ra

g ra p h 2 u n d
cu r r ent s
er h e a d
. i n g N o I V . .

2 TOO low br us h pres s u r e

. S e e para g r ap h 6 u n d e r h e a d i n g N
. o I . .

3 B r us hes of i ns ufi ci ent ca
. rr yi ng ca p a ci t y C ons u l t a b ru s h m a
n u .

fa
ct u r e r .

VI . C A U S E S A N D RE M E DIE S FOR B R U S HE S P I C KI N G
U P C OP P E R

1 . a
H vy o ci rcu i t curren ts
e s h rt - . ra
S ee pa g p
r a h 2 u n d e r h e a d i n g N o I V . .

2 .
Sa
nd u nder the bru s h fa
ces . Wi pe bru sh face ca r e fu l l y a ft e r s a
nd

a
p peri n g e i t h er bru s h e s or com m u tat or .

3 . C om m u t a
tor not n ed a
thorou g hl y cl ea f ter tu rn i n g . Fi ni s h t h e su rf ce a
wi t h acom m u t a
t or s t on e a
ft er t urni n g .
346 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

f o rm ame n ta l pi cture of t h e work d e s cri be d whi ch wi ll a pp r o x i

ma te a s close ly a s pos s i bl e t h e i mp r e s s i o n th a t would be se
cure d by a ctu a lly do i n g t h e work .

C os t of R e pa i r s for P ol yph a s e M ot or s For t h e pur po se

—

of furn i s h i n g e sti ma te s for re pa i ri n g polyph a se moto rs tha t

wi ll g ui d e t h e re p a i rm a n who h a s ha d ali m i t e d e x pe ri e n ce of
re pa i r work Ge o rge A S ch n e i d e r h a
,
. s comp i le d t h e a ccomp a ny

i n g ta bl e (J ourn a l Of E l ectri ci ty M a, y 1 1 9 1 7) ,
fr om co s t s of
a ctu a l r e pa i r j obs wh i ch h e h a s ha n dl e d Th e t a .ble a s p re

s en te d h a s b ee n re vi s e d to t a ke i n to con s i d era ti o n t h e cost

of ma teri a ls en ter i n g i n to re p a i rs for t h e ye a r 1 9 1 7 Th e .

da ta re fers p a r t i cul arly to 60 cy cle — two a,

n d th re e ph a -
se ,

s qui rr e l ca ge motors woun d for t h e s ta

- n da r d volt a ges of 1 1 0
to 550 .

For mo st of t h e s i zes li s t e d t h e cos ts were a rr i ve d a t by

ta ki n g t h e a ve r a ge co s t of re pa i rs for agi ve n fra me a n d th e n

a pplyi n g thi s co st to t h e va r i ou s r a t in gs bu i lt i n tha t fra me .

Th i s wi ll be a pp a r e n t by comp a r i n g t h e co s t s for t h e d i ff e r e n t

ra ti n gs Ta . ke for exa mple fra ,

me G Th e co s t of re wi n di ng
.

t h e sta tor i s T h i s figu re h a s b e en a ppli e d to t h e

followi n g ra t i n gs a ll of whi ch a re bu i lt i n th a t fra m e : 1 ho rse
powe r 900 re voluti on s pe r m i n ute ;
,
ho rs e powe r 1 200re vo
,

lut i on s pe r mi n ute a ,
n d 3 ho rse pow e r 1 800 re voluti o n s per
,

mi n ute Th e fra
. me s i zes s pe ci fied do n ot a pply to a n y pa r

t i cu l a r li n e of moto rs but wer e a

,
r b i tr a ri ly cho s e n f or t h e

pur po s e of th i s ta bl e Howe ve r t h e rela

.
,
ti ve output of a
gi ve n fr a me a t t h e d iff e re n t s pe e d s wi ll be fou n d to a gree qui te
clo s e ly w i th s e ve r a l li n e s of i n du cti o n motors on t h e ma rk e t .

Th es e es ti ma tes m a y a l s o b e u s e d e qu ally w e ll f o r moto rs of

oth e r fre que n ci es by t a ki n g t h e figure s a pplyi n g to a60 cy cle -

ra ti n g bui lt in t h e sa m e fra m e Thi s com pa

. ri s o n ca n be

ea s i ly m a d e by refe rri n g to t h e ma nufa ctu re r s ra ti n g a nd

’

d i m e n s i on sh ee ts for tha t pa rt i cul a r l i n e of moto rs . Th e

ta bles m a y b e fu r th e r a ppl i e d to s l i p r i
- n g o r ph a s e- wou n d
moto rs s i n ce t h e co s t of re wi n d i n g t h e rot or of su ch am a
,
chi n e

wi ll n ot di fle r m a ’
teri a lly from t h e co s t of re wi n d i n g i t s s ta tor .

On th i s b a s i s t h e co s t of co m pl e t e ly re w i n d i n g a 1 0ho rs e power ,

1 800 re volut i o n s pe r m i n ute s l i p r i n g moto r bu il t i n fra

- me J
wi l l be $ 1 1 9 or ,
for t h e roto r or s ta tor se pa ra te ly .
 I N S P E C TI ON OF M OTOR S A N D GE N E R A TOR S 347

C OS T or RE PA I R S FOR (to-C YC L E P OL YPH A S E M or ons B A S E D ON A L A R GE

N U MB E R or RE PA I R J os s

cr a
t i ng

on s i der wh e n E s ti m a
P oin t s t o C t i ng C o s t of a M o t or R e pa ir
J o b . Th—
e es t i m at e s for r e w i n d i n g t h e s t a
to r or re s old e r i n g
t h e rotor g i ven i n t h e a ccomp a n yin g t a ble do n ot i n clude a ny
3 48 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

p re l i m i n ary wo r k re qui re d to put t h e s ta tor s tru cture i n fit

co n d i t i o n to r e ce i ve t h e n e w wi n d i n g or wo r k re qu i red on t h e

r oto r b e fo re t h e a ctua l re s olde ri ng ca n be s t a r te d . I n oth er

words t h e figures cove r o n ly t h e a
, ctua l re wi n di n g or re s old e r
ing a , s t h e ca se m a y b e . H ow e v e r th
,
i s p r e li m i n a r y wo r k i s

freq ue n tly ne cess a ry a nd mus t a lwa ys be co ns i dered i n m a ki n g

up e sti ma tes I t i s du e to an u mbe r of ca
. us e s .

For e x a mple t h e moto r be a

,
ri n g li n i n gs m a y h av e wo rn

down s uffici en tly to a llow t h e roto r to ru b a ga i ns t t h e s ta tor .

I f t h e moto r h a s o pe ra te d very lon g i n thi s con d i ti on t h e la mi

na ti on s of ei the r or both s ta tor a n d r oto r w i ll p rob a bly be
da ma ge d whi ch m a
, y r e qu i r e c o n s i d e r a bl e wo r k to put th e m
i n to th ei r or i gi n a l con d i ti on A ga . in ad e fe cti ve or br ok en
,

b ea ri n g m a y i n ju re t h e s h a ft . S om e t i m e s th i s d a m a g e w i ll b e

s e ri ou s e n ough t o re qui r e a n e w sh a ft N e w be a
. ri n g li n i n gs wi ll

proba bly be re qui re d in ei th e r ca se B u rn e d out wi n di n g s

.
—

ma y a ls o b e a c c omp a n i e d by fu s i n g of p a r t s of t h e s ta tor la m in a
ti ons Th es e fus e d po rti on s mu st n e cess a
. r i ly be re moved

before a ctu al re pla ce m e n t of t h e co i ls ca n be comm en ced .

I n ar oto r wh i ch h a s be e n b a dly overhe a te d a ,ll owin g t h e

me lte d s old er to be thrown out a ,
r ci n g i s fr e que n tly s e t up

betwee n t h e rotor ba rs a n d t h e e n d ri n gs ca us i n g se ri ous

burn i n g Wh e n thi s o ccurs n e w e n d ri n gs a
.
,
re oft en n ee d e d

e i th e r for on e or both e n ds of t h e r oto r or pe rh a ps p a rt of t h e

ba rs wi ll h a ve to be re pla ce d .Wi th bolte d e n d ri n g cons tr ue

ti on th ere i s a ls o l i a bi li ty of trouble Th e ex pa . n s i on of t h e

e n d ri n gs ca us e d by t h e e x ces si ve h ea t ten ds to s n a
, p t h e bolts
b e twee n t h e rotor b a rs a n d t h e ri n gs p rodu ci n g t h e most
,

fa vora ble condi ti on s for a

. r ci n g B u rn out s of thi s ki n d
.
,

for e i th e r s old ere d or bolte d co n s tru cti o n a r e qui t e commo n

,

i n con ne cti o n w i th moto rs wh i ch h a v e b ee n s t a rt e d fr om

ti m e to ti me un d er lo a ds whi ch h a ve re qui re d he a vy s ta r t in g

torque wi th lon g peri ods of a cce l e ra ti on T wo or th r ee

.

ph a s e moto r s a llowe d to op era te s i n gle ph a -

s e for a co n s i d er a ble
le n gth of ti m e m a y a ls o d e v e lop t r oubl e s of th i s k i n d V. e r y
oft e n t h e r oto r wi ll be ba dly d a ma ge d whi le t h e s ta tor h a s

on ly be e n o n ly s li ghtly ove rh e a te d C on ve rs e ly i n s ome

.
,

ca s es t h e s t a to r wi ll be burn e d out whi le t h e rotor i s un i n j ured .

From th es e po i n t s i t w i ll be cl e a r th a t es ti m a tes for re p a i ri ng

35 0 A R M A T U RE WI N DI N G A N D M OTOR R E P A I R

urre n t goes ofl t h e li n e a nd t he a rm fli es b a ck to t h e s t a rt i n g
'

po si ti on Th e a. rm i s re tu rn e d to t h e s t a r t i n g po s i ti o n by a

s p ri n g ,whi ch i s a lwa ys a ct i n g i n oppo s i t i o n to t h e pull of

t h e ma gn e t th a t te n d s to ke e p t h e a rm i n l a s t n ot ch po s i t i o n
-

a s lo n g a s t h e ma gn e t i s e n e rgi ze d I f t h e pull of t h e s pr i n g
.

i s too gre a t wh i ch s om t i m es o ccurs whe n a

,
n i n e x pe r i e n ce d

m a n ma ke s ce rta i n ch a n ge s i n t h e w a y of c o r r e c t i n g th i n g, s

t h e pull of t h e m a gn e t wi ll n ot be s uffi ci en t to hold t h e a rm

i n pl a ce whe n i t i s b r ought up a nd t h e a rm wi ll fly b a ck.

C o n ve rs e ly i f t h e s tre n gt h of t h e s p r i n g b e com es r e du ce d
, ,

wh i ch oft en h a p p e n s wh e n moto r s a r e pl a c e d i n d a mp pl a c e
, s

or wors e s t i ll wh e r e d a ,
mpn e s s a n d ce rt a i n bl e a ch i n g a ge nts
( s u ch as c hlo r i n e a n d o x i d e s of c hlo r i n e ) a c t j o i n tly i n b r i n g i n g
a bout m eta lli c d e te ri o ra t i on i n a pp a ra tus s t e e l s pri n gs w ill
,

be foun d corrod e d to su ch a n e x te n t th a t th e y do n ot pos se ss

th ei r o ri gi n a l s tre n gth a nd ela s t i ci ty . A s a p re ve n t i ve
me a s u re s p ri n g s a
, s w e ll a s a l l oth er m e t a l pa rt s e x po s e d to

co rro s i v e a ct i o n s hould re ce i v e ad rop or two of am i n e ra l

oi l or be s li ghtly s m e a r e d w i th va s e li n e o cca s i on a lly to p re ven t
s u ch d e t e r i o ra ti on Th e pu l l of t h e s p ri n g a
. n d t he pull of

t h e ma gn et a re ba la n ce d a ga i n st ea ch oth e r ,
but th ere a re

oth e r co n di ti on s th a t m us t be ta k e n i n to a cco un t i n m a ki n g
a djus tm e n ts .

A ft er t h e curre n t ce a s e s t o flow i n t h e low volt a - ge re lea se

ma gn e t coi ls whi ch wi ll not be u n ti l t h e motor com es to

,

r e s t ( t h e moto r a ct i n g a s a ge n e r a tor wi ll m a i n ta i n thi s cu rre n t

u n ti l t h e motor s tops ) t h e m a , g n e t w i ll s t i ll e xe r t a c o n s i d e r a bl e

pull on i t s a rm a ture du e to t h e rel a ti vely l a r ge a mou n t of

re s i du a l ma g n e t i s m th a t r e m a i n s i n t h e c o r e of a n e l e c t r o
ma gn e t a ft e r t h e cu rre n t h a s ce a s e d t o ci r cul a te a n d b e fo re t h e

a rm a tur e i s pulle d a wa y from t h e ma g n e t pol e s . A n a r m

th a t wi ll n ot fly b ack to s ta r t i n g po i n t wh e n t h e moto r s tops ,

i f mov e d b a ck by h a nd a n d th en b r ought up a ga i n wi ll n ot
,

s t i ck . I n ce rt a i n ca s e s how e ve r i t m a
, , y s t i c k a n d wh e n i t do es

do s o i t i s n ot du e to a n y pull e x e r t e d by t h e m a g n e t but i t w i ll
prob a bly be foun d th a t t h e s li d i n g con ta ct on t h e bottom of t h e

a rm be a rs s o h a rd a g a i n s t t h e c o n t a c t s th a t t h e s t r e n gth
of t h e s p ri n g i s n ot s u ffici e n t to ove r come thi s br a ki n g eff e ct
due to t h e fri cti o n of t h e s ho e movi n g ov e r t h e co n t a ct s .
 I N S P E C TI ON OF M OTORS A N D GE N E R A TOR S 351

S omet i m es thi s fri cti on eff e ct m a y e x i s t o n ly o n o n e c o n ta ct ,

on e co n t a ct s ta n d i n g hi gh e r th an t h e re s t a n d if t h i s pa rt i cul a
, r

co n ta ct h a ppen s to be n e x t to t h e m a gn e t t h e move m en t ,

of t h e a rm w i ll be re ta rd e d b e fo re t h e a rm h a s ach a n ce to

a cqu i re a n y mom en t um th a t would ca rry i t b a ck provi d e d

i t o n ce got s t a r te d .

I f t h e ma g n e t pull du e to re si dua l ma gn eti sm a fter curren t

ci r cul a ti on cea s e s s hould be r es po n s i bl e for t h e a r m s t i cki n g

a fte r t h e motor s tops (thi s wi ll very ra re ly be t h e ca s e how ,

e ve r) t h e k e e p e r ca
, n be l i ghtly t i n n e d ov e r wi th as old e ri n g

i ro n thus pla
, ci n g ace r t a in a moun t of re lu cta n ce i n t h e m a g
n e t i c ci r cu i t of t h e m a g n e t an d i t s k ee p e r A d r op of o i.l
o cca s i on a lly on t h e s tud on whi ch t h e a rm i s pi voted w i ll
h e lp i n securi n g fre e movem e n t .

II . I N S P E C TI ON A N D OV E R HA UL I N G OF A U TO-S TAR TE R S FOR

A .
- C . M OTOR S

Wh en exa mi ni n g a n d t es t i n g a n a u tos t a r t er t o lo ca te
troubl e s T H R e a , . dron (E l ectri ca
. l R evi ew M a y 2 5 1 9 1 8)
, ,

me n ti o n s t h e followi n g poi n t s a s po s s i bl e ca us es of t h e troubles

A uto s t a rt e r s a
-
re g e n e r a lly use d for s ta rt i n g a lte rn a tin g
cur re n t moto rs of t h e i n du cti o n type wh e n t h e moto rs a re

a bove fiv e hors e powe r S ma ll moto rs a

. r e us u a l l y th rown di
re ct l y on t h e lin e w i thout a n y s ta rt i n g d e vi ce a nd although ,

t h e s ta r t i n g cu rr e n t i s four or five ti m es gre a t e r th a n the

n o rm a l cur ren t t h e flu ctua

,
ti o n a s a r u le i s n ot s e r i ou s e n ough
, ,

to n e ces si ta t e t h e us e of a n a uto st a rt e r U su a l pr a
- ct i ce i s a
. s

follows : P olyph a s e i n du ct i o n moto r s up to 5 hp a r e thrown .

di r ectly on t h e l i n e M otors of . to 3 0 hp a r e s ta rt e d .

by m ea n s of as t a r d elt as wi t ch wh i ch i s n ot a
- n i n du ct i o n

st a rt e r but s i m ply as wi t ch op e r a ti n g i n oil a n d ch a n gi n g t h e

co n n e cti o n s of t h e moto r f rom s ta r on s t a rti n g to d e lt aon

r un n i n g Th e moto r i n th a
. t ca s e i s p rovi d ed wi th s i x t e rm i

na ls to a cc ommod a t
t e h e c h an g e A uto -sta rt e rs or a
. uto
tr a n s fo r m e r s a re mos tly us ed for s qui rrel ca ge i n du cti on -

motors of co n si d era bl e s i z e or over 3 0 hp .

Th e a uto s ta rt e r
-
bei n g a da pt e d for a lt ern a ti n g curr e n t -

wo rk di ff ers from t h e rh eos t a

,
t i n th a t i t poss es s es n ot o n ly
3 52 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

s om e res is ta n ce but cons id era bl e rea cta n ce in d a m pi n g

curr en t flow whi l e t h e rheos ta
, t poss es s es res ist a n ce o n ly .

M e o r ov e r t
,
h e r h e o s t a t i s a s t e b
p y -s t e p s t
- ar t i n g d e v i ce ;
i ts a rm is to be mov ed s lowly over t h e con ta ct s whil e t h e ,

a uto-s ta rte r h a s but on e s te p fr om s ta r ti n g to ru n ni n g a nd

t h e ha n dl e s h ould a lwa ys be thro wn promptly from on e pos i

ti on to t h e oth er pos i ti on .

Th e a ccompa n yi n g d i a gra m (Fi g .

242 ) sh ows t h e pla n of t h e a uto s ta rte r -

a s usu a lly cons tru cte d S i x wi r es a . re

brought to t h e ro cker cyli n d e r of t h e

s w i t ch whi ch i s move d by t h e s wi t ch
,

ha n dl e On e wi r e i s afee d or li n e
.

wi re t h e wi re n e xt g oes to t h e motor
, ,

t h e n e x t wir e i s li n e a n d t h e n e x t on e

moto r a ga in e t c Wh en t h e s wi t ch
, .

i s thr own to t h e s ta rt i n g po s i ti o n t h e ,

si x co n ta cts on t h e s wi t ch cyli n d e r

m ee t s i x co n ta ct s on t h e s ta r ti n g

blo ck a nd t h e curre n t from a li n e

co n ta ct on t h e s w i t ch cyli n d e r p a ss es

t o t h e co n t a ct on t h e s ta r ti n g blo ck

thr ough on e coi l of t h e rea cta n ce a nd

b a ck to t h e n e x t con t a ct on t h e s wi tch
F o 241 A —
at o
cy h n de r a
r n u
n d t h e n ce to t h e moto r
. .

s t at
r er or m p
co at f en s or or , .

W en t h e ha
it h
“ 9° ‘
Y
u l r r e l agc d t u c 1 on
h n dl e i s thro wn to t h e

onl y thr ee con ta

s q e 1n

m t o ors .
run m n g po s m o n , cts

on t h e s wi t ch cyli n d e r m a k e con ta ct

these a re t h e moto r co n ta cts on t h e s w i t ch cyli n d e r a n d th e y

m ee t three con ta cts on t h e ru n ni n g blo ck whi ch co n ta ,

cts a re

di re ctly con n e cte d to t h e li n e wi res e i ther through fus es or

overlo a d re la ys .

Th e li n e con ta ct s on t h e s wi t ch cyli n d e r wh e n t h e cyli n d er ,

i s th rown to ru n n i n g po si ti o n do n ot conn ect wi th a ,

n yt hi n g

the y s ta n d cl e a r or de a d e n d ed The se con ta

-
. cts on t h e s wi tch

cyli n d e r ca n be i d e n tifie d by us i n g al a mp ba nk a n d ma ki n g
co n ta ct w i th th e m t h e s wi t ch h a n dl e b e i n g in ofl i t o
'

, p os i n .

A li ght wi ll be obta i n e d be twee n li n e a n d li n e .

Th e firs t trouble to look for i s bur n e d or im pe rfe ct con ta cts .

 3 54 A R M A TURE WI N DI N G A N D M OTOR R E P A I R

re n t e n ough t o gi ve adull li ght on ala mp ba n k or a fee ble

r i n g on t h e m a g n e to W h e n .i t i s d e c i d e d th at a ce r t a i n w i r e

i s b roke n t a ke out t h e two s cre ws tha

, t hold tha t pa rti cul a r

co n t a ct to t h e s w i t ch cy lin d er a n d pul l do wn t h e te rm in a l
wi th apa i r of pl i e rs .

I f t h e wi re i s i n ta ct i t w i ll re s i s t a
, s tro n g pull I f t h e wi re .

i s b rok e n a n d i s h e ld by t h e i n s ula ti on i t wi ll ea s i ly pull

,

a pa rt . I f i t pulls down thr ough t h e s wi t ch cylin d e r S l l fli

ci e n t l y a tta ,
ch api e ce of n e w w i re or ca ble to i t a n d u se i t

f or asn a ke to dra w t h e n e w wi re i n to pla ce p u lli n g a t t h e top

,

wh e re t h e wi re s en te r t h e a u to—s t a rt e r I f thi s does n ot work

.
,

dr a w t h e broken wi re out a t t h e t op a t a ll e vent s a n d g et a

pi e ce of s ti ff b ra s s or s t e el wi r e a bout N o 1 4 ga
,
ug e B en d a. .
“

s mooth s m a ll loop on t h e e n d of i t a n d pa ss i t down fr om

a bove H a . ve ah e lpe r wi th asma ll hook wi re wa t ch for i t a nd

hook i t a bove t h e s wi t ch cyli n de r so t ha t i t ca n be p a ss e d

through t h e proper hol e i n t h e s wi t ch cyli n d er Wh en thi s i s .

don e t h e t ermi n a
,
l ca n be s old er ed on a t t h e low er wi re a nd th e

t ermi n a l d ra wn b a ck a n d wi r e s pl i ce d a t t h e s top of t h e a uto

sta rt e r I t s hould a
. lwa ys be t h e a i m to m a ke s u ch ar e pa ir
i f pos s i bl e wi thout d i s a ss e mbl i n g t h e pa rts of t h e a uto-s t a r t er

a s s uc h p a rts go b a ck wi th d i ffi culty .

It m a y b e ad v i s a bl e or e v e n n e c e s s a r y t o use a w i re s l i ghtly
s ma l le r tha n t h e o r i gi n a l on e i n o rd er to g et thr ough ti ght
pla ce s . Th er e wi ll be n o d e ci d e d obj e cti on to doi n g thi s a s the

cro s s se cti o n of copp e r i s a

-
lwa ys s uffi ci e n tly a mple to j us ti fy
asli ght re du cti on wh en s u ch aredu cti on i n si z e i s re a lly
n e ce s s a ry .

Th e followi n g me th od of i n s ula t i n g le a ds on a uto st a rt ers

'

will prevent si phoni n g of Oi l :

a
( ) R e m o ve i n su l a
t i on f r o m e a ch l e a d j u s t a b o ve t h e h i g h e s t o i l l e v e l
for adis t a n ce of t w o i n ch es .

( )
b S w e a t t h e s t r an d s o f t h e c a b l e t h o r ou h
g y l t o g e t h e r s o a s t o c l o se

up a ll s pa ce s be t w ee n t h e con du ct ors for adi s t a n ce of on e i n ch .

( )
c I ns u l a t e t h e l e ad w i t h t r e at e d c l o t h t a p e ,
w r a pp g i n t h e t ap e t i g h t l y
a rou n d t h e con du ct or a n d bru s hi n g e a ch l a y er w i t h i n su l a t i ng va rn i s h
W h il e w r a pp g i n .

( )
d E x t e n d t h e w r a pp gi n t o t a p e w i t h t h r e e o v e rl app g i n l a y e r s a t
l ea s t on e i n ch on t h e i n s u l a t i on a t ea ch e n d of t h e ba re s e ct i on .
 I N S P E C TI ON OF M OTOR S A N D GE N E R A TOR S 355

II I . I N S P E C TI ON A N D OVE R HA U L I N G OF DR U M TYP E
C ON TR OL L E R S

Th e drum type con troll er i s u s e d wi th va ri a ble s pe e d s hop

motors on troll e y ca
,
rs ele va te d s ubwa
,
ya n d ra ,
i lwa y tr ains ,

on cra n es an d on s om e typ es of e le v a
,
tors Th i s con trol le r .

m a y b e mo un t e d i n an y po s i t i o n s o a s to p e r m i t h a
n dy c o n

trol On t r olle y a
. n d ra i lwa y ca r s i t i s pl a
ce d v ert i ca
,
lly wi th
t h e le ve r on top For s hop u s e i t i s s om e t i m e s moun t e d on a
.

ma ch i n e or on t h e w a ll upsi d e down be i n g well out of t h e w a , y

a n d ye t h a vi n g i t s le ver wi th i n re a ch On s om e e l eva tors i t i s
.

RE S IS TA NC E .

C ONTROL L E R .

FI G 243
. G ri di r on
.
—
re s i s t a
n ce u se d w i t h d ru m t yp e con t r oll e r s h ow n at
t h e r i g h t for v a ri a bl e s pee d m o t or s . Fi
( g u re s re fe r to n um be rs of pa
ra

g ra p h s of t e x t ) .

i n s ta
l le d hori zon t ally a n d op e ra t e d wi th as t ee l ca bl e run n i n g
ove r agr oove d s h e a ve wh e el S o m e d rum type co n t r oll e rs
.

ha ve onl y as i n gle a rr a
n g e m e n t of se g m e n t s w i t h t h e r e v e r s i n g

con n e ct i o n s op erate d by as e par a te l eve r wh i le oth e r s h a ve ,

dupli ca te s e gmen ts ha lf of whi ch a

,
re a rr an g e d to op e r a t e on
re ve rs e .

l *
Th e h a
. rd usa ge to wh i ch acon trolle r i s s ubj e cte d u s ua lly
wi ll loos e n s ome of i t s s cr e ws or co n n e ct i o n s s o th e s e s hould ,

be look e d ove r ofte n a n d k e pt t i ght Th e l i n e co n n e ct i o n s .

*
Th e foll ow i n g pa
ra ra
g p h n um be rs re fe r t o t h e pa
rt s i n Fi g s 2 43 . a
nd
3 56 ARM A TUR E WI N DI N G A N D M OTOR R E P A I R

to t he fin ge rs a n d t h e s e gm e n ts th e mse lve s re qui re t h e m o s t

a tte n ti on A fin ge r gen e ra
. lly ca rri es a coppe r blo ck of v a r i ous

be ve lle d s ha pe s ri ve ted to astiff phos phor bro n z e s tri p whi ch

,

provi des t h e n e ces sa ry t e n s i o n a n d i s r e gula ted by a n a dj u s ti n g

scre w . Th e fin ge rs s ho ul d be pr ovi d ed wi th flex i ble s tr a n ded

copp e r pi g ta -
i ls whi ch ca rr y t h e curr e n t . I f t h e s pri n g ca r ri es

t h e curre n t i t i s li a ble to h ea t a n d loose i t s te n s i on S et the

a
, .

fin ge rs so tha t the y c n n ot be j a mm e d un d er ase gm e n t i n s te a d

of ri din g upon i t I f a . ny a re ba dl y worn ren e w th e m li ke ,

wi s e overh ea t e d s p ri n g s a n d d e fe ct i ve pi g ta i ls
- .

2 Th e pri ma
. ry se g m e n ts for i n du ct i on mo t or con t r ol a nd

t h e fie ld se gm en ts for d i r e ct curren t moto rs do n ot ca

-
rr y a s

mu ch curr en t a s the a r ma tu re or s li p ri n g s e g me n ts a nd a re

thus s ubj e ct to less wea r Th e on es mos tly wo rn a

. re i n se r i es

wi th t h e sl i p ri n g s or t h e d i re ct curre n t b rus h e s thus i f con

-
,

ta cts a re ve ry poo r t h e moto r wi ll n ot Ope ra te or i t m a y run

s lowly i f on a lte rn a ti n g curren t I f t h e coppe r s e gme n ts a

. re

ba dly worn re pla ,

ce th e m wi th n e w o n es ha vi n g t h e pr ope r
cur va ture a n d wi th coun te r s un k s cre w s t i ghtly fa s te n e d dow n .

A s li ght lub ri ca ti on of va s e l i n e i s good for s e gm e n t s .

3 Th e d i re ct c u rr e n t co n t roll er s houl d s upply t h e m o t or

.
-

s hu n t fi e ld wi th cu rre n t on t h e firs t poi n t l i k e wi s e t h e a ,

lte r
na ti n g c urren t con troll er s hould clos e t h e ci rcui t to t h e i n duc
-

ti on motor pri ma ry w i n d i n g e i the r b e fo re or a t t h e sa me i n s t a nt

tha t the a rma ture re ce i ves curren t I f th ese con ta . ct s a re n ot

prop e rly m a de a t t h e firs t poi n t fuses a ,

re l i a ble t o blow a s the

r es ult of n o fie ld .

4 I n s ul a
. ti n g p a r t i t i o ns a re oft en p r ovi d e d be tw ee n t h e

s e gm e n t s to pre ve n t a rci n g ove r I f th es e a

. re b a dly b urn e d ,

re n e w th e m .

5 C o n t roll er d i a
. gr a m conn e cti ons whi ch a re g e n e ra ll y
pa s t e d i n s i d e of t h e cov e r a re wo r th s a vi n g I f const a
. nt a r ci n g

i s li a ble to d efa ce t h e d i a g r a m e,
i th e r p r o v i d e a dupl i ca te for
re s e r ve or r e move t h e on e fr om t h e cove r a nd m a rk on i t t h e

co n troll e r n u mb e r e t c ,
for i d en ti fi ca
.
, ti o n .

6 Tes t wi th ama
.
g n e to o n a d e a d c o n t r oll er o r,
w i th a t es t
la mp on ali ve on e for a n y po ss i bl e st ra y g roun d t o t h e ca si n g.

I t s hould tes t fre e a s a, groun d would li ke ly bot he r t h e ope ra to r

.

7 Th e con t roller resi s ta

. n ce i s us ua lly Of t h e gri di ron type
3 58 A RM A T URE WI N DI N G A N D M OTOR R E P A I R

p ri ma ry co nn e ct i o ns a t t h e con tro ll er con ta cts m a y re v ea l a n

ope n ci rcui t I f t h e moto r s ti ll re fuse s to run tes t t h e res i s t

.
,

a n ce for ope n ci r cu i t a n d look ca r e ful ly ov er t h e s l i p r i n g -

brush es for poor con ta ct s E x po s e d w i ri n g be twee n t h e motor

.
,

re s i s t an ce a n d co n t roll e r m a y g e t b r ok e n a n d thu s s top i t s

op e ra ti on On e ope n s li p ri n g con ne cti on wi ll ca use s low

s pe e d .

1 1 Th e s udd e n a
. n d re p e a ted ope ra ti on s to whi ch acon
troll e r i s s ubj e cte d de ma n ds th a t i t be ti ghtly bolted down .

For th i s p u r po s e ca s t lugs a re p rovi d e d to t a ke t h e bolts .

1 2 To kee p dus t from ge tt i n g i n a

. n d s pa r k s f rom g e tti n g

out t h e fron t ca
,
se s hould be ke pt fa s te n e d on by t h e fin ger

n ut s p r ovi d e d on both s i d e s .

1 3 Th e c o ntrol of t h e s pe e d i s a
. cc om pli sh ed by m e a ‘

n s of

t h e s t e pp e d S e g m e n t s wh i ch cu t out t h e res i s t a n ce g r a du a l ly .

1 4 Th e ON a
. n d OFF po s i ti on s s hould be pl a i n ly m a r ke d

for t h e ope ra tor s gu i da’

n ce .

1 5 S e e th a
. t ali mi t s top i s provi de d e i ther i n t h e s ha pe of a
ca s t p roj e ct i o n or a n e x t ra lon g tooth on t h e s ta r wh e e l s o th a , t
t h e s e gm e n t s ca n n ot be r ot a te d be yond awhole ci rcle .

1 6 I t is a
. dvi s abl e to provi d e aci rcui t bre a k e r i n t h e li n e
wi th t h e co n trolle r s o th a t i n ca s e i t i s l e ft on pa r t s p ee d wi th a

dea d li n e n o d a, ma ge ca n be do n e to e i ther t h e moto r or i t s

d r i ve n m a ch i n e wh e n t h e curr e n t re tu rns .

1 7 On e ph a
. se co n n e ct i o n ope n wi ll pre ve n t t h e motor
from sta rt in g a nd i t m a
, y s mok e wh i l e t r yi n g to s t a rt .

IV . OV E R HA UL I N G A L A R GE C OM P OU N D D - C . . M OTOR

All motors s hould be i n s pe ct ed n d gi ve n agen era a l over

ha uli n g a t lea s t o n ce a ye a r La
. r ge s i z e s s houl d n ot be s li ghte d

in a n y d e ta i l jus t b e ca us e the y look r ugge d a nd a ppe a r to s tand

e ve rl a s t i n g wor k C los e obs e rva

. ti o n of a ll pa rt s an d con

n e ct i on s wi ll oft e n re ve a l s o m e s u rpri s i n g d e fe cts H owever .

sma ll th e y s ho uld n ot be a
, llowe d to g o un a tte n ded .

Wh e n re p a i r i n g amoto r i t i s a ,
dvi s a ble to re move a ll fuses
a n d pu t th e m i n to t h e tool ki t or your po ck e t s o th a t by n o
ch a n ce cu r ren t ca n be s w i t ch e d on t o t h e motor wh en n ot

e x pe ct e d .
 I N S P E C TI ON OF M OTOR S A N D GE N E R A TOR S 3 59

In c sea of abe lt d ri ve shi ft mot o r s li p off t h e be lt a

,
the nd ,

t i e t h e la tt e r up t o s ome thi n g n ea r by I f d i re ct co n n e cte d .

-
,

ope n t h e coupli n g by re movi n g a ll t h e bolts R e pl a ce t h e .

n ut s on th e m a n d t i e t h e whol e bun ch toge th e r t o s a ve los i n g

the m .

I f t h e moto r i s s us p e n d e d i t would be we ll to lowe r i t wi th

,

two cha i n ta ckl es a sse mbl e i t on t h e floo r a

n d di s a s i t s pa rt s ,

a r e t oo h e a vy to ca rry dow n a la dd e r a n d ra the r la r g e to s t e p

ove r on as ca ff old I f on as h e lf or pl a
. t for m s l i n g i n g i t to ,

t h e floo r i s ofte n n ot ve ry d ifficult .

FI G . 2 45 .
—
E ss e n t i l pa
a rts of acom p ou n d di r e ct -c u r r e n t m ot or . Fi
( g u res
re f e r t o n u m be r of p a
rag ra
p h s of t e x t ) .

l *
. a
R e move t h e k e y n d pull e y fi r s t m a rk i n g or m e a s u ri n g
,

the la
tter s lo ca
’
ti on ,whi ch wi ll h e lp i n re pl aci n g i t I f .

di re ct con n e cte d re move t h e commut a

-
,
to r e n d s hi e ld to a llow
the a rma ture s h a ft to dr a w op e n t h e coupl i n g M a r k lo ca t i on .

of t h e coupli n g on t h e s h a ft I f t h e k e y i s ve ry ti g ht re move
.
,

t h e s e t s cr e ws a n d pou r k er o s e n e i n to t h e hol e s whi ch wi ll ,

work a r oun d t h e k e y t h e n s om e mo t o r oil m a

, y be d r opp e d
i n to lub ri ca t e t h e key w a y B y l i g htly
-
t a p p i n
.
g p r op e r s h a p e d
dri fts t h e ke y ca
,
n oft e n be s t a r t e d i n afe w m i n ut es w i thout

alot of b a tte ri n g a n d da m a g e W h en t h e k e y i s r e
. mov e d i f
t h e pull e y i s ti g ht on t h e s h a ft mo re k e ros e n e Wi ll h e lp ,
.

A l s o by u s i n g a n 1 8 i n ch mo n k e y w re n ch on t h e r i m
-
it ,

Th e foll ow i n g p a
ra ra
g ph n um be rs refe r t o t h e pa
rt s s h own in Fi g 245 . .
 3 60 A R M A T UR E WI N DI N G A N D M OTOR RE P A I R

a often be sta
c n rte d Do not ha . mmer on t h e ri m i t m a y ,

cra ck I f ma
. de of pa pe r i t wi ll fla tte n S tri ke aha .rd wo od

blo ck butte d a ga i n s t t h e hub or d ri ve thin we dges b e hi n d Ti e .

t h e k ey a n d s e t s cre ws to t h e pull e y wh e n r e mov e d for s e cu ri ty .

2 B e fo re re movi n g com muta

. tor en d sh i e ld ma rk the ,

pos i ti on of t h e ro cke r a rm wh i ch m a y g e t s h i ft e d .

3 Wi th t h e pull e y re move d t ry to l i ft t h e s ha
.
,
ft atri fle
i n t h e be a ri n g li ni n g to l ea rn i f i t i s wo rn out of tru e A yea
’
r s .

we a r m a y c a u se t h e a r m a tu r e to s t ri k e t h e low e r p o l e s ho e .

I t i s w ell to obse rv e thi s be fore d i s a sse mbli n g .

4 Ma
. rk or t a g t h e a r m a tu r e l e ad s c o nn e c t e d t o t h e b rus h .

ri ggi n g th e n d i s conn e ct a
, n d re move t h e bru s h es .

5 D ra
. i n t h e oi l we ll s a n d re mov e both e n d hous i n g s a ls o
the brush ri ggi n g C lose up t h e oi l wel ls b efore t h e s cre w
.

plugs g et mi sla id B e ca re ful of t h e gla

. s s ga uges .
6 R e move t h e a
. rm a ture to a pi le of blocki n g s tra i ght
a h ea d Thi s ca. n be do n e w i th on e li ft by s li ppi n g al a rg e .

i r o n pi pe ove r t h e pulle y s h a ft whi ch wi ll ca rry t h e a

,
rm a ture
clea r thr ough a n d two fee t b e yo n d wi thout d r oppi n g i t .

A s u s p en d e d motor ca n be d i sa s se mbl e d to bes t a dva n ta ge

on t h e floo r S et t h e a rm a
. ture on s om e burla p a n d n ot

wh e re a n y m e ta l cl i ps wi ll i mbe d th e mse lves i n to t h e i n s ula

ti o n C l ea
. n the a rm a ture thoroughly es pe ci a lly t h e a ir
,

du ct s .

7 I f t h e commuta
. tor h a s e n ough s to ck l e ft a n d i s rough or

groove d turn i t down i n al a

,
th e ta ki n g on ly ve ry fin e cu t s
,

wi th adi a mon d poi n ted tool The n poli s h wi th oi l a

. n d N o 00 .

sa n dpa per but n ot e me ry I f t h e commuta

,
. tor i s ba dly
worn down an ew on e s hould be on h a,
nd a n d re pl a ce d h a vi n g ,

t h e sa m e n umb e r of s e g m e nts .

8 B low t h e dus t out of t h e fie ld fra

. me a n d f rom a r ou n d t h e

field coi l s or s cra pe wi th ast i ck but us e n o m e ta

,
l ba r or kni fe .

Wi pe out cl ea n w i th wa s te a n d s om e b e n z i n e E xa m i n e th e .

i n s ulati on of t h e fie ld coi ls shun t a n d s e ri e s fie ld l e a

,
ds a nd if ,

a ny a bra s i o n i s foun d us e t a pe thi ck a rm a ture va ,

rn i s h or

s h ell ac for i n s u l a ti on I f t he fie ld coi ls a

. re loo se ti ghte n ,

t h e bolts us ua lly foun d outs i d e t h e fra me I f acoi l i s burn e d .

out re move a n d re w i n d Wei gh t h e wi re tha t i s s tri ppe d OE

a
,

n d re pla ce t h e s a me si z e a n d w e i ght ca re ful ly woun d on a nd

3 62 A RM A T U R E WI N DI N G A N D M OTOR R E P A I R

cu t i n for lub ri ca
ti o n a
nd s cr a
pe t h e i ns i d es for ape rfe ct ly
sn ug fit .

15 . out t h e oi l we lls wi th ga
Flus h s o l i ne or b en z i ne a n d w i pe

them out dry wi th cheese cloth a s wa s te i s li a

, ble to le a ve
threa d s to en ta n gle t h e oi l ri n gs .

1 6 C lea
. n t h e b ru s h ri gg i n g e s pe ci a lly a roun d t h e i ns u l a to rs
on t h e hold e r b a rs R e n e w s hort br us h es a
. n d be v el th e m

a s n ea r a s po s s i bl e R e ne w b r oken or w ea
. k t e ns i on s pri n g s .

S ee tha t t h e holde r ba rs a r e bolted ti ghtly or th e y m a y t u r n .

C l ea n out t h e b rus h hold e rs a nd a ll ow t h e brush es free move

m en t wi th t h e pi g ta
,
i ls fa s t en e d t i ghtly for g ood cu rr e n t
-

conn ecti o n .

1 7 N ow re pl a
. ce t h e b rus h ri gg i n g put i n t h e a rm a
, ture a nd

put on both en d s hi elds C on n e ct t h e le a . ds to t h e bru s hes .

S e t t h e r o ck er a rm i n i t s ori gi n a l n eutra l posi ti on a n d oil t h e

be a ri n g s en ough t o a llow t h e s ha ft to be rota ted by ha nd If .

i t bi n d s look for t h e ca
,
use a t o n ce a s i t s hould turn e a
, s il y

wi th t h e Oil ri n gs i n thei r g r ooves Tu r n t h e a . rm a ture by

us i n g amon ke y wre n ch on t h e s ha ft pus hi n g a ga i ns t t h e ke y
cov ere d wi th t a pe to a voi d m a rr i n g .

1 8 S e t t h e brus h hold ers on e e i ghth i n ch a

.
- bove t h e com
muta tor B e ve l a
. l l ne w a n d old br us hes by d r a wi n g un der
the m s tri ps of N o 1 sa . n dpa pe r un ti l agood a n d full co n ta ct

s urf a ce i s a s s u re d Ha. ve t h e te n si o n on a ll S pri n g s si mi l a r ,

but n ot too stron g S m ea r t h e commuta

. tor wi th al i ttl e .

va s e li n e ; i t wil l n ot ca r bo n i z e l i k e oil R e pl a ce t h e pulle y

.

a n d k ey a n d th en rot a te t h e a rm a ture a n d s ee th a t n o pi g ta il s -

i n t e rf er e .

1 9 R e pl a
. ce t h e moto r a n d bolt i t down fir mly Oi l t h e .

be a r i n gs fully a n d run t h e a rm a ture wi th curr en t for afew

mi n utes wi th t h e be lt ofl L ook s h a r ply for tr oubl e es pe ci a lly
a
.

see tha t t h e oi l ri n gs a re lubri c te d pr ope r ly .

20 S li p on t h e be lt ti ghte n i t up a
.
,
n d ru n motor u n de r s ome
,

loa d I f di re ct conn e ct e d ha
.
- ve t h e coupli n g we ll i ns ul a ted
a n d se cu re ly bolte d L ook es pe ci a
. ll y f or s pa r ki n g a s t he

brus he s m a y h a v e im p e rfe c t c o n t ac t too l i g ht s p,

ri n g t e n s i o n

or be off n e ut ra l Wa . tch t h e motor for afe w hours un de rloa d .

M otor brus hes s ho u ld be se t ba ck of ne u tra l poi n t or gi ven a ,

“
la g
”
as i t i s t e rm e d .
 I N S P E C TI ON OF M OTOR S A N D GE N E R A TORS 3 63

21 acom poun d m otor persi st s i n s pa

. If r ki n g b a dly un der
ne a rly a ful l loa d it m a y b e t
,
h a t du ri n g t h e re p ai ri n g p r o ce ss

t h e s hun t a n d se ri es fie ld s were co nn e cte d oppos e d t o e a ch

other where a s the i r pol a

,
ri ti es s hould be si mi l a r a t ea ch pole .

Oppose d fie lds re a lly ca use as till we a ker fie ld a t i n crea s ed

l oa ds a n d wil l re s ult i n S pa r ki n g a n d fla s hi n g but wi th t h e ,

se ri es an d s hu n t fi e lds m a g n e t i z e d i n h a r mo n y th e re s hould be
n o s pa rki n g a t t h e b rus hes i f the y ha ve good full con ta cts a nd

a re n e utr al !y pla ced .

22 . I f t h e di re cti on of the rm a
a tu re is w ro n g ,
re verse t he
br us h l e a
ds .

V . OVE R HA UL I N G A bo-H OR S E P OWE R I N DU C TI ON M OTOR

A lthough a n i n du cti o n motor does n ot f re qu e n tly ca ll for a

compl e te ove r h a uli n g t h e de ta , i ls gi ve n i n wha t follows cover
s u ch aca se i n or d er t o b ri n g out t h e poi n t whi ch s hould be
.

co nsi d e r e d wh e n t h e motor i s compl e te ly ta ken a pa rt a n d th e n

re a ss e mbl e d a f t e r r e pai rs .

l *
R e move a
. ll fus es a n d ki ll t h e li n e .

2 S li p off t h e b elt a
. n d t ry tu rni n g t h e r o t o r by h a nd If .

i t wi ll n ot tur n the n on e t roubl e h a s be e n lo ca te d

'

, .

3 R e move t h e key a
. n d p ull e y by d ri vi n g we dge s b e hi n d t h e

la tte r .

4 Dra . i n t h e oil we lls a n d remove both e n d s hi e ld s whi ch i n

thi s si ze of moto r a re pr oba bly i n ha lf se cti on s .

5 R e move t h e r otor s tra

. i ght out a he a d on to api le of block
i ng . S li p api pe over t h e s hort s ha ft so tha t t h e rotor m a y b e

ca r ri e d thr ough wi th on e l i ft I f i t s ee ms to be pol i s he d on

.

i t s pe ri phe ry thi s i s evi d e n ce tha

,
ta t le as t on e be a ri n g l i n i n g

i s wor n ba dly a nd ha s a llowe d t h e rotor t o drop C le a n the .

rot o r of a l l dus t a n d di rt .

6 C lea
. n t h e p ri m a ry wi n d i n g wi th w a s te a n d be n z i n e a nd

then look for a n y pos s i bl e a b ra s i o n on t h e wi n di n g I f n ec .

ess a ry a pply s om e thi ck s hell a c C oa t a l l t h e wi n di n g wi th

.

a rm a ture va rn i s h w hi ch wil l dry i n a

,
s ho rt ti me .

7 R e move both be a
. ri n g li n i n g s if the y a re worn e n ough to

a llow loos e pla y on t h e s ha ft I f they a . re s pli t th e y m a y b e

Th e foll owi n g pa
rag ra
ph n um be rs re fe r t o t h e pa
r ts s h own in Fi g 2 46 . .
3 64 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

re -
ba bbi tte d on t he premi ses but mus t fit s n ugly a
, n d ha ve
oil ch a n n e l s pr ope rly cu t i n the m .

8 C lea
. n out both oil w e ll s a s di rt i s l i a
ble to s e ttle an d s top

t h e ri n gs .

9 R e pl a
. ce t h e r oto r a
n d oil t h e be a ri n gs Try to turn t h e
.

former by ha nd a n d s ee tha
, t t h e oil ri n gs tur n fre e ly .

1 0 I f t h e motor se e ms to be i n good s ha
. pe put on t h e pulle y
a n d k e y i t s e cu re ly .

OV E R L OA D R E L KY

R OTOR

Fro .2 46 . S q u i r re l ca
—
g e i n d u ct i on m o t or i n s t all at ion s h o wi n g a
rr a
n g e~

m e n t of s t a rte r a n d t yp e of r e l a y th a t can be u s e d i n s t e ad of fu ses .

( Fi g u res
r e fe r t o n u m be rs of p a g ra
ra p h s of t e x t )
.

11 . ompe n s a
Ope n t h e c tor ca se a n d look f or t r oubl e M os t .

compe n s a tor ca se s a fter be i n g un bolte d s hould be l e t dow n ca re

fully a s th e y co n t a i n oi l i n whi ch t h e co n t a ct s a re s ubm e rge d .

1 2 P ul l t h e ope r a
. ti n g h a n dl e ove r to t h e s t a r ti n g s i d e and

see th a t t h e con t a ct fi n g e r s a re m a ki n g good con n e ct i on s .

If a ny a re bu rn e d s ho rt re n e w th e m I f the i r ca
. bl es or l e a ds
ar e n ot a l l ti ght on e or mo r e m a
, y be fou n d wh i ch h a s t h e co n

du ctor broke n i n s i de of t h e i n s ul a ti on T hese mus t be re

. .
3 66 A R M A T URE WI N DI N G A N D M OTOR R E P A I R

to ha
ve plun ge r work t oo qui ckl y a
the s a n i n du cti o n motor

ma be ca ll ed upo n t o c ar ry a h e avy lo ad fo r a bout a m i n ut e

y ,

when i t would be bothe rs ome to ha v e t h e re l a ys ki ck B ut .

more tha n ami n ute a llows ala r ge curre n t to he a t up t he

motor These rel a
. ys a re trus twor thy a n d whe n e n ca s ed i n a
,

s tee l box the y wor k s il e n tly a n d pr omptly j us t wh e n con

di t i ons dem a n d the i r a cti on Whe n the y ki ck out a . n d t he

powe r goe s off t h e rel a ys wi ll re s e t themse lve s but they wi ll

, ,

a ct a ga in a t t h e v er y n e x t overloa d .

Af te r a ll t h e ope ra ti o ns outli n e d i n i tems 1 to 1 5 ha ve bee n

ca refully compl e t e d t h e j ob m a
, y b e co n s i d e re d fi n i s h e d
a n d t h e motor r ea dy to run .

VI . OVE R HA UL I N G A 2 5 H OR S E P OWE R S L I P RI N G M OTOR

- -

A ma chi n e li ke abull -doze r i n a forg i n g s hop acra n e or a ,

dre dge i s l i kely to ha ve amotor of t h e sl i p ri n g type wi th a - n

e x te rn a l resi s ta n ce co n trol S u ch amotor dr a

. ws curre n t from
t h e l i n e wi th n o hea vy rus hes a n d wi ll s t a r t w i th n ot more tha n

o en a n d o n e qu a
- r t e r ti m e s i t s n o rm a l full loa d de m a nd This .

i s agood f e a ture a s it is ea s y on t h e ge n e ra tor fus es a n d li ne ,

volta ge Otherwi se there mi ght be t h e a

. n n oy a n ce of s topp i n g

a n d s ta r ti n g e ve ry fe w m i n ute s These motors howe ver

.
, ,

n e e d re pa i ri n g a t ti m es li ke a ll oth er m otors a n d t h e fol lowi n g

pr oce dure is gi ve n for su ch re pa ir :

1 A ss u m e aca s e th a t upon re movi n g t h e belt a n d tr yi n g

to turn t h e r oto r by pow er i t i s foun d tha ,

t i t r uns very s lowly ,

s udde n ly blowi n g afuse or t h e ove rlo a d re le a s e ope ns t h e

li n e a n d t h e motor s tops .

2 R e move a
. l l fuses dra i n t h e oi l well s a
,
n d r emov e both e n d

s hi e lds .

3 R e move t h e be a
. ri n g li ni n g s f rom t h e e n d s hi elds a nd

t ry th e m on t h e s ha ft I f the y a
. r e wor n loos e re n e w or re

ba bbi tt the m to fit snugly a n d cu t i n oil gr ooves

,
.

4 R e move t h e a
. rm a ture a n d res t t h e s h a ft on some block
i ng . E xa mi n e t h e sli p ri n g s a n d i f the y a re wo rn down thi n

or r ough e i the r r e n e w the m or tu rn th e m down v e ry s m oothly

,

i n al a the The y a . re li a ble to rough en from poor brush

Th e f oll ow i n g p a
ra r
g pah n um be rs re fe r t o t h e pa
rt s s h own i n Fi g 2 47 . .
 I N S P E C TI ON OF M OTOR S A N D GE N E R A TORS 3 67

o ta
c n ct I f re n e we d s ee tha
. t the y a r e pr ope rly i ns ul a te d
from e a ch othe r wi th on e qua rte r i n ch fi ber boa- rd a n d ti ghtly
-
,

bolte d up .

5 S ee tha
. t t h e ba n d wi res a re ti g h t on t h e a rm a ture I f .

the y a re wo rn thi n re n e w a n d s old e r the m a ll ar ou n d .

6 C oa
. t a ll t h e a rm ature wi n di n g wi th as pe ci a l bl a ck

va rn i s h a voi di n g t h e core di s ks for m a

, g n e t i c co n du c t,i o n .

B R US H R IGG I NG .

25 4 1 9 . S L I P R ING MOTOR .

WI R I NG .

24 7.
—
Pa
rts a
nd e x t e rn a
l re si s t an ce con t r ol for as l i p ri n g a l t e rn at in g
curr e n t m ot or .
( Fi g u re s re fe r to nu m be r s of p a
rag r ap h s of t e x t )
.

7 C le a
. n a ll t h e dus t a n d d i r t f r om out of t h e pri m a ry

wi n di n g but use n o s ha
, r p me t a l a
s t h e i ns ul ati o n i s e as i ly

da ma ge d Wa sh .wi th be n zi n e a
nd co a t wi th a rm a tur e
,

va rn i s h .

8 C le a
. n t h e bru s h ri ggi n g of a l dus t a
l l me t a n d gumm e d oil .

R e n e w t h e s hort bru s he s a n d t h e b r ok e n a n d we a k te n si on
s p ri n gs A ll brus he s s hould ha
. ve good si ze d pi g t a i ls to ca rr y -

t h e curr e n t Th e bru s h co n ta
. ct s s ho u ld be perfe ct on t h e ri n g
s urf a ce s .
3 68 A R M A TU R E WI N DI N G A N D M OTOR R E P A I R

9 R e pl a
. ce t h e a rm a ture brus h ri gg i n g a
, n d both e n d s hi e ld s .

S m ea r va s e l i n e on t h e s li p ri n g s a nd a djust t h e te n si on s pri n g s
fa i rly s tr o n g .

1 0 S ee tha
. t t h e l eads t o t h e brus hes a re n ot loo s e or di s

co n n e cte d a s t he a rm a ture wi l l turn ve ry slowly a n d he a t

ba dly i f onl y one con ductor is ope n I t ma . kes n o diff e re n ce
to whi ch ri n g a n y lea d i s con n ecte d comi n g from t h e ex te rn a l
r e s i s tan ce .

1 1 E xa . mi ne t h e rheos ta t a n d s ee tha t ea ch le a d is con

t i nu ou s f rom i t s ow n re si s ta n ce s e cti o n a n d th a t n o coi l
is ope n or loosely con n e cte d Th e sl i di n g a
. rm s mus t b e a r

s i multa n e ous ly on s u ccess i ve butto ns If a ny a

. r e wo rn or

ba dly burne d the y s hould be re n e we d .

1 2 Th e moto r pri ma
. ry l e ads mus t be con n e cte d e a ch to t h e

proper l e g of t h e three or four wi re s upply li n e -

.

1 3 S e e th a
. t t h e li n e i s se cur ely bolte d to t h e s wi tch a n d ha
, ve
t h e la tte r s cli ps cle a
’
n a n d ca pa ble of ati gh t co n ta ct a s cu r,

re n t for a 25 h p motor i s l i a
- . bl e to bu rn a n y loo s e co n n e cti o n s .

1 4 Ove rloa
. d re l a ys or fu se s m a y b e u s e d w i th th i s moto r .

R ela ys s a ve ti m e a s th ey ca n be res e t a n d li m i t e d to a
,
ny

re a s on a ble loa d .

1 5 Oi l t h e b e a
. ri n g s fully a n d ru n t h e moto r S ee tha
. t t he
oi l ri n gs a re tu rni n g pr ope rly .

1 6 Whe n ope r a
. ti n g asli p ri n g moto r be ca
- r eful to move

t h e r he o s t a t l e ver slowly to a voi d arus h of curre n t For .

s pe e d re gul a ti o n t h e co n trolle r h a s ma n y s pee d s fo r w a rd

a n d re ve rse wi th twen ty or more co nta

,
ct fi n ge rs a n d blo cks

whi ch ha ve to be re n e we d a t ti me s be ca use of a rci n g .

1 7 I f an on re ve rs i n g moto r ru n s t h e wr o n g w a
.
-
y m e r e
, ly
e x ch a n ge t h e l e ads of on e pha s e of i t s li n e C ha n gi n g t h e s l i p
.

ri n g co n n e cti o n s h a s n o e ff e ct .

1 8 A sl i p ri n g motor s hould h a
.
— ve i t s brus hes a nd ri n gs

prote cte d from dust a n d di rt an d t h e we a

,
r on t h e be a ri n gs

wa tche d j us t a s clo sely a s tho se of a n o r di n a ry i n du cti on motor .

VII . OVE R HA UL I N G A S I N GL E P HA S E
- C OM M U TATOR M OTOR

On a ther s pe ci a
ccoun t of t h e r a l con s tru cti on of t h e s i n gle
ph a s e commut a tor mo t or th ere a ,
r e ce rt a i n poi n ts to wh i ch
t h e re pa i rm a
n s hould pa y e s p e ci a
l a tt e n t i o n wh e n i t b e com es
370 A R M A T U RE WI N DI N G A N D M OTOR R E P A I R

be fitted to kee p dus t from settli n g wh ere i t m a y ca u se t h e o il

ri n g to s top .

5 Oil ga
.
uge Wh en ove rh a
. ul in g amotor t a ke a pa rt a nd

cl ea n out t h e ga uges a s a ny ob s tru cti o n m a y p r odu ce a f a l s e

oi l le ve l . Th e b e a ri n g s s ho u ld a lso be dra i n ed a n d flus h e d

wi th ga s o li n e .

6 Oi l plug s
. S ee tha
. t they a re ti ght or t h e oi l m a y d r i p
from them a nd wa s te .

7 B rus h holde r s tuds B olt a

.
- l l Of th es e up ti ght to a
. voi d
t 1 pp1 n g t h e b r us h es from t h e commut a tor by th eir a cci d e n ta l
turn i n g .

8 Ca
. rbon b rus h es w i th copp er pi g ta i ls in t h e va - ri a ble ,

s pe e d compe ns a ted type of s i n gle pha s e motor re m a - in on t h e , .

commut a tor a ll t h e ti me s i mi la r t o d i re ct curr en t moto rs

,
- .

Wi th t h e repul si o n type they a re s ho rt ci rcu i t ed a t t h e s ta

-
rt

but a re re mov e d by ace n tri fuga l govern or wh en up to s pee d .

Gi ve a l l b rus h es good con t a ct wi th t h e commut a tor by dra wi n g

un d er the m N o 00 s a n dp a
. pe r a ga i ns t t h e ca r bo n A li ttle .

va s e li n e wil l s top t h e s que a k of b rush es .

9. S ho t ci r cui ti n g conn e cti o n on t h e b a

r - ck of t h e b rus h

yok e for t h e m a i n b rus h s et or en e r gy b ru s h es .

1 0 B rus h hold e rs
. S ee th a t they a
. r e cl ea n e d of a l l gum
a n d di rt t o a llow free a cti o n of t h e b ru s h e s R e n e w we a k .

S pr i n gs .

1 1 Th e brush yoke i s s om eti m es of mould e d compo s i ti on

.

a nd s ome ti m es of ca s t i ro n Th i s s hould be well cl e a

. n e d to

a voi d s hort ci rcu i ts .

1 2 A fa
. n i s us e d to k ee p up a ci rcul a ti on of cool a ir a ga i ns t
t h e wi n d i n gs .

13 La. mi n a te d a rm a ture wi th slot wi n di n gs Th e s qui rrel .

ca ge wi n di n g i s us ua lly pla ced i n t h e bottom of t h e s lots a nd ,

t h e compe ns a ti n g wi n di n g n e a r t h e s u rfa ce a n d b e twee n t h e ,

two wi n di n gs as te e l ba r s e pa ra tor A l l coi ls should be well .

i n sula te d to be moi sture pr oof S e e th a t ba. n d wi res a re

ti ghtly sold e re d wi th plen ty of m i caun d er them I f t h e

,
.

be a ri n g li n i n gs a re w orn t h e s urfa ce of t h e a
,
rm a t ure wil l
S how poli s h e d pl a ces .

1 4 C ommuta
. tor To i t a . re con n e cte d t h e l e a ds of t h e
commut a ted typ e of a rm a ture wi n di n g I n t h e re puls i on .
 I N S P E C TI ON OF M OTOR S A N D GE N E R A TORS 371

type t h e com muta to r ba rs a re a ll conne cte d a t full speed a nd

t he a rm a ture runs li k e a n i n du cti on r otor S e e th a ta ll com

.

muta to r le a ds a re w ell s old e red i n I f comm uta tor i s rough

t at i m e wi th a
.
,

turn i t down in al a th e but ever so li ttle a

,

di a mon d po i n t tool P oli sh wi th N o 00 s a

-
. n dpa per a
. nd oi l .

N e ve r use e me ry cloth .

1 5 S ha
. ft I n s ome m a
. kes if i t be com es wo rn or d a ma ge d
i t ca n be e a s i ly wi thd r a wn a n d an e w on e re pla ce d I f its .

bea r i n g s u rf a ces a re out th e y s hould be tu rn e d down s moothly

be fore n e w b ea r in g li n i n g s a r e fitted on .

16 a n d 1 7 M oto r te rm i n a
. ls to t h e li n e S ome d e si gn s a . ll ow
for 1 1 0 volt ope ra
- t i on by con ne cti n g t h e term i n a l s in p a ra llel ,

a n d 2 2 0 volt ope ra
-
tion wi th them i n se ri es .

1 8 Te rm i n a
. l s from t h e a uxili a ry or compe n sa ti n g fie ld
wi n d i n g .

1 9 P ull ey e n d s hi e ld
. .

20 B ea
. ri n g li n i n g s I f th e y a
. re wo rn e n ough t o a ll ow loose
pl a y of t h e s ha ft n ew ones s hould be put i n or t h e old on es
,

re b a
— bb i tte d wi th oi l cha nn e ls cu t i n fr om e n d to en d .

2 1 Oi l ri n g s
. S e e tha
. t th e y a r e n ot b e n t out of s h a pe a nd

whe n t e a ss e mb l i n g be ca
-
re ful to g e t th e m i n to t h e s lo t s .

Th i s i s v ery i mpo rt a nt a n d ali ght m i ght b etter be us e d

th a n to gu e ss a t thei r lo ca ti on A ls o turn t h e a. rm a ture

by ha nd a n d see th a t t h e ri n g s turn a ls o Oi l we ll before .

ru n n i n g .

2 2 P ull ey s hould be ti gh tl y k eye d on a

. n d fa s te n e d w i th a

s e t s cre w On ly ab a
. la n ce d moto r pull e y s hould be u s e d .

2 3 S e t s cre w for moto r p u ll e y

. .

N OTE N O rh e o s t a
—
t i s n ee d e d a lthough s pee d co n t rolle rs a
,
re

use d To re ver se t h e a
. rm a ture rot a ti on i n tercha n ge t h e ,

lea ds to t h e compensa ti n g or a uxi li a ry b ru s h e s .

VI II . OV E R HA UL N
I G A DIR E C T- C UR R E N T E N GI N E TYP E
GE N E R A TOR

A t l ea
st once aye a tors of a
r t h e ge n e r a ny ma nuf a cturi n g

pla n t s hould be thor oughl y ove r h a ul e d cl e an e d pa i n te d a nd , , ,

m i n or r e pai rs m a de e ve n though n ot ba
,
dly out of orde r .

S u ch a n i ns pe cti o n doe s n o h a rm a n d oft e n r e ve a l s awe a k

pa rt t h a t ma y l at er c au s e a b re a
k dow n at a bu s y ti m e - .
37
2 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

A good jo b c a n b e do ne i n t w o o r t h r e e d a y s by two good

re p a i rm e n o n m a c hi n e s up to 1 5 0 k i low a tt s .

l .
*
If eb lt d r i v e n m a r k t h e po si t i o n of t h e s l i d i n g b a s e b e fo r e

s e tt i n g b a ck wi th t h e be lt scre w .

2 On. both b e lt d -
r i v en a n d d i rec t - c o n n e c t e d m a c h i n e s ,

ma r k the po s i t i o n of t h e r o c k e r a r m a,
s s u r i n g t h e r e tu r n

of t h e brus hes to t h e n eut ra l poi n t .

3 A . vo i d i f po ss i bl e d i s
,
tu r b i n g t h e b r u s h hold e rs .

FI G . 2 49 . Pa—
r t s of a n e n g i n e t y p e d i r e ct -c u r r e n t g e n e r at or t h a t sh oul d be
re g u l a
r l y i n s p e ct e d. Fi
( g u r e s re fe r t o p a r ag r a
p h s o f t h e t e
. xt )

4 . Wi th atra
ve li n g cr a
ne or atri pod ri ggi ng move t h e
,
re

on th e whole b rus h ri ggi ng

t he arm atu re l e a
ds for

bloc ke d u p le ve l t o i t s
oth e r wi se t h e p o l e s w i ll
11 g s l e e ve

Fi g ra
dar to t h e pa
rt s sh own i n Fi g .
374 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

13 . I f the ha sft s hows a ny m a rk s of cutt i n g h a ve i t s s urfa ce

true d be fore a n y be a ri n g s l e e ve i s re pa i re d .

1 4 I f t h e be a
. ri n g s lee ve s a re wor n de ci d e dly h a ve the m ,

re b a
-
bbi tte d to fit s nugly but n ot t oo ti ghtly a n d groove d ,

for o i li n g .

1 5 B e ca
. r e ful n ot to d a ma ge t he oil ri n gs e s pe ci a l ly wh en
,

r e pl a ci n g t h e be a ri n g s A l s o s e e th a
. ta l l se di m en t i s remove d
f rom t h e oil we ll s a n d t h e gl a
, s s ga uges cle a n e d out .

1 6 If t he a
. rm a ture ba n d wi r e s or mi cai n s ul a ti o n a re

loos e sl i p un der s ome s hee ts of mi caa

,
n d re s old er t h e b a - n ds

s e cu re ly .

1 7 S e e th a
. t n o field coi ls a re l oo se on t h e pol e s ; i f s o a pply
more we dgi n g of wood s tri ps .

1 8 I f t h e b rus he s a
. re di rty r e move th e m on e s e t a ,
t ati m e ,

to a voi d a n y m i x up a n d cl e a n t h e hold e rs wi th ga s ol i n e a llow ,

i n g t h e bru s he s to move free ly R e pl a . ce S hor t b ru s h e s w i th

n e w o n e s ; r e n e w we a k s pri n gs ; ti ghte n t h e pi g ta i l s ; or if of -

coppe r g a uze they m a y be s e t a h e a d G i v e e a c h

. b ru s h t h e

pr oper a n d sa m e te ns i o n n ot too loose a

,
n d n ot s o ti g h t a s to

ca us e cutti n g A llow a. bout on e ei ghth i n ch un d e r t h e holde rs

-
,

a n d t i p b r us h es a t p r ope r a n gl e s Get t h e pr ope r be ve l

.

on e a ch br us h to fit t h e commut a tor a r e by d r a wi n g N o 0 .

or N o 1 s a . n dp a per un de r i t cutti n g t h e ca,

r bo n a wa y whi le
i t re s ts on t h e commut a tor V a . s el i n e a ppli e d l i ghtly to t h e
com mut a tor wi ll he lp t h e lub ri ca ti o n of t h e brus h con ta cts

a n d pr e ve n t cutti n g a n d S pa r ki n g .

1 9 C o n n e ct t h e m a
. i n le a ds to thei r prOper bolts ti ghtly ,

a n d if b e lt d ri ve n S l i p on t h e p u ll e y wi th i t s ke y a n d s e t scre w ,

a n d wi th pl e n ty of oi l i n t h e be a ri n gs turn t h e a rm a tu re by
ha n d an umb e r of ti m e s a n d wa tch a ll pa r ts f o r i n te rf e re n ce .

E s pe ci a lly s ee tha t t h e Oil ri n gs a re turn i n g .

2 0 A ti m ely w a
. rn i n g do n ot co a
—
t t h e ge n e r a t or wi th
a lumi n um p a i n t jus t f or looks a s i t i s am e t a
, lli c con du ctor .

Le a ky volta ge a n d S hor ts m a y r e s ult W hi t e e n

. a m e l r ad i a te s

he a t t h e be s t a lthough i t i s s ome trouble to kee p cle a

,
n .

Da r k g r ee n i s t h e u s u a l color .

A All thes e ope ra

. ti o n s t a ke some ti m e whe n properly don e ,

but wha t apre tty run ni n g m a chi n e on e h a s whe n the y a re

hon e stly comple te d .

 I N S P E C TI ON OF M OTOR S A N D GE N E R A TORS 375

B ai ns ul a tion is found peel ed ofi or cra cke d ope n ,

'

. If ny

use a li ttle mi ca , t a p e ,
s h e l l a
c, or a
rm atur e va r n i s h .

C Whe n re a
. dy to a ss e mble t h e ge ne rator, put a ll bolts
possi ble i n to pl a ce be fore ti ghte ni n g a ny C lose a
. l l oil cocks
a n d fill up t h e be a ri n g s . Kee p t h e arm ature lea ds a wa y from
t h e rota ti n g arm a ture .

D Whe n a
. l l i s re a dy , sli p on t he belt, sli de ba ck t he b a se

to forme r posi ti on a
its nd st a
rt t he en g i ne s lowly wa
, tchi ng
ca
r eful ly t h e oil ri n g s .
 C HA P T E R XV

DIA GN OS I S OF M OTOR AN D GE NE R ATOR TR OU B LE S

Th e l t
e ec ri c motor a n d g e n e ra tor a re s tu rdy p i e ce s of a p
pa ra tus wh en gi ven t h e prope r a t t en ti o n a n d op e ra te d wi thi n
thei r n o rma l ra ti n gs Th e t roubl es whi ch th e y d evelop ca
. n

us ua lly be tra ce d t o two m a i n ca us e s 1 Fa . . ulty ope ra ti n g

co n d i ti on s 2 M e ch a
. . ni ca la n d e l e ctri ca l d e fe cts .

Fa ulty opera ti n g con di ti o n s m a y e i th e r b r i n g to li ght e x i s t

i n g m e ch a n i ca l a n d e l e ct ri ca l defe cts or cr e a te n e w o n e s .

U n d er n orma l con di t i on s the re fore corre ct Opera

, ,
ti n g con
di t i on s wi ll re du ce to am i n i mum t h e tr oubl e s du e to t h e
,

s e co n d ca use Th e fa . cto rs i n f a ul ty ope ra tin g con di ti on s m a y

be cl a ss i fi e d a s fo llows :

1 La
. ck of p rop e r cl e a nin g .

2 Ope ra
. ti o n i n d a mp pla ces .

3 E xpos ure to a
. ci d fum e s a n d ga se s .

4 La
. ck of fre q uen t i n s pe cti o n a n d re pl a ce m en t of worn

pa rt s.

5 Op era
. ti n g tempe ra ture s too hi gh .

La ck of P r ope r C l e a
.
n i ng —
A ll m a ch i n e ry h a vi n g movi n g
pa rt s re qui res lub ri ca ti on a n d how e v er w e ll t h e p rovi s i o n s a re

ma de to con fin e t h e oi l to t h e pa rt s n ee d i n g t h e lub ri ca ti o n i t
,

wi ll fin d i t s wa y i n t i m e to a dj a ce n t p a r t s of t h e m a c h i n e.

I n moto rs a n d gen e ra tors t h e oi l wh i ch i s a llowe d to a ccu m u

la t e on t h e w i n d i n gs h a s ad e t ri m e n t a l effe ct on t h e qua li ty
of t h e i n s ula ti n g m a te ri a ls us e d a nd i s afre qu en t ca us e of
s ho rt ci r cui ts a n d g r ou n d s . Th e p re s e n ce of oi l a ls o in vi tes
the a ccumul a ti on of dus t a n d d i rt whi ch qu i ckly fil ls up s m a ll
spa ce s th a t ha ve be e n p rovi d e d for v en ti la ti on of wi n di n gs
a n d co re Th i s re sults i n a
. n i n cre a s e i n t e mp e ra ture of t h e
pa rts i n volve d Th e o n ly re me dy for troubl es res ulti n g from
.

thi s ca us e on are pa i re d m a ch i n e or wh e n an e w on e i s su b
,

s t i tut e d i s f re qu e n t cl e a
, nin g a t reg ul a r i n te r va ls M otors
.

37
6
37
8 A R M A TUR E WI N DI N G A N D M OTOR RE P A I R

ma chi ne sh oul d a lso recei ve acoa t of a ci d -res i s ti n g p a int a t

freq uen t in terva ls.

La ck of Fr e qu ent I nspe cti on a nd R epl a ce m ent of Worn

Pa rt s —
S ho rt ci r cui ts a n d groun ds a re fre que n tly tr a ce d t o

ru bb i n g of t h e moto r wi n di n g on fi eld pol es ca us e d by aben t

sha ft or worn b e a ri n g s. A wo rn or ben t sh a ft m a y a ls o c a u se

t h e co re of t h e a rm a ture to stri ke t h e pole fa ces a n d ja m the

p u n c h i n g s of t h e c o r e e n ough t o cu t t h e c o i ls a n d ca use a
g r ou n d i n t h e w i n d i n g
. A loo s e fit of t h e c ommut a to r o n t h e

s ha ft when i t h a
, s b ee n re pla ce d a fter are pa i r j ob m a
, y re s ult
i n suffici e n t move m en t to b rea k off t h e le a d s to a rm a ture coi ls
a t t e e cks of
h n t h e commut a tor T e re s old e ri n g of su ch a
. h -

d e fe ct does n ot cure t h e trouble A n in s pe cti on s hould be

.

ma de to lo ca te t h e ca us e a n d e li m i n a te i t I n t hi s ca
. se i t

wi ll prob a bly ca ll for ane w sha ft A mi xture of dus t a

. nd

forei gn ma te ri a l i n t h e bea ri n g oil cups or n ot en ough oi l is t h e

s ta rt of m a n y be a ri n g tr oubles whi ch ca n be e li mi n a te d by
freq ue n tly dra i nin g t h e bea ri n g s a n d cl e a ni n g wi th kerose n e .

When oi l i s us e d tha t ha s s tood for s om e t i m e i n a re ce pt a cle

or b ee n pumpe d fr om b a r re l s t o a ta nk i t i s a
,
dvis a ble t o filter
i t b e fo re us i n g i t i n motor or gen era
'

tor be a ri n g s . Wea r of

be a ri n g s s hould be i ns pe ct e d frequ en tly wh en al a r ge ti ght

be lt i s use d on t h e motor .

R ough n es s of t h e commut a t or s ho u ld be g u a rd e d a ga i nst

.

Whe n i t o ccurs a n d s toni n g doe s n ot r e m ed y t h e t rou bl e t h e ,

re a l ca use s hou ld be se a r ch ed out . Th e s a me a pp li es t o hi gh

mi ca Th e a
. ir g a p of t h e m a c h i n e s hould a l so b e f r e q u e n tly
che cked by thi ckn e s s ga uges for thi s i s agood che ck on t h e
co n di t i o n of t h e b e a ri n g s
. A re co rd m a d e of a ll of th ese tes t s
a n d i n s p e cti o n s for r e fe re n ce whe n oth er troubles d e ve lop

wi ll sa ve mu ch ti m e a n d t roubl e .

A fre que n t ch e ck for pro pe r en d pla y of t h e a rm a ture sh a ft

in i t s be a ri n g s will prev e n t groovi n g of t h e commut a t o r tha t
othe rwi s e mi ght be sus pe cte d to be ca use d by un s ui ta bl e
br us hes .

Ope ra ti n g Te m pe ra tur e s Too Hi g h —

A ll i ns ula ti n g m a teri a l
s u ch a s pa pe r a n d cot t on m a te ri a ls ha ve ama x i mum te m pe ra

ture li mi t a bove whi ch the y wi ll n ot re ta in th e i r i ns ula ti n g

s t ren gth a n d will s i mply ch a r a n d eve n tu a lly cru mble ca ,
usin g
 M OTOR A N D GE N E R A TOR TR OUBL E S

l t a
e e c ri c l faul ts in t h e wi n di n g s Th e ma teri a ls whi ch ha . ve
t h e hi ghes t ma xi mum ope ra ti n g te mpe ra ture a re m i ca a nd ,

s yn the ti c resi ns li k e b a keli t e Whe re surroun di n g te mpera .

tures a re kn own to be hi gh a s i n t h e ca se of motors used to

dri ve blowers i n aboi ler room or t h e scra pers on a n econ omi z e r ,

s pe ci a l h ea t res is ti n g insul a
-
ti on mus t be p rovi ded in st ea d of
tha t o rdin a ri ly u se d .

For t h e or d i n a ry d e s i g n of i n dus tri a l motor t h e S t a n da rdi

z at i on R ul es of t h e A m e ri ca n I ns ti tute of E l e ct ri ca l E n gin ee rs
re co m m en d t h e followi n g a s ma xi mum t e mpe ra tures for t h e
di ff e re n t ki n ds of m s ul a t i ng ma te ri a
ls s peci fi ed :
For cot ton silk pa , pe r an d ot h e r fibrou s m a
, t eri a
l s n ot so t e at ed as to r

i n cr ea
s e t h e t h erm a
l li m i t , 95 C
°
. Wh en a
m e su red by t h e r
80 C
°
m om e t er , .

For cot t on , s il a
p pk er,an d ot h e r fibrou s m a
t er i a
l t re a
t ed or i m pre g
a
t ed a
n d i n cl u d i n g e na m el ed w i re 1 05 C Wh en m ea
°
n ,
. s u red

90 C
°
by t h erm om et er , .

For m i ca
, a
s bes t os , a t eri a l ca
or ot h er m p a bl e o f re s i s t i n g hi g h t e m pe r a
t ures i n w h i ch t h e prev i ou s m a
, t eri a l s if u se d a re for s t ru ct u r a ,
l pu rposes
onl y a nd m a y b e d es t roy e d w i t h ou t i m p ai ri n g t h e i n s u l a t i n g o r m e ch a n

i cal qu ali t i es 1 25 C
,
°
. Wh en m ea su red by t h erm om e t e r 1 1 0 C ,
°
.

All pa rt s of el ect ri cal ma chi n e ry ot h e r t h an t h ose w h os e t e m per at u re

ff ect s t h e t e m pe ra
a t in g m a
t u re of t h e i n s u l a l, m a
t er i a y b e o p a
er t ed a t
su cht em pe ra t u res s m ay n ot be i a
n j u ri ou s i n a
n y es pect
r B ut . no artp
a
of con t i n u ou s-d u t y m ch in ery su bj ect t o h n dl i n g i n ope r a
t i on , a su ch as

bru s h ri g g i n g , sh a ve a
ll h a t e m pe ra in e xcess of 1 00 C for
°
t u re .

m ore t h n a av ery bri ef t i m e .

N or m Wh en at h er m om e t er is u s e d t o m ea
—
s u re t h e m a
xi m u m (h ot t es t

t u re acorrect i on of 1 5 O is a
s pot ) t e m pe r a dde d t o t h e t h e rm om e t e r
°
.
,

a
red i n g i n order t o a l l ow of t h e i m poss i bil i t y of l oca t i n g t h e t h erm om e t er
a
t t h e h ot t es t s pot wh i ch will be be n e a
,
t i on n e x t t o t h e m e t a
t h t h e i n su l a l
of the con du ct or .

Th e ha n d i s ave ry poo r th ermom e te r a n d s hould not be

re li e d upo n e x ce pt a s age ne r a l i n di ca tor of oper a ti n g t e m

p e r a t ur e s A. n y t e mpe r atu r e ab ov e 1 2 0 F i s v e ry un c om f or
°
.

ta ble to t h e tou ch but i s well wi thi n t h e ra n ge of s a fe Opera

ti on U n ti l as urfa
. ce t e mpe ra ture of a bout 1 76 F i s r e a che d
°
.

the re i s l i ttl e d a n ger to i n j ur y of i n s ul a ti on Th e motor .

s hould howe ve r be clo s ely w a tche d a t thi s t empe ra ture a nd

n ot a llowe d to go m u ch beyon d i t exce pt for avery s hort

380 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

C a
u ss s AND RE M E DI E S FO R TR O U B L E S IN DI R E C T-C U R R E N T M A C HI N E S

1 . T oo h i g h 1 . T oo h ig h s p e ed 1 . V a
ol t m e t e r
ds re 1 . S l ow t h e eng i ne .

v ol t a
ge . of e n g i n e . a
g re t e r tha
n st and a
rd

an d l am ps bu r n wi t h
u nd u e bri l l i an cy .

2 . T oo s t r on g m a
g 2 . Sam e . 2 . I n t r od u ce m or e
net i c fi el d . r es i s t an ce in s h u n t
fi el d .

2 . T o0 10w 1 . T oo l ow s p e e d of 1 . V ol t m e t e r s h o w s 1 . I n cr e a
se s p e ed of

v ol t a
ge . e ng i n e . l ow e r t h a11 st a
nda
rd eng i ne .

a
nd lam ps bu rn di m l y .

2 . T oo k m ag
wea 2 Sa m e . . 2 . T ak e ou t r es i s t
netic fi eld . a
n ce in s h unt fi el d .

3 . B r u s h es n ot p r op 3 . Sa
m e . 3 . R oc k br u s h e s

erl y set . bac k an d f o r t h t il l

hi g h es t a v ol t
g e c ons is t
e n t wi t h s p a r k l e s s

com m u t a t i o n i s s h ow n .

3 . E x ce s s i v e 1 a g e n er a
. In
t or , 1 B y t oo h i g h r ea
d 1 . C u t ou t n e cess a
ry

cu rr e n t . t oo m a
ny lam p s bu r n i ng of a m m e t e r f or nu m be r of lam ps . Re
ing or m ot ors r u n n i n g c a
paci t y of m ach i n e . d u ce lo d a on m ot or

By e x cess i v e sp ar ki n g I n t h is ca
ci r c ui t s . se

of dy n am o br u s h es n on e of t h e m ot ors

a
nd t oo h i g h re a
di n g ma y be d oi n g t oo
of dy n a
mo a
m m et er . m u ch w or bu t t h e re k .

m a
y be t oo m a
ny in
dy n a
m o ci r cu i t .

2 . In am ot or t oo , By
2 . e x c e s s iv e 2 . R e d u ce t h e l oa
d
m u ch m e ch ani cal spa
r ki n g of m ot or on t h e m ot or .

w or kb i e ng d on e by i t . br us h es n a
d t oo h i g h
r e ad i n g of m ot or
am m e t e r .

3 . S h or t ci r c u i t ; l e ak 3 . B y ex c e s s iv e 3 . L oca
te an d re

or g r ou n d in e x t e r na
l . spa rk of i ng br us h es ,
m ov e l e aks or g r ou n ds .

ci r c u i t . an d h e a t i ng of w h ol e
arm a t u re .

4 . S h ort ci r cui t in 4 . By h ea
ti ng of 4 . St op m ach i ne .

a
rm a
t u re coil . s h o r t - ci r c u i t e d c oi l L oca
te coi l . If en

m or e t h a
n t h e ot h e rs . t i r e l y bu r n e d ou t m us t

be re n e w ed .

5 . G r ou n d s i n a
rm a 5 . Sam e a
s 4 . 5 . L o c at e t h e

t u re . Tw o g r ou n ds g r ou n ds . R e -i ns u l a
te
t o the co re a
m ou n t to the co i l s co n t a
i ni n g
as h or t ci r c ui t . t h em .

6 . D ue t o e xce s s i v e 6 . By sp r ki n g
a of 6 . Fi l e aw a
y p ol e
f r i ct i o n i n be a
ri n g s or br us h es . By s ou n d p i e ces or r e -ce nt e r a
rm

by a
rm at u re s t ri ki ng of rm a
a t u re s t ri ki ng at u re . C l ea
n an d oi l

p ol e I n g en
p i e ce s . w h il e run ni n g . By j ou r n a
ls , or r e —fit be a
r

er al a n y caus e t e n d i n g h eat i ng of m ot or be a
r ing s .

t o s l ow m ot or . ings .
 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

C A US E S AN D RE M E DI E S r on TR OUB L E S IN DI RE C T-C U R R E N T M AC HI N E S

1 0 Re n e w
. brus h es .

fl y di ff er e n t g r a
d es of
hard a n d s oft brus h .

11 . By ah u m m i ng ,

si ng i ng s ou n d of
brus h es .

12 . W r on g i nt erpol e
a
p ol ri t y .

13 . B y i nspect i on .

14 Tr a
. ce ou t by
fol l owi ng up coi l e n ds .

15 . I n t erp ol e ir g a
a p 15 . al l i n t er
S ee if
t oo l on g or t oo s h ort .
p ol e ga re eq ua
ps a l .

5 . He a
t i ng 1 Sa
. me as g i ve n 1 . Sa
me a
s g i ve n
rm a
a un d e r E xcess i ve cur und er
“
t ur e . E xces
s i ve cur
" ”
re n t . r en t .

2 . C or e be c o m es

h ot t er t h a
n a
rm a
t ure
coi l s a
fter run ni n g for
as h ort ti m e .
 M OTOR A N D GE N E R A TOR TR OU B L E S

C A US E S AND RE M E DI E S FOR T R OUB L E S IN DI R E CM U R RE N T M A C HI N E S

6 . H ea
ti ng
com m u t a
t or .

3 . E x ce ss i v e ou r 3 . S mea . 3 . D is cov er a
c use of

re n t . e xcess i v e cu r re n t a
nd

4 . Same .

7 He a
.t i ng
fi lde coi l s .

2 E ddy curre n t s i n
.

p ol e p i e ces . h ea
t bei n g
con d u ct e d t o t h e coil s .

1 . La
c k of l ubri ca 1 . Fi ll oil cu ps ; cl e a
n

t i on .

4 . R ou g h or cu t

sh a
ft .

5 . S ha
f t be n t .
 A R M A T U RE WI N DI N G A N D M OTOR RE P A I R

C AUSE S AND RE M E DI E S FO R TR OU B L E S IN DI R E C T- C U R R E N T M A C HI N E S

( C on ti n u ed )

C a
us e
H ow m os t re a
di l y
R e m ed y
d e t ect e d

6 . Oi l ri n g s s t u c k . 6 . I ns pect i on . 6 . A djus t ri n g s in
g roov e s .

1 . T oo m u ch l oa
d . 1 . By s pee d i n d i ca 1 R e d u ce
. th e m e
t o r ; h e vy a sp ar ki n g , ch a l l oa
n i ca d .

h ea
ti ng of l l pa
a r ts

a
nd be a
r i ng s .

2 . A ny of a
t h e c us es 2 Sa m e a n d same .
, 2 . Di s cove r a
p rt i en
g i ven u n d er H eat i ng a s g i ve n und e r He a
t la
r ause a n d r e m edy
c

of bea
ri n g s , ca us i n g i ng of bea ri n g s . same a s g i ven u n de r

He a
t i n g of be a
”
e x ces s i v e fri ct i on . ri n g s .

3 . S h ort ci r cu i t or 3 . By m ot or k
t ai n g 3 Sa .m e a s u n de r 5 .

g rou n ds i n a
rm a
t ure . e x ce s si v e cu rre nt E x cess i v e cu rre n t .

aa
w i t h ou t l o ds s h ow n

by a m m e t e r or h ea vy

r ki n g a
s pa nd h e a t i ng .

4 . T oo l ow v ol t a
ge 4 . By m ot o r v ol t 4 . B y i n c re a
s i ng t h e

a
t t e r m i na
ls . m e t e r or sp ee d i ndi li ne v ol t a
ge .

c at o r . By h eavy

sp a rk i n g and h ea ting .

1 . T oo l i g h t l o d (i n a 1 B y n ot i ce a
. bl e i n 1 . se l oa
I ncre a d .

s e ri es m ot ors ) . cr e ase i n s pee d .

2 . W ea kfi e l d s h un t 2 Sa me
. . 2 . S t re n g t h e n fi ld e .

m ot or .

3 T oo h ig h v ol t a
.
ge 3. S a
me . 3 .C orre ct l i n e v ol
at t e r m in al s . d ue t o ta g e by r e m edi es 1 a nd

hi g h v ol t a
g e of d y n a 2 un d er Too h i g h
v ol t a
"
mo .
ge .

1 . T oo w e a r es i d u a
l k 1 . t t ra
V e ry li t t l e a c 1 S e n d a cur ren t
.

ma g n e t i s m ca
us e d by . t i on by t h e p ol e p i e ce s t h roug h e l d fr om a fi
a jar or re v e rsa l of w h e n t es t e d wi t h a fe w ce l l s or fr om a
cu rr e n t n ot s u fi ci e n t p i e ce of i ron . r u n ni n g dy n a mo .

to re v ers e m a
g n e t is m .

2 . S h or t c i r cu i t 2 . Ma
g n eti sm ve ry 2 . L o c at e t h e

wi t h i n m a
ch i n e , or g r ou n ds or s h or t ci r

g r ou n ds i n fie l d wi nd cu i t s a
n d co rrect t h em .

ing s .

3 . R e v e rs e d fie l d 3 A l l pol es sh oul d
. 3 M ae p ol a
. k
ri t y op

coil s . ha ve a l t e rn ate m a g p os i t s by re v e rs i n g t h e
n e t i s m ; i f ac oil i s r e c on nec t i ons of t h e coil .

v e rse d i t w i l l s h ow E a ch p ol e s h ou l d be
‘

m a
g n et i s m , bu t m a
y opp osi t e t o t h e on e on

n ot be of opp os i t e p o ea ch s i d e of i t .

la
ri t y .

4 . S e ri es a
nd sh u n t 4 a
. V
g e fa lls a
ol t s 4 R e v erse con n ec
.

w i n di n g s con n e ct e d u p l oad i s i n cre as ed t h e , t i ons of e i t h er el d, fi

opp os i t e to e a
ch ot h er . e t e rn a
x l ci r cui t bei n g but n ot bot h
cl os e d s h ow i n g a
th t
t h ey ar e w or ki ng

a
g a
i n s t on e a
n ot h e r .
3 86 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

C A US E S AND RE M E DI E S FO R TR OUB L E S IN DI R E C T-C UR R E NT M A C HI N E S

( C oncl u ded)

13 . Fl i c k e ri n g 1 . U nev e n r un ni ng 1 . By fli c k eri ng of 1 . Ov er h a
ul e ng in e .

of la
m ps . of eng i n e , a
pr ob bl y la m p s or vi br a t i on of s p eci a
lly g ove rn or .

due t o g overn or fa
il v ol t m e t er i n di ca t or .

i ng t o proper l y f un c

2 . L oos e c on n e c 2 . Sa
me .

t i ons . ei t h e r on m a
ch i n e , s wi t c h bo rd or a

14 . N oi se . 1 S ee t hi r d fa
. ul t

fou rt h f a ul t ( 4 , 5,

9 , 1 0, ei g h t h fa ul t

( s 4.
r a n d te n t h

fa ul t .

2 A rm a
. t ure run n i ng 2 . By un us u a
l n oi se . 2 . C orre ct di rect i on
ga
a i ns t t h e bru s h es . of r ot a
t i on .

E l e ctri c l a Def ects Troubles i n mot ors a n d ge n e ra

.
—
tors
du e to el ectri ca
l defe cts s how up i n ava
ri e ty of w a
ys T he i r .

loca ti on howeve r i s more ofte n as i mple tha

, , n a di ffi cult m a tte r
a n d d e pe n ds upo n afe w tes ti n g d e vi ces a n d ag re a t dea l of
pa ti e n ce a n d pe r si s t e n ce A n e x pe ri e n ce d ope r a . t o r or re
p a i r m a n l e ar n s to d i ag n o s e e l e ct ri ca l t r oubl es by a p r o c es s

of eli mi n a ti o n whe re there m a y be se v e r a

l ca u s e s F o r .

s u ch a n a na lysi s of commo n ele ctri ca l trouble s i n motors

a n d ge n e r a tors t h e ta ble on p a ges 380 to 386 wi ll be foun d
us e ful I t wa . s comp i l e d by t h e a uthors of t h e N a va l E l ec
tr i ci a ns Tex t B ook a nd ha s bee n t a ken from tha t m os t pra ct i ca l
'

wor k .

C AU S E S A N D RE M E DI E S FOR TR OUB L E S I N A L TE R NA TI N G
C UR RE N T M A C HI N E S

I n du ct i on M ot or Troubl e s most common troubles .

—
Th e
wi th i n du cti on motors S how up by t h e ma chi n e f a i li n g t o s ta rt

or by s topp i n g wh i l e co n n e ct e d to t h e l i n e Wh en t h e m a .

chi n e r e fu s e s to s t a rt a n d t h e fus e s a re n ot blown t h e ca us e ,

m a y b e i n too l a
r g e a lo ad T h e r e m e dy i n s u ch ca s es
. i s to e i th e r

re du ce t h e lo a d or u s e aclutch for sta rti n g s i n ce t h e s q ui rre l

ca ge motor h a s a li mi te d s ta rti n g torq ue but ca n oft e n ca rry

 M OTOR A N D GE N E R A TOR TR OUB L E S

amuch la rg er l o a d whil e runni n g . When i n vesti ga ti n g a

trouble of thi s ki n d i t i s i mporta n t t o se e th a t t h e volta ge i s
n orm a la n d th a t t h e be a ri n g s a r e i n good co n di ti o n . I f n on e
of thes e con di ti ons s ee m to ca use t h e trouble at es t s hould be
ma de for ope n ci r cui t s i n t h e wi n din gs (S e e C ha . pter I X ) .

A n e xcess i ve cu rre n t a t s ta rt i n g m a y b e d u e to a h i gh volt

a ge a ppli e d or too g re a t aloa d
. Wh e n t h e volt a g e i s h i gh
a n a uto tra - n s form e r wi th s ui t a ble ta ps mus t be us e d for
s ta r ti n g . When a n a uto tra
- ns fo rm e r i s use d a n d t h e s ta rti n g

curre n t i s e x ces s i ve a , te s t s houl d be m a de for prope r co nn ec

ti ons Too low t a
. ps on t h e s ta r te r s hould be a v oi d e d .

A n overloa d on a n i n ducti o n moto r will u s u a lly S how up ,

by t h e m otor comi n g to res t or t a ki n g a bout 1 0ti me s more tha n

n orm a l curre n t Whe n fuses a

. n d ci rcu i t br e a kers do n ot
oper a te un der s uch he a vy curre n t t h e m a
, chi ne wi ll burn out .

I t i s th e r efo re i mpo rt a n t th a t fus e s a n d se tti n g s of ci rcui t

b re a ke rs be use d to pre ve n t s uch bu rn outs S i nce t h e torque

- .

of a n i n du cti o n m oto r v a ri es w i th t h e s qua re of t h e volt a ge ,

l ow su pply volta ge m a y b e t h e c a u se of t h e m ac h i n e s top

pi n g A l s o worn be a
. ri n gs wi ll a ll ow t h e r oto r to dr op on t h e
sta tor a n d thus blo ck t h e fo rm e r a n d s top t h e m a ch i ne .For
oth er de ta il s i n t es t i n g a nd in s pe cti on of i n du cti on motors s ee

C ha pt e r X I V .

L oca ti ng Troubl e s i n Wi n di n g Of I n du ct i on M ot ors .

When t h e ca us e of tr ouble wi th a n i n du cti o n mo t o r i n s t a rt i n g

or i n ope r a ti on h a s bee n tra ce d to t h e s t a tor wi n di n gs de ta ,

il s
of loca ti n g t h e f a ult a re outli n e d i n C h a pter I X Whe n .

t h e s ta t or h a s b e e n re p a i re d a nd a ga i n pl a ce d i n serv i ce i t s con

n e ct i ons s hould be ca re fu lly looke d ov e r Th e po in ts to be

.

ob s erve d whe n ins pe cti n g s uch as ta tor a re outli ne d on p a ge

3 63 . I n ca s e t h e co n n e cti o ns of a n a uto sta rt er a
- re re v e rs e d ,

t h e s tarti n g cu rre n t wi ll be e x cess i v e a n d i ns uffi ci e n t tor qu e

wi th t h e s wi tche s i n t h e run n i n g posi ti o n wi ll S how up If .

t h e motor refus es to s ta rt t h e ca us e m a y b e du e t o a d e f e ct i n

t h e cha n g e ov er s wi tch or to al oo se co nn ecti o n or op e n

-

ci rcui t in t h e a uto s ta r t er
- .

M e ch a ni ca l Adju s t m ent s I n those ca

—
s e s wh e re i n du cti o n

motors a re i n co n ti n uous ope r a ti o n reg ula r i n s p e cti o n s S ho u ld

be m a de of t h e a ir g ap to s ee th a t i t i s n ot a pp r e ci ably re du ce d
3 88 A R M A TU R E WI N DI N G A N D M OTOR R E P A I R

a t t h e bottom of t h e rotor on a ccou n t of w e a r of t h e b e a ri n gs .

Whe n t h e a ir g a p i s r e du c e d a t es t s hould b e m a d e b e fo r e t h e

trouble i s a ttri bute d d e fin i t e ly to we a r of t h e b e a ri n g s . I t is

a ls o i mpo r ta n t th a ta n a rma ture h a ve as m a ll pla y e n dwi s e i n
t h e be a ri n gs Th i s S hould be a
. bout / i c i n ch
l . E x cess i v e
he a ti n g or ex cess i ve be lt te n si o n m a y b e t h e ca us e of a g r e a t
de a l of be a r i n g t r oubl e on a n i n du ct i on moto r whi ch i s be l t
'

d ri v e n .

Trou bl e s Du e t o E l e ct ri ca l Fa ul t s . Wh e n e rr ors ha
-
ve b e e n
ma d e i n wi n d i n g a n i n du cti o n motor or i n re co n n e ct i n g t h e -

coi l s ,
tr ouble wi ll us u a lly s how up i n he a ti n g of t h e coi ls a ,

p e culi a r humm i n g s ou n d for l a r ge a n d un b a la n ce d cu rr e n t s

i n t h e d i ffe r e n t ph a ses . B e fo r e t es ti n g for f a ults of r e con n e c

—

ti on of co i l s i t mu s t be d et erm i n e d th a
,
t t h e co n n e ct i on s Of t h e
wi n d i n g to t h e s upply ci r cui t a r e co rr e ct a n d th a t n on e Of t h e
co n n e cti o n s of t h e ph a s e coi l s h a ve be e n a cci d e n t a lly j a mm e d
toge th er s o a s to S ho r t ci r cui t th e m
-
. Troubl e s i n r otors of
i n du cti o n moto rs a re r a re howe ver i n s qui rre l ca
, ,
- ge types
trouble m a y b e lo c a t e d i n s old e r e d j o i n t s wh i c h h a v e m e lt e d
or co rr od e d .Hi gh re s i s t a n ce a t joi n ts lowe rs t h e e fii ci e n cy ,

i n cre a s es t h e h e a ti n g a nd a ls o i n cre a s e s t h e s ta r ti n g tor qu e of

t h e motor .He a ti n g or ope ra ti o n a t re du ce d output or sp e e d

m a y b e d u e to a th re e ph- a s e moto r ru n n i n g o n o ne o r two
ph a s es .

Tr ou bl e s wi t h S yn ch r on ou s M ot or s —
Wh e n as yn chr on ous
motor f a i ls to s t a r t t h e tr ouble i s ge n e r a lly du e to a n ov e r lo a d.

I n t e sti n g out for s u ch aco n d i t i o n t h e moto r s hould be s t a rt ed

li ght I f t h e Opera
. ti on i s n ot s a tis f a ct o ry t h e lo a d s hould be
r e du ce d . P oo r s t a rti n g m a y a l s o b e c a u s e d by r e du ce d volt
a g e o r op e n o r f a ulty c o n n e c t i o n s i n s t a r t i n g a pp a r atu s . A n

Op e n ci r cu i t i s us u a ll y i n d i ca te d by n o curr e n t flowi n g i n a
pa rti cul a r ph a se . A n ex ce s s i ve cu rre n t u s u a lly i n di ca te s a
s ho rt ci rcui t but m a y b e d u e to g r ou n d s . A n e x ce s s i v e c u r

r e n t i n as yn chr o n ous motor i s ad a n ger ous co n di ti o n a nd the

troubl e s hould be lo ca te d .

Wh e n asyn chr o n ou s motor i s us e d for powe r fa -

ctor corre c

ti on ov e r h e a t i n g i n di ca tes a n ex ce s s i v e cu r r e n t . Th e m a ch i n e

ca n usua lly be t e mpo r a ri ly op e r a te d by re du ci n g t h e lo a d or

r e d uci n g t h e a mou n t of le a di n g curre nt Wh e n as yn chr on ous
.
3 90 A RM A TURE WI N DI N G A N D M OTOR R E P A I R

a ble s our ce of t h e trouble a n d i t i s d e ci d e d to s hut d ow n t h e

motor as e con d fus e i s s ome ti m es blown by t h e excess i ve

,

curr en t pe r ph a se I f on ly t h e firs t d efe cti ve fus e fou n d i s

.

re pl a ce d t h e moto r m a
, y b e s t a r t ed f r om t h e l i n e s i d e of t h e

s wi t ch wh i ch i s con n e ct e d a he a d of t h e fus es When t h e .

s wi tch i s thr own ov e r i n to t h e run ni n g pos i ti on t h e motor i s

a ga i n opera ti n g on S i ngl e pha se B eca

. u se t h e motor con
t i n u es to h e a t up t h e use r oft e n th in ks there mus t be
s ome thi n g w r on g wi th t h e mo t o r i t s e lf a n d ca lls for h e lp ,

wherea s if h e h a d on ly te s te d a l l t h e fus es i n t h e fir s t pl a ce a nd

r e pl a ce d a l l of t h e burn t out fus es i n s tea

- d of on ly on e of
the m h e could ha
,
ve put t h e motor ba ck i n se rvi ce wi thou t

a ss i s t a n ce a n d wi th a m i ni mum lo s s of t i i n e . A n oth e r s our ce

of trouble whi ch m a y b e d e t e c t e d a t t h e se r vi c e fu ses i s low
volta ge Thi s Ca
. us e s ex ce ssi ve hea ti ng a n d oft en burn s
out s ta tor coi ls Th e volta . ge ca n be ch e ck e d r oughl y wi th

te s t l a mps .

I n s pe ct i on of M ot or s t a rt i n g De vi ce s
- —
From t h e fus es i t i s
u
c s tom a r y to p r o ce e d to ex a m i n e t h e moto r -s ta r ti n g s wi tch ,

comp e n sa to r or con troller C on ta . ct fin ge rs a re ofte n foun d

ben t or burn e d s o tha t th ey do n ot m a k e con ta ct a nd t h e

con n e cti n g l e a ds a re s om e ti m e s burn e d off Th e two mi n ute-

.

s ta r ti n g re s i s t an ce s up p li e d by t h e m a n uf a ctu re rs for s t a r ti n g

S li p ri n g moto rs i s Ofte n bu r n e d out by b e i n g us e d for s pe e d

-

r e gul a ti n g duty wh i ch r e qui r e s amu ch h e a vi er res i s ta n ce .

e n t e s ti n g a ern a
T e s t i ng M ot or for Groun d s W —
h n a l t ti ng

cu rr e n t moto r for gr ou n d s am a , g n e to o r h i g h volt

-
a g e te s t i n g
tr a n s fo r m e r S hould be u s e d a s t h e li n e volt a ge wi ll s eldom
S how a groun d un l ess i t i s m a ki n g very good co n t a ct .

Na t i on a l E le ct ri ca l C od e rule s requi re tha t moto r fra mes be

gr oun de d but thi s r e qui re men t i s n ot a
,
lw a ys ca rr i e d ou t .

Wh en t h e motor fra m e i s i n s ula te d from t h e gr oun d t h e motor

ca n be k e pt i n Ope r a ti on wi th on e pha se gr oun d e d to t h e

motor fra m e but t h e de fe ct S h ould be re me di e d a

,
t t h e firs t
oppor tun i ty A s e con d con n e cti on b e tween t h e s ta
. ti on a ry

w i n d i n gs a n d t h e moto r fr a m e wi ll burn out t h e coi ls whi ch i t

s ho r t ci r cui ts a n d if n ot gi v e n p r ompt a
,
tten ti on t h e two
g r ou n d s m a y r es ult i n t h e bu rn i n g out of t h e e n t i re w i n d i ng .
 M OTOR A N D GE N E R A TOR TR OU B L E S

When both t h e s upply sys te m a n d t h e moto r fra mes a re

gr oun d e d a , s i s us u a lly t h e ca se on e gr oun d on t h e s ta

, tor
wi n d i n g wi ll blow on e of t h e moto r fuses un le s s t h e fus e i s
t oo h e a vy i n whi ch ca
, s e t h e gr oun d m a y bu r n out s om e of t h e
st a to r coi l s H owever e very g roun d wh i ch blows a fuse
.
,

does n ot o ccur i n t h e motor wi n di n g I f t h e mot ors tes t .

cle a r t h e wi ri n g l e a
, di n g to t h e motor m a y e foun d groun d e d
b
t o t h e con dui t .
~

I t i s agood pl a n to ru n t h e d efe cti v e moto r whi l e t e s ti n g

when i t I s p ra cti ca ble to do so Thi s ma . kes i t pos si ble to

con duct a ddi ti on a l tes t s a n d very of t en to obs erv e s y mptoms

whi ch do not a ppea r wh en t h e motor i s s ta n di n g s ti ll . U n de r

s u ch op e ra ti n g con di ti on s t h e s pe e d should be tes te d L ow .

s pe e d a nd i na b ili ty t o pull t h e loa da re us u a lly a n i n di ca ti on

of ba d con n ecti on s be tween t h e r oto r b a rs a n d t h e roto r en d

ri n gs .

Hot S t a t or C oil s A h oth er con d i ti on to obs erve whi le t h e

.
—

motor i s ope ra tin g i s whether t h e s t a t or coi l s a re hott er i n

'

one pl a ce th a n in a n oth e r Thi s is on e of t h e s i g n s of b e a

. ri n g

tr ouble Wh en t h e b ea
. ri ngs b e come wo rn t h e s t a to r coi ls
a rou n d t h e se cti on of r e du ce d a i r ga ps g et hotte r th a n t h e co i l s

a dj a ce n t t o t h e s e cti on whe re t h e a ir g a p h a s b e e n i n cr e as e d .

I f t h e bea ri n g s a r e n ot re n e w e d b e fore t h e rotor b e gi n s t o

ru b on t h e s t a tor t h e motor win di n gs m a

, y b e s e r i ou s ly i n

j ured es pe ci a
, lly if t h e fuse i s too la rg e a n d doe s n ot blow .

When i t i s i mpra cti ca ble t o ope r a te t h e motor t h e b elt should

be t a ken 03 a n d t h e bea ri n gs ex a mi n e d to fin d out if there
i s t oo mu ch pla y i n th e m .

Te n s i on of B e l t s M u ch be lt a
.
—
n d be a ri n g tr oubl e i s ca u se d
by t h e b elt b ei n g too ti ght Thi s i s es pe ci a . l ly tru e wi th
ve rt i ca l belt d ri ves from s qui rrel ca ge motors to h i gh s pe e d
- -

ma chi n e s . Wh en be a ri n g tr oubl e i s ex pe ri e n ce d wi th i n

st a l la t i on s of thi s d es cri pti on i t i s us ua lly b eca us e t h e pulle y

s ur f a ce i s too s m a ll to a cce le ra te t h e d ri ven ma chi n e a s fa st

a s a S qui rre l ca
- ge moto r com es up t o s pe ed a n d con s equ en tly
,

t h e b e lt com e s off In a
. tte mpti n g to k ee p t h e b elt on t h e
pulle y t h e belt i s us ua lly ma d e s o tig ht tha t t h e excessi ve
ten si on soon w ea rs down t h e b e a ri n g s T hi s trouble ca
. n
3 92 A RM A T URE WI N DI N G A N D M OTOR R E P A I R

s ome ti mes be ove rcom e i n i n s ta lla ti on s of s m a ll motors by

us i n g la r ge r pull e y s a la
,
rg e r m ot O r or by ch a
, n gi n g fr om a ve r

ti ca l be lt dri ve t o aho ri zo n ta l be lt dri ve wi th t h e S la ck si d e

of t h e be lt on top Wi t h la . rg e b e lt e d moto rs d ri vi n g hi gh

s pe e d m a chi n e s t h e s li p ri n g typ e of moto r s hould be u s e d i n

-

ord e r to b ri n g t h e dri ven m a chi n e up to s p e ed mo r e s lowly .

Tr oubl e s i n R ot or Wi nd i ng s A ba
.
—
d con ta ct i n t h e r oto r

wi n di n g i s n ot s o ea s i ly foun d wh e n t h e e n d ri n g s a r e ca st

on to t h e e n d of t h e r oto r b a rs T h i s ca
. s t con s t ru cti o n w a s

ori gi n a lly a dopte d to ove r com e t h e ba d j oi n ts wh i ch d e v e lop e d

wi th s cre we d a n d s old e r e d co n n e cti o n s i n t h e roto r wi n di n gs .

Th e cha n ge h a s n ot e n t i re ly e l im i n a t e d t h e tr ouble howe ver

, ,

b e ca us e t h e molten m e t a l do e s n ot a lwa ys un i te wi th t h e e n d
of t h e coppe r ba rs wh e n t h e e n d r i n g s a re b e i n g ca st . Whe n
thi s is t h e ca se tr oubl e du e to t h e poo r co n t a ct oft e n d e v e lop s ,

e s p e ci ally i f t h e m otor i s s ubj e ct t o mu ch di r t a n d vi b r a ti o n.

Wi th ali t tle e x p e ri en ce ad e fe cti ve j oi n t be twee n t h e ea st

e n d ri n gs a n d t h e r oto r b a rs ca n be foun d by t a ppi n g t h e en d

ri n g s w i th ah a mm e r a n d n oti n g t h e d i ff e r e n ce i n s oun d a t
va ri ou s pl a ces . A ba d joi n t i n th i s type of con s tru cti on ca n

be r e p a i re d by w e ld i n g t h e ba ra n d e n d ri n g s tog e the r . We lde d

ro t o r wi n d i n g s h a ve b ee n v ery su cce s sful a , n d i t i s u n u s ua l
t o fin d ba d j oi n t s i n r oto r wi n d i n gs wh i ch h a ve b een put
toge th e r i n thi s m a nn er .

E xa m ina t i on of S ta t or Win di ng T h e s ta
—
to r wi n di n g
s hould a ls o be tho r oughly exa mi n e d wh i le t h e e n d s h i eld s
a re off t h e moto r . I f on e or two coi ls a r e bu r n e d ou t , t he
oth e r coi ls ca n i n mo s t i n s t a n ce s be r a i s e d ou t of t h e S lot a nd

n e w co i l s s l i pp e d i n to pla ce p r ovi d e d th a t t h e coi l i n s ula ti on

i s fl exi bl e a n d i n g ood co n d i ti on S hould thi s be a
. tte mpted ,

howe ve r a ,
ft er t h e i n sul a t i on on t h e co i l s h a s b e com e b r i ttle ,

the r e i s agra ve d a n g e r of d a ma gi n g t h e i n sul a ti on to s u ch a n

e x t e n t th a t t h e e n ti r e s t a tor win di n g m a y h av e to b e r e n e w e d .

Wh e n t h e con d i t i on of t h e i n s ula ti on i s doub t ful a n d o n ly on e

or two co i l s n e e d r e pl a ci n g it ha
,
s b e e n foun d agood pla n

to cu t a wa y t h e burn t out coi ls a - n d th r e a d n e w wi re through

t h e s lot s tu rn by tu rn wi tho u t d i s tu rb i n g a
,
n y of t h e oth e r co i l s .

Th e d a ma ge fr o m aloca l S ho rt ci r cui t i n t h e s ta to r wi n di n g
 C HA P T E R X V I

M E TH ODS US E D BY E LE C TR I C A L RE P A I R M AN TO
S OLV E S P E C I A L TR OU B LE S

Whe n ca ll e d upon to l Oca t e t roubl es i n el ectri ca la ppa ra tus

ma n y e l e ct ri ci a ns a n d re p a i rm en fin d the m s e lve s i n as ta t e of
won d eri n g jus t wha t to do firs t Th e myste ry s uppose d for
.

s o lo n g to be a ss o ci a te d wi th t h e ope ra ti on of el e ctr i ca l a ppa

ra tus s e ems to d i s coura ge m a ny a ble e le ct ri ca l m en to a tte mpt
t o sea r ch out a n e l e ct ri ca l troubl e whe n i t s ee ms to be acompli
ca t e d on e . B y t h e us e of t h e s a me good sen s e th a t ma ke s
s u ch m e n s u cces s ful i n t h e wo r k w i th wh i ch t h e y a re f a mi li a ,
r

mos t e le ctri ca l probl e ms i n re pa i r ca n be lo ca te d a n d as a ti s

fa cto ry re m e dy a p pl i e d . I n a s e r i ou s ca s e wh ere e x p e r t h e lp
i s re a s on a bl e a n d wi thi n e a sy a n d p rompt a cces s i t m a
, y n o t
a lwa ys pa y f o r a n i n e x p e ri e n ce d m a
n to s p e n d t h e n e c e ss a r y
t i m e to h a n dl e ad i ffi cult t r oubl e but i n t h e o rd i n a ry r u n of

pla n t op er a ti on s u ch trouble s a re f e w . Wh a t i s mos t n e e d e d

i s ali ttl e cle a r thi n ki n g a
-
i d e d by afe w tes ti n g i n s trum e n t s .

On e of t h e wa ys by whi ch are pa
. i r ma n ca n d e v e lop con

fiden ce in hi s own a b i li ty t o s e a r ch out tr oubl e a n d pre pa re

hi ms e lf to p rope rly di a g n o s e t r oubl e s ,

i s to r e a d an d p r ofit
by t h e e x p eri en ces re la te d by those who h a ve worke d out
puzzli n g troubl es a n d ha ve told i n t h e column s of ele ctri ca l
t ra d e journ a ls how th e y pro ceed e d Th e a . uthor h a s ma de
ase le cti on of s u ch e x peri en ce s coveri n g aw i d e ra n ge of op e ra t
i n g t r ouble s whi ch a r e li a bl e to come up a t ati m e or u n de r
ci r cums t a n ce s wh i ch m a ke th e m di ffi cult to h a n dl e . Th e
d e ta i l s gi v en wi ll furn i s h s ugges ti ons a s to m e thod s of pr o

ce du re i n m a n y oth e r ca -
s es th a n tho s e d e s cri b e d .

S pa rk i n g a t C om m ut a t or C a us e d by P oor B e l t J oi n t s —
In
opera ti n g motors or ge n e ra tors wi th l a ce d b e lt s i t i s i mpo rt a
,
nt

th a t t h e joi n ts be fl exi ble a n d t h e e n ds n e a tly la ce d clos e

toge th er to pres e n t a s nea r ly a s po s s i bl e aco n ti n uous s urfa ce

to t h e pulle y Wh ere thi s i s n ot don e l a

. ce d b e lt s v e ry fre

3 94
 M E TH ODS US E D TO S OL V E S P E C I AL TR OUE L E S 3 95

quen t ly ca use s pa rki n g du e t o a n y on e of t hree ca us e s : (1 )

Th e l a ce d b e lt wh en pa ss i n g ov e r t h e pull e y m a y c a u se a j e r k
or m e ch a n i ca l vi bra ti on of t h e a rm a ture whi ch i s se vere
en ough to th r ow t h e b rush es fr om t h e co m mut a tor a n d ca use
s pa r ki n g du e to t h e b r ok e n ci r cui t ( 2 ) W h t h b a i g a
'

. e n e e r n s re

loos e i n thei r hous i n gs or wh en t h e a rma ture s ha ft is loose i n

i t s bea ri n gs t h e j erk of t h e l a
,
ci n g m a y p u l l t h e a r m a tu r e to
on e si d e . Thi s d evelops ah i gh e r volt a ge i n agen era tor or a
hi gher coun ter ele ctromoti ve for ce i n amotor i n t h e pa rt of t h e

a rm a ture whi ch i s pull ed clos e s t to t h e pole fa Thi s wi ll

'

ces .

ca us e s p a r ki n g du e to ap ul s a ti n g current or i n se vere ca s es

due to as hort ci rcui t curr en t b e tw e e n studs of t h e s a

.

me
pola ri ty .
( )
3 Th e b e lt m a y s l i p wh i l e t h e l a ce d en d s a re

pa s s i n g ove r t h e pull e y whi ch wi ll p e rm i t av a

, ri a ti o n i n t h e
s pe e d of t h e a rm a ture This wi ll ca . use as udden cha n ge i n

t h e curren t a nd m a y p r odu ce s p a r ki n g d u e t o t h e i n du ct a n ce

of t h e a rm a ture coi ls .

P l ug g in g aC om m ut a t or Whe n commuta .
-
tor ba rs S how a

ten d e n cy to b li s ter a nd h ea d a t t h e out e r en d s pluggin g ‘ ’

,

t h e commut a tor Often gi ves re li ef To do thi s pr o ce e d a .

, s

follows : Gri n d a ll of t h e s et
”
from t h e teeth of api e ce of
“

ha cks a w bla d e Wi th thi s pi e ce of bla

. d e sa w t h e commut a tor
s i d e mi cato t h e out li n e i n d i ca te d a t (a ) i n t h e a c c omp a n y i n g
di a gra m Fi g 2 50 N e xt dri ve i n mi cawe dges or plugs so
,
. .

ca l le d to e n ti re ly fill a
,
nd

perfe ctly fit t h e groove s

ma d e by s a wi n g Th e .

b es t re s ults a re to be oh

ta i n e d by loo se n i n g t h e
commut a tor befo re dri v
F 2 50 M t h od of ai i g mi a g
i n g i n t h e w e dge s but
—
IG. p e re
c
. r n se

t by a wm g a t (a ) ad p l g g g
,
m
thi s I s n ot a
en s n u in .

bs olute ly
n ecess a ry . For oth er d e t a i ls of commut a tor re pa ir see
C ha pt er XI I .

Kn ock i n aM otor Arm a tur e Du e t o B a

n d Wi re s B e i n g Too

Hi g h .
—
In t h e ba
n di n g of m a r ma
n y type s of d i r e ct cu r r e n t a -

tures t h e b a
,
n ds a re la i d o n to al a ye r of fis h p a pe r or of thin
fibe r whi ch a fi ords s mooth b e dd i n g for t h e b an d w i re s a
n d wh i ch

als o pro vi d es addi ti on a

l in sul a ti on b e tween t h e b a n d wi res and
3 96 A RM A T URE WI N DI N G A N D M OTOR R E P A I R

t he rm a
a ture coil s ma
. n y of t h e l a
On te r d es i gns of a rm a tur es
t h e t e ns i o n us ed i n b a n di n g h a s been g re a tly i n crea s ed a , nd a s

afurthe r pre ca uti on a ga i ns t t h e ba n d s cutt i n g i n to t h e i n s ul a

ti o n of a n y co i ls th a t ma y b e h i gh i n t h e s lot 3 l a,y e r of th i n

t i n i s i n te r pos ed b e twe en t h e b a n d wi r e a n d t h e i n s ula ti n g

ba nd . Th a t it m a y n o t b e a dv i s abl e to a dopt th is i mp r ov e d
m e thod on m a ch i n es th a t ha ve n ot b ee n des i gn ed for i t is ,

i llus t ra te d by t h e followi n g ex pe ri e n ce (E le ctri ca l R ecord ,

J une ,

A 20 h p di r e ct curre n t mo t o r whi ch h a
- .
-
d j us t be e n re p a i re d
a n d S h i pp e d w a s re turn e d w i thi n af e w d a
, ys wi th t h e com
pla i n t tha t the a rm a ture h a d akn o ck i n i t
“
A t t h e t i me of
.

t es ti n g t h e moto r aS li ght vi b ra , ti on h a d b e en n o t i ce d but ,

leve li n g of t h e motor h a d e lim i n a t e d t h e vi b r a ti o n C a . re ful

i n s pe cti on of t h e motor th i s ti me how e ve r re ve a , ,

le d tha t on e
of t h e t i n cli ps of a n en d b a nd h a d b ee n s t ri ki n g on e of t h e
bottom pi e ce s I n ves ti ga . ti o n di s clos e d tha t acon tri butory
ca us e of t h e kn o cki n g wa s th a t on e of t h e be a ri n g li n i n gs h a d
bee n bo re d ali ttle out of cen te r but e ve n a ,
fte r thi s h a d b e en
co rre cte d a pi e ce of % 4 i n ch fib e r could n ot be in s erte d be tw ee n
-

the a rm a tu re co re a n d t h e bottom pol e p i e ce s i n ce r t a in

posi ti on s of t h e a rm a ture Th e re a l ca us e of t h e tr ouble w a s
,

then tha,
t t h e la ye rs of i n s ul a ti on a n d t i n un de r t h e b a nd

wi re s proj e cte d t h e w i r e s a
,
n d th e i r hold i n g cli ps too fa r i n to

the a ir g a p A s
. t h e a i r a
g p w a s th i n n e r th a n o r d i n a r i ly fou n d
on s u ch moto rs t h e re m e dy w a ,
s to re move t h e t i n a n d i n sta ll
ba n d w i re s of s m a lle r di a m e te r a n d w i th l es s t e n s i o n a ,
n d to

us e th i n C opp e r for t h e b a n d wi re cl i p s Th e se ch a
. n ges r e

su l t e d i n a %2 i n ch a
-
i r a
g p T h e
. t es t e r s w er e d ece i v e d a s to
t h e ca us e of t h e vi b ra ti on b e ca us e t h e t i ltin g of t h e ma ch i n e

floa te d t h e a rm a ture to apos i ti on where t h e hi gh cli p cle a re d

t h e pole pi e ce i t w a s s t ri ki n g .

Hea tin g of a n Ar m a t ur e Tra ce d t o P oor S ol de ri n g of C om

m u ta t or C onn ecti on s E C Pa—

. r ha m ha
. s d e s cri b e d ( E l ectri ca l
R ecord M a ,
r ch 1 9 1 9 ) a
,
n i n t e re s ti n g ca s e wh e r e i t w a s n e ce s s a ry

to re pl a ce t h e a rma ture of a n e x ci t e r t h a t ha d be e n i n Opera

ti on s o lon g tha t t h e commuta tor b a rs h a d wo r n s o tha t t he
pre ss ure of t h e e n d ri n gs w a s b e gi n n i n g to bu ckl e t h e b a rs

up i n t h e mi ddle A n e xtraa . rm a ture wa s obt a i n e d be ca use

3 98 A R M A TUR E WI N DI N G A N D M OTOR RE P A I R

B e fore t h e mmuta
co to r wa s Ope n e d i t wa s blow n out wi th

a n a i r bl a st a t t h e fr o n t a n d ba ck to r e move t h e C oppe r a nd

ca r bo n du s t a n d pr e ve n t i t f r om f a lli n g in to t h e commuta tor

a n d g i vi n g tr ouble whe n t h e l a tter wa s ope n e d On e of t h e
.

ba rs th a t s howe d s i gn s of bei n g hot h a d we ld e d to t h e re a r

e n d ri n g ,
formi n g agr oun d A s thi s ba . r pa ss e d f r om on e

bru s h to t h e other t h e groun d cha n ge d fr om t h e pos i t i ve to t h e

n e ga ti ve ba r ca usi n g t h e gr oun d l a
. mps to fli cker C on s i de r .

a bl e oi l h a d cre pt a lon g t h e s ha ft
a n d fou n d i t s wa y i n to t h e c o m
muta tor s ta rti n g
,
th e troubl e by
Fm 2 5 1 S tio f pa t h d ca us i n g t h e bi n der i n t h e mi cari n g
—
. ec n o c e

dn g
en n ’

to di si n te gra te Four se gme n ts were

.

re move d s o th a t ap a tch coul d be put i n t h e m i cari n g a s s hown

,

i n Fi g 2 51
. .T h e ol d ri n g w a s me a s ure d f or thi ck n e ss a nd ,

two pi e ce s of s pe ci a l ri n g m i cawere put i n wi th athi n pi e ce,

of cle a r m i cacove ri n g e a ch of t h e fou r j oi n ts A hi gh gra

. de -

s h ell a c Wa s u s e d to hold t h e pi e ce s i n pl a ce un ti l t h e commut a tor

wa s ti ghte n e d a nd a l s o to fill up t h e sm a ll Ope ni n gs i n t h e
mi caa n d k e e p oil out .

Th e ri s e r s us e d on thi s m a chi n e we re poo rly a tt a ch e d

to t h e commuta tor ba rs b ei n g m erely s oldere d i n aS ha

,
llow
s lot i n t h e ce n t er of t h e ba r B e fore t h e he a
. t e d s eg me n t s
could be re pl a ce d i t w a s foun d to be n ese ss a ry to s cr a pe t h e
thi n coa ti n g of s older from t h e ri s er a n d out of t h e s lot i n

order to ma ke agood j oi n t I f acur r en t i s p a

. ss e d th r ough a

s old e re d j oi n t whi l e t h e s old e r i s hot e n ough to flow the ,

s tr u ctu r e of t h e s old e r i s s o cha n ge d tha t t h e r esi s ta n ce of t h e

j oi n t i s very mu ch i n cre a sed a n d wi ll co n ti n u e to gi ve tr ouble

i f wor ke d n e a r i t s o ri gi n a l ca r ryi n g ca pa ci ty a lthough to a

,
ll
a ppe a ra n ce a good j oi n t h a s b ee n m a de .

Whe n t h e commuta tor w a s buil t a mbe r m i cawa s us e d

be twe e n t h e ba rs A bout e ver y two ye a

. rs i t h a s b e e n n e cos

sa r y to r e move a few pi e ce s a n d th e s e h a
,
d bee n re pl a ce d by

mi ca ni t e whi ch i s s uppos e d to be a
, ble to w i ths ta n d t h e ba d
e ff e cts of oi l b e tte r th a n t h e fo rm e r A t thi s ti m e 1 0 pi e ce s
.

of mi catha t s howe d si gn s of pi tti n g were ta ken out Tw o .

p i e ce s w e r e of t h e o r i gi n a l amb e r a n d t h e r e s t w e r e m i ca n i te ,

s om e of whi ch h a d n ot b e e n i n s er vi ce more th a n two ye a rs .

 M E TH ODS US E D TO S OL V E S P E C I A L TR OU B L E S 399

This c sea h owever, a

does n ot , ff or d a fai r com pa ri son betwee n

t h e two gra des of mi ca I f t h e l ea ds h a

. d bee n poorly s oldere d
i n to t h e r is e r or t h e ri se r i n to t h e ba r, ahi gh-re s i s t an ce j oi n t

would ha ve res ulte d , ca us i n g i m perfect commuta ti on wi th

cree pa g e o f curre n t a cr o ss t h e m i ca b e twe e n b a rs T hi s .

cre e p a ge wi ll i n ti ms bre a k down t he mi caseg m en t a n d thus

s hor t-ci r cui t t h e b a rs .

In order to tes t for ashort circui t a fter t he lea ds were ,

s old e re d i n an d t h e commuta tor dra wn ti ght t h e en gi n e wa

s

s tar ted a n d t h e fi e ld s wi t ch close d If as hort cir cui t h a d .

FI G . 252 .
—
M e t h od of a
t ta
ch i n g t u rn i n g ri g to m a
chi n e s h owi n g its o pe r at i on
wi t h t ool u p si de d ow n .

e xi s e t d ,
it would ha ve ca us ed on e or more coi ls to g e t hot
in afew mi nutes but s u ch acon di ti on wa
,
s n ot ob s er v e d i n

thi s ca
se .

S i n ce i t h a
d ary to tu r n thi s commut a
be e n n e ce s s tor s o
ofte n t h e own e rs h a
,
d pur ch a s e d atu r n i n g r i g whi ch w a s

s uppose d to fit this m a chi n e A commo n di ffi culty of turni n g

.

de vi ces i s tha t the y s eldom fit am a chi n e un l e s s m a de S pe ci a lly

fori t I n thi s ca
. s e if t h e r i g h a d bee n put on t h e prope r si de of
t h e pedes t a l i t woul d ha ve be en n e cess a ry t o le a
ve t h e be a r

i n g cap o ff o r to h a v e t h e to ol co n s i d e r a
bly abov e t h e c e n te r

of t h e comm uta tor I n t h e la tter i n s ta

. n ce i n ca s e t h e tool ,

ca ught i t would ha
,
ve du g i n to t h e commuta tor Th e only .
4 00 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

other wa
by whi ch t h e ri g could be a
y tt a che d wa s t o pl a ce i t

so a s to cu t wi th t h e tool ups i de down A lthough t h e ri g .

wa s n ot s o s te a dy a s i t would h a ve bee n if worked i n t h e cor

re ct pos i ti o n n o di ffi culty w a s e n cou n te r e d
, .

Th e tur n i n g ri g use d on thi s j ob w a s ve ry ea s i ly a ttache d .

I t wa s u nn e cess a ry to re move asi n gl e brus h h ol de r in or der

t o put i t i n pl a ce Th e scr e w s a t A i n Fi g 2 52 he ld t h e ma
. in .

pa rt of t h e r i g t o t h e be a ri n g ca p T h e two s cr e w s B w ere .

s cre w e d a ga i n s t t h e S i d e of t h e pe des ta l to s te a dy t h e e n d of
t h e ri g B y loos e ni n g t h e s cre w C t h e tr a
. ns ve rse fe e d l e n gth -

wa s re a dily a dj uste d Th e e n d of t h e tra n s ve rs e f e e d a

. rm -

wa s s uppor te d by t h e lo n g s cr e w D re s ti n g on abru s h h ol der

a rm To pre ve n t a
. ny la te r al moti o n of t h e a rm a ture t h e ,

s cre w E w a s he ld i n t h e ce n ter of t h e s h a ft by t h e a dj us t able

a
rm F .

Hol d er for San dp pe ri n g a

C om m u tat ors I n Fi g 2 53 —
.

th ere is s hown ahold er for us e i n s a peri n g com muta

n dp a tors
tha t ma kes i t un n ecess a pe ablock to fit t h e curved
ry to s h a

ce of t h e com mut a
s urf a s ma
tor Thi s d e vi ce a d e by P et e r .

J M C lut e (P opu l ar . .

S ci ence M on th l y, J un e ,
onsi s t s ess en ti a
1 9 1 9) c l ly
of a ha n dl e whi ch i s
b ro a d en ed a t i t s low er
e xt r e mi ty a nd h a s two ,

blo cks 2 by 2 34 i n wi th ,
.
,

a n a rc of a ci r cl e on ea ch

fa ce Th es e blo cks a
. re

pi voted a n d wi ll a dj us t
,

a nd a ccommod a t e th e m
ad
Selves to a
FI G . 2 53 .
—
C on v e n i e n t de vi ce f or s n
com m u
pa
p e ri n g acom m u t at or ny

ta tor curva
.

ture Two or .

mo re of t h e blo cks m a y be us ed d e p en d i n g upon t h e S i z e of

,

t h e commuta tor .

U s e of aP orta bl e E l e ct ri c Dril l t o U n de rcut M i ca

'

of C om

m ut a t or A n i n t e r e st i n g m ethod of u n d e r cutt i n g acom m u

.
—

ta tor on whi ch t h e mi cah a d com e to t h e s urfa ce a ft er t h e

commut a tor h a d b e en turn e d h a s b e en d e vi s ed by R H N ,
. . .

L ock yea r of Tra il B C , ( E l ec tr i cal R ec

,or d J.u n e.
, ,
 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

a
ft er the ommuta
c to r h a d b ee n turn ed Wo rk h a .d com
m e n ced by h a n d but i t w a s foun d d i ffit to m a ke h ea d
wa y. W e h a d a m a ch i n e for u n d e r cutt i n g r ai lwa y commuta
tors h a vi n g a wi dth of a b out thr ee i n ch es Th i s m a . ch i n e w a s

re bui lt wi th lo n ge r gui d e r od s a nd a b ra
ck e t m a de for moun ti n g
i t on t h e b rus h s hi fti n g yok e of t h e gen era tor Thi s m a chi n e
.

wa s co n n e ct e d w i th a flexi ble s ha ft but s oon di sca r d e d b e ca use

of t h e vi b ra ti on I t th en o ccurre d to t h e wr i t er to d i re ct
.

co n n e ct aV a n Do rn typ e D A C C e l e ct ri c d ri ll
-
whi ch w a s,

a va i labl e to t h e s pi n dle of ami ll i n g m a

, chi n e a n d u n d e r cut t h e

mi cawi th thi s equi pme nt Th e s ch em e prove d most effe cti ve

.

a n d si n ce th a t t i m e we h a ve us e d i t on 2 6 gen e ra tors wi th a
grea t savi n g of t i me whi ch i s a
,
n i mpo rt a n t fa cto r i n apow e r

pla n t wh en re p a i ri n g l ar g e g e n e rators I n t h e tool we e mploy

.
,

t h e cutte r h a s a S pe e d of 1 650r pm adi a me t e r of i n a

.
,
nd a -
.
,

thi ckn ess of in .

J e rky Ope r a ti on o f N e w C o m m u t a
t o r T r a
c e d t o B urre d C o m
m ut a t or B a
rs I n s om e i n s t a
—
n ce s wh e re i t h a s b e e n n e ce s s ary

to t e mpora ri ly r e du ce t h e s p e e d of as e ri es moto r a n d th e r e

ha ve n ot b e e n a va i la ble s ui ta ble re s i sta n ces for co n n e cti n g i n

seri e s wi th th e a rm a ture t h e d es i re d res ult h a

,
s b e e n Obt a ined
by con n e cti n g aresi st a n ce a cro ss t h e b ru s h es Th e r e s is t an ce
.

so di s pos ed n ot on ly di ve rts pa rt of t h e l i n e cu rr e n t fr om t h e

a rm a t ure but a
,
l s o p r o v i d es an e xt e rn a l pa th thr ough whi ch
t h e motor a rm a ture ca n a ct a s a gen e ra tor the re by produ ci n g a
,

b ra ki n g eff e ct The e xt re m e of thi s con di ti on i s a

. cti v e wh en

ara i l wa y motor fla s h es ov e r f r om b ru s h to b r u s h Th e cu r .

r en t gen e r a te d th rough t h e S hort ci r cui t form ed by t h e a re

i s s o gre a t th at t h e s udd en ly i mpos e d loa d che cks t h e s p ee d of

the a rm a ture t h e sudden che cki n g of t h e s pee d con s ti tuti n g
,

wha t ra i lwa y m en ca ll bu cki n g An a ct i o n wh i ch i s s i mi l a

“
. r

i n ki n d but wh i ch i s mi ld e r i n d e gree o ccurs wh en a ,

n a rm a ture
co i l i s s hort ci r cu i t e d
- Th e coi l b e comes as ho r t ci r cui te d
.
-

loop movi n g i n as tron g field a n d t h e lo ca

,
l curren t of t h e coil
i s so hea vy a n d t h e d ra g i mpo se d by i t so grea t th a t t h e re
m a i n der of t h e a rm a ture m a y be un abl e to s uppo rt c on t i m i ous

moti on U n d er thi s co n di ti on t h e a
. rm a ture wi ll turn i n
e r s , e ca
j k b u s e t h e re s i s t i n g d r a g of t e S ho t ci r cui te d coi l
h r -

i s grea ter i n s ome pos i ti on s th a n i n oth e rs .

 M E THODS US E D TO S OL V E S P E C I AL TR OUB L E S 403

ace rta
In i n ca s e (E le ctri cal R ecor d J un e 1 9 1 8) an e w com , ,

muta
tor wa s i n stall e d on adi re ct curren t a rma tur e whi ch h a
- d
ope ra t e d n or m a lly up to t h e ti me of r e movi n g t h e old com
muta tor A fte r i n s ta
. lli n g t h e ne w commuta tor on tryi n g ,

to s ta rt i n t h e us u a l ma n n er t h e a ,
rm a ture would t urn ve ry
s lowly a n d i n j e rks a n d i f t h e s ta
,
rt er w er e a dva n ce d h a lf of
i t s t ra ve l t h e b r e a ke r woul d blow A n a . mm e te r wa s con n e cte d

i n s e ri es wi th t h e a rm a ture a n d t h e cu rr e n t w a
,
s foun d to be

of a lmos t full loa - d va lue on t h e firs t n otch of t h e s ta rt e r .

A ba r to ba r te s t wa s ma de a roun d t h e commuta tor a n d n ea rly

a l l of t h e a rm a ture coi ls app ea r e d to h a ve z ero re si s ta n ce .

J us t a t thi s ti me fu ll lo a
,
d curr en t bei n g in t h e a
- rma ture whi ch ,

wa s blo ck e d s o th a t i t could n ot r eturn a n e x plo s i on a

, ccom

p a n i e d by a fl as h o cc u r r e d o n t h e c ommut a to r I n v e s t.i g a t i on

d is clos e d aburn be tween two b a rs i n t h e groov e th a t is

turn e d i n t h e rea r e n d of acommut a tor C los e i ns pe cti on
.

s how e d th a t t h e gr oove a pp ea re d a s aco n ti n uou s coppe r

ba n d ex t e n d i n g e n t i re ly a roun d t h e commut a tor I n cutti n g .

t h e groove t h e tool h a d b e en a llowe d to dra g t h e coppe r over

from ba r to ba r a l l roun d t h e com muta tor On cl e a . ri n g

t h e mi cabodi e s of t h e coppe r b ri dge s op e ra ti on beca

, me
n orm a l .

Wh y B ru sh S t uds He a t e d on a n E i g h t pol e M a - ch i n e Th e .
—

a ccomp a n yin g d i a gr a m s hows t h e p a ths of t h e curren t th rough

a mu lti ple con n e cte d a rm

a t ure th a t i s use d i n afo ur

pole m a ch i n e t h e two b ru s h
,

s tud s of t h e s a m e pol a ri ty

be i n g con n e ct e d by me a ns b
of copp e r bu s s es wi th en ds
s t run g o n to t h e s tud s th a t
a re to be co n n e ct e d Th e .

i n co m i n g curre n t a rri v i n g

a t b rus h adi vi d e s a mo g n F I G 2 56 . D i.a

—
g a m o f p a trh of o s ur

re t t h o g h m a
ths i n orde r to re a
tm
thre e p a n r u
ch
'

bru s h d to whi ch t h e oth er en d of t h e e xte rn a l ci r cui t i s con

n e ct e d . On e p a th a ,
d i s d i r e ctly th r ough on e q u a
,
rt e r of t h e
-

a rm a tur e to d ; t h e s e con d p a th s through o e q ua

i n - rt e r of t h e

a rm a tur e to b ru s h b a n d th en ce by w a y of b us b d t o b rus h ( 1
 A RM A TURE WI N DI N G A N D M OTOR R E P A I R

a
n d out ; the thir d pa th ca rri e s a s mu ch curr e n t a s t h e t wo

othe rs combi n e d ; i t run s t hrough bu s a c to c wh e r e i t d i vi d e s

e qu a lly ha
,
lf pa s s i n g th r ough t h e upp e r ri ght h a n d qu a rt er of

the a rm a ture di re ctly to d a n d out a n d t h e oth e r h a lf thr ough

t h e upp er l e ft h a n d qua rt e r of t h e a rm a ture to br us h b a nd

then ce by wa y of bd to d a n d out . W i th t h e bu ss e s of n e gli

g i b l e r es i s t a n ce a n d t h e s e t s of b r u s h es e qu a lly s p a ce d on t h e

commut a tor a l l of t h e s tud s wo u ld ca rry a pproxi m a te ly eq ua l

curr en t s .

On a n e i ght pol e m a- ch i n e th e re a r e mo r e cu rr en t r a m i fica

ti on s b e ca use the re a r e mo re s tud s a n d mo re bu s s es a n d th ere

,

fore there a
,
re mo re p a ths for t h e curre n t .

I t wa s on s u ch am a ch i n e i n a pa r t i cul a r pl a n t th a
, t two of
t h e b rus h s tud s would g et so hot a s to bur n t h e i n s ul a ti n g
bu s hi n gs by m e a n s of wh i ch t h e s tud s w e re i n s ula te d from t h e
yoke I n ves ti ga
. t i o n d i s clo se d th a t t h e ma ch i n e w a s a bus i ve ly
overloa de d a n d th a t a l l s tuds he a te d a bove n orma l but th a t
on ly two got hot e n ough to burn bus hi n gs A n i n s pe ctor .

s ugges t e d th a t t h e he a t in g w a s du e to t h e ge n er a lly poor con

di ti on of a l l con t a ct s a n d e s p eci a lly to t h e poor con ta ct s be

tween t h e s tud threa ds a n d t h e th re a d s of t h e n uts by m ea n s of

whi ch t h e bu ss es t h e yok e t h e w a
, , s h e rs a n d t h e s tud s w er e

held togeth e r .

A ct i n g on thi s th e o ry V -s h a ,
pe d pi e ces of coppe r s tra p w er e
f or m e d a n d s o i n sta ll e d on t h e studs a s t o fo r m aco n du ct i n g

bri dge from t h e out si d e n u t a n d wa s h e r ov e r t h e yok e ( wi th

out tou chi n g t h e yoke ) to t h e i n s i d e n u t a n d wa sher . Thi s

b ri dge short ci r cui te d a
- l l co n t a cts wi th wh i ch t h e th r e a de d
pa rts of t h e s tud s w e r e i n volv e d . T h e s ch e m e wo r ke d s o w e ll
th a t s i mi l a r b r i dg es w e r e i n s t a ll e d on a ll of t h e s tuds . A fter
gi vi n g t h e whol e s tud con s tru cti on agood cl ea n i n g th er e wa s no

fu rth e r trouble .

A n A cci d e n t Du e t o I n corr e ctl y S e t B ru s h e s .

—
I n aca se

wh ere a n i s ol a t e d pl a n t wa s fu rn i s hi n g am e a t pa ck e r w i th

e l e ct ri c pow e r a t 1 1 0 volt s for al O h p moto r i n ord er to

-
.
,

provi de em er gen cy s e rvi ce con n e cti on s were ma

,
d e to t h e
ce n tr a l sta ti on s 22 0 volt m a Th e hi gh e r volt a ge re qui red
’
- ins .

t h e i n s ta ll a ti on of a n a ddi ti on a l motor wi th i t s s e pa ra t e s ta r te r
.

When t h e n ew 2 20 volt motor w a -

s i n s ta lle d n o e lectri ca l te st
 ARM A TU R E WI N DI N G
.

406 A N D M OTOR R E P A I R

thei r bein g un a ble to ha n dl e a n a b n o rm a l curr en t S hun t .

wound moto rs ope ra te b etter wi th the i r b rus hes s e t ali ttle

ba ck of n e utr a l tha n the y do w i th t h e b r u s h es s e t fo r w a r d of

n e ut ra l or on n e utra l be ca
,
us e wi th as li ght b a ckw a r d s h i ft

field di s tort i on helps commuta t i on .

I n on e ca s e me n t i o n e d by E . C Pa rh a
. m (E lectri ca l R ecor d ,

Octobe r ,
a20 h p moto r h a
-
. d b e en ove rh a uled a nd

wa s to be gi v e n ali ght r u n n i n g t e s t A s th e re w a s no

s ta rt i n g box a va i lable i t w a
,
s n e ce s s a ry to s t a r t t h e moto r

from full volta ge thr ough as wi t ch a nd a ls o aci rcui t b r ea ke r .

On clos i n g t h e b re a ke r a n d th e n clos i n g t h e s w i t ch th e re w a , s

ah ea vy fl a sh a t t h e b ru s h e s followe d by blowi n g of t h e ci r cui t

b re a ke r but t h e motor fa i l e d to s t a rt Th i n ki n g th a t t he ‘

.
,

fla s h i n g m i ght be du e to full volt a ge b e i n g a ppli e d to a rm a ture

a n d fi e ld co n n e ct e d i n p a ra ll e l a n d w i thout as ta r t i n g re s i s t

a n ce ,
t h e motor w a s r e co nn e ct e d s o th a
- t i t s fi eld b e ca me
e n e r gi z e d on clo s i ng t h e b r e a ker t h e a
,
rm a ture re cei vi n g cu r
ren t on clo s i n g t h e s wi t ch a fter clos i n g t h e b re a k er A n .

a ttempt to s ta rt a ga i n ca use d fl a shi n g a n d blow i n g of t h e

b re a ker but thi s ti m e t h e a

,
rm a ture a ctu a lly b e ga n to tu rn

a n d i t wa s ob s erve d to h a ve s t a r t e d to tu rn i n t h e wr o n g

d i re cti on On revers i n g t h e fie ld con n e cti on th e re w a

.
,
s no

furth er d emon s tra ti on A l l of t h e trouble w a

. s du e t o t h e

br us hes ha vi n g a fo rwa rd s h i ft wh en t h e motor w a s co n n e cte d

to ru n i n t h e wron g di r e cti o n .

P rope r A dju s t m e nt of a Re a
cti o n -
t ype B ru sh -h ol d er .

Th e an gl e a t whi ch ar ea ct i o n typ e b r u s h hold e r i s s e t on a

- -

commuta tor pla ys a n i mpo rt a n t pa rt i n t h e li fe of t h e b r u s h e s

a n d commut a tor Whe n t h e b rus h i s s et a

. ga i n s t t h e d i r e cti o n
of rota ti o n of t h e commut a tor a,
s s how n i n Fi g 2 5 7 t h e co rrect.
,

s e tti n g of t h e b ru s h i s of g r e a te r i mpo rta n ce th a n wh e n s e t i n

t h e oppos i t e d i r e cti o n . I f t h e b ru s h i s s e t too s t ra i ght t h e ,

fri cti o n wi ll pull i t a wa y from t h e holde r a n d ca u s e ach a tte ri n g

a n d s pa r ki n g . I f i t i s s e t too fla t th e r e wi ll be at e n d e n cy for
,

t h e b r us h to w e dge b e twe en t h e hold er a n d t h e commut a tor .

S om e m a chi n e m a n uf a ctu re r s u s i n g th i s s tyl e of b ru s h hold er -

furn i s h ate mple t by whi ch t h e hold e r ca n be a ccur a te ly set ,

a n d i n s u ch aca s e i t s hould be ca r e fu lly u s e d .

R L H e rve y (E l ectri ca
. . l Wor l d J a , n 2 2 1 9 1 6) re la
.
,
tes aca se
 M E THODS US E D TO S OL V E S P E C I A L TR O UB L E S 407

where h e wa s ca lled upon to lo ca te t h e ca us e of s pa rki n g on a

gen e ra tor usi n g thi s type of holder U pon ma . ki n g i n qui ri es

i t wa s lea rn e d th a t t h e en gi n ee r h a d pur ch a s ed a s h e e t of h i gh

gr a d e ca rbon s o ca
, lle d a n d ma , d e h i s own b ru sh es To s a ve .

ca rbo n a n d wo r k both e n d s w e re m a
, d e wi th t h e s a me a n gl e

a n d t h e hold e r w a s turn e d t o s u i t t h e b ru s h Th e bru s h .

len gth h a d b ee n m a de s o gr ea t
th a t the a rm pus h e d t h e b rus h

a wa y from t h e holde r i n s te a d
of a ga i n st i t . Th e l en gth L
F
( g i . 2 5 7 ) s hould n e v e r b e so

gre a t th a t e n d of a rm B wi ll be

a bove t h e li n e A O d ra wn pe r
p e n d i c u l a r to t h e f ac e an d
through t h e a rm ce n t e r 0 Th e .

ma nuf a ctu re rs of t hi s hold e r

r ecomm en d th a t t h e holde r be
s et a s s hown ; n e ver th e l e s s th e re ,

a re a gr e a t ma n y i n sta ll a ti o n s F 2 5 7
7 D i m W i
-
IG8 - 8 s r8 n

g fo re at o ty p
fiffi fif
n-
wor ki n g in t h e opposi te di re c fiifi
c i
fi
‘ r e

ti o n .

H a g
e t i n o f B ru s h h old er s Tra
- ce d t o D e f e cti ve C on t a ct

S pri n g s a n d R e m e di e d by aFl e xi bl e S h un t R L H e r ve y —
. .

( E l e ct ri c a l W o r l d J uly
, 1 1 9 1 6 ) r e
,
l at e s t h e follow i n g c o n d i t i o n s

i n aca s e wh e re hi s a tten ti on w a s ca lled t o t h e di s colori n g a nd

h ea ti n g of bru s h hold ers on s e ve ra

-
l g ene ra tors Th e hold er .

wa s of t h e p a ra lle l moti on typ e a

-
s s hown i n t h e s ke t ch
, ,

Fi g 2 58
. . To p r e ve n t t h e burn i n g of t h e h i n ge jo i n ts of
t h e pa ra ll e l moti on pho s phor br on z e sp ri n gs
,
i n thi ck .

we re us e d to ca r r y t h e cu r r e n t a r oun d th e s e po i n ts A s lo n g .

a s t h e con t a ct b e tw ee n th e s e th i n s p ri n g s a n d t h e movi n g

a rm s w a s p e rf e ct n o t roubl e o ccu r re d B ut a s s oo n a
. s a ny

pa rt of t h e co n t a ct b e ca me d efe cti ve a n ov e r lo a d wa s th r own

on t h e re m a i n i n g con t a cts ca us i n g ove rhe a

,
ti n g Th e tota l
con t a ct a rea of t h e s pri n gs on t h e holders of t h e s a m e pola ri ty

wa s s q i n for 2 50a
. . m p A p r op e rly d es i gn e d co n t a
. ct t o

ca rry thi s a mou n t of cu rren t s hould h a ve 1 % s q i n of s urfa ce

. .

To re li ev e t h e t r oubl e t h e s p ri n gs w e re t a
,
ke n out a n d r e pl a ce d

wi th aflexi ble s hun t a s s hown i n t h e s k et ch

, I n su ch aca. se
408 A RM A TURE WI N DI N G A N D M OTOR R E P A I R

it shou ld be men ti on ed th a t un less t h e solde ring of t h e flexi ble

wi re i n to t h e lug i s ve ry ca re fu l ly do n e t h e s old e r wi ll g e t i n t o

t h e wi r e a n d s t i ff e n i t I n o rd e r to pre ve n t thi s t h e s h a
. n ks ,

of t h e lugs were fl a tte n ed wi th t h e wi re i n i t form i n g ave ry ,

s t ro n g e l e ct ri cal j oi n t .

Th e box typ e of con s tru cti on of th is hold er a fi orded as u b

st a ntia l co n t a ct b e twe e n t h e hold e r a n d t h e b r us h Due t o t h e .

wei ght of t h e movi n g box a n d i t s s up po rti n g a r m s how ever , ,

thi s b r us h hold e r w a -
s d i s pl a ced by as t a ti o n ary hold e r a nd

s li d i n g b rus h w i th ali ght s p ri n g Wi th ahi gh commuta . t or

s pe e d t h e h e a
, vy b rus h a n d hold e r do e s n ot foll ow t h e i rre gul a r

l x t Iv

FI G . 258 .
— ~
S u bs t i t u t i on of w ov e n w i r e s h u n t for s p ri n g s of p a
rallel m ot i on
brus h -h ol d e r
.

i ti es of t h e commuta tor a s w ell a s t h e li ghte r b rus h Th e .

b rus h tha t ca n mov e i n i t s hold e r i s b e tt e r a ble to follow t h e

groove s of t h e commuta tor a s the a r ma ture we a ves b a ckwa rd

a n d for w a r d i n t h e be a ri n gs A lthough t h e brus h hold er is

.
-

us ua lly con s i d ered ami n or pa rt of t h e moto r or ge n e r a tor i t ,

ha s he ld t h e a tt e n t i on of t h e de s i gn i n g e n gi n ee r for agood
ma n y ye a rs a n d s ti ll n ee d s t h e a tten ti on of t h e Ope r a tor a nd

re p a ir m a n .

S i m pl e S ch e m e for B a n di n g Ar m a t ur e s Th e m et hod .
—

s hown i n Fi g 259 h a s b e e n foun d co n v e ni e n t i n on e r e pa

. ir
s h Op (G H V es ce l i us E l ect ri ca l Wor l d J ul y 1 9 1 9 1 9 pa
’

. . .
, g e, , ,

1 3 2 ) wh er e ab a n di n g la the a n d t e n s i o n d e vi ce wa s n ot a va il
a bl e a n d o n ly on e m a n to do t h e wo r k I n us i n g thi s sch e me
.

t h e f r e e e n d of t h e ba n d i n g Wi r e i s s old e r ed to t h e a rma ture

41 0 A RM A T UR E WI N DI N G A N D M OTOR R E P A I R

Th ree tu of a
rns i n ch r op e we r e wo un d on thi s r otor a
- nd

on e e n d fa s ten e d to t h e hook of a tr a ve l in g cra ne Th e cra ne .

wa s th e n run t h e fu ll l e n gth of t h e s t a ti on wi th on e m a n fe e d i n g

t h e m m t o t h e d rum a n d k ee pi n g i t t a ut I n thi s w a y a .

s mooth t i ght b a, nd wa s wo un d on t h e rot a ry arma tur e wi th

co n s i d e r a
bl e s a vi n g i n t i m e ov e r t urn i n g i t by h a nd .

M e t h od U s e d t o B a nd a 2000 Hp R ot or Th e b a -n d i n g of
. .
—

a rm a ture s a n d r oto rs wh e n do n e i n a
, fa cto r y wh e r e s u ch j ob s

a re a n e v e ry d a y o ccu r r -
en ce h as b ee n more or les s re du ce d to a
,

s ci e n ce a n d t h e m e thod s of p r o ce du r e a r e ma ny Wh en .
,

howe ver t h e rotor to be b a

, n de d rea ch es t h e 2 0 00 h p ma rk - .
,

g/fi
e
gg g
Wi r e Te ns i on 0cvi ce . Spool .

fi ns / on .

"
FI3 wh ee l . E dg e of PH:

FI G . 2 60.
—
An a
rr an g em en t de v i se d t o band a2 000 h p
- . m ot or a
rm at u re .

it is of t h e questi on to thi n k of tra

ou t n s po r ti n g i t to t h e r e p a ir
s hop .S u ch ap r obl e m ca m e up i n as te e l m i ll a t on e ti m e wh en
a2000 h p motor whi ch ope ra
-
. te d t h e roll s be ca me s e ri o us ly
groun de d Th e followi n g me th od w a
. s d e ci d e d upo n ( M a uri ce
S C l e me n t E l ectr i ca
. l R e cor d A p ri l
, Th e e n ti re t r oll ey
, t

of atra v e lin g cra n e wa s low e r e d to t h e floo r a n d pl a ce d i n l i n e

wi th ahuge fly whe el whi ch w a —

s on t h e s a me s ha ft a s t h e r otor .

Th e ca bl e d rum of t h e cra n e t r o ll e y w a s co n v e r t e d i n to a belt

d rum by coverin g i t w i th ca n va s wh i ch w a s h e ld i n pla ce by

me a n s of fri cti on ta p e Thi s m a d e amore or les s fla

. t s ur f a ce

a n d e li m i n a t e d both t h e cable groove s a n d t h e gr e a se fr om t h e

fa ce of t h e b e lt .

A s t h e low er h a lf of t h e fly whee l wa s i n api t i t wa

- s nec ,
 M E THODS US E D TO S OL V E S P E C I A L TROUB L E S 41 1

es sa r y to pl a ce a r ol l e r a t t h e e dg e of th i s p i t a s a b e lt r u n n e r .

An oth er r oll e r w a s pl a ce d o n a f ra m e s om e wh a t r e s em bl i n g
aa l r g e b r a c e b o th ,
e n d s of wh i ch w e re s e c u r e d to t h e fl oo r ,

ha lfwa y be twe e n t h e cra n e tr olle y T e fly wh e e l w a

h -
. s a r

ra n ge d s o a s to ri d e t h e b e lt a n d s e rv e a s a b e lt ti ght e n e r Th e .

ba n d i n g w i r e t e n s i o n d e vi c e u s e d i n th i s ca s e w a s s i m i l ar i n

pri n ci ple to those use d on wi re n a i l ma ch in es t h e sh e a ves ,

b ei n g a djus ta ble i n t h e slots so a s to t i ght e n or s l a cken t h e wi re

a t amom e n t s n oti ce
’
.

A n I m pr ovi s e d M e t h od U s e d t o Tur n aC om m ut a t or .

I n aca s e wh e re ar us h o r d er w a s re ce i v e d by ar e p a i r s hop
to turn t h e commuta to r of age n era tor a t al a r ge cou n try

house R L H e rve y (E l ectri cal Wor ld J un e 1 0 1 9 1 6) de

,
. .
, ( ,

FI G . 261 .
—
M e t h od of u s i n g lat he cr os s -fe e d i n t u rn i n g acom m u t at or .

s cr ib es t h e followi n g m ethod of doi n g t h e work wh en t h e s ma ll

turni n g ri g whi ch wa s ta ke n a lon g wa s foun d too s m a ll I n .

t h e ga ra ge howe ver ala ,

r ge e n gi n e la th e w a
, s foun d Th i s .

sta rt e d a n exa m i na ti on to de ter mi n e wh e the r t h e a rm a ture

could be t a ken out a n d s wun g i n t h e l a th e Thi s prom is ed .

i mpo ss i ble Whi le looki n g a

. rou n d t h e s hop a n a n gl e pl a te
wa s un cov e re d Thi s pl a te a n d t h e cr o s s fe e d of t h e l a
. the -

we re bolte d toge th er by as pe ci a l s cre w of t h e ri g Th e pla te .

wa s th e n bolt e d to t h e e n d pl a te of t h e ge n e ra to r fra me a s ,

s hown i n Fi g 2 6 1 T h e re w a
. s but on e bolt holdi n g t h e a
. n gl e

pla te on t h e ge n e ra to r fra m e whi ch ma d e t h e e qui pm en t look

,

v e ry u n s t e ady A hol e i n t h e a . n gl e pl ate wa s s e l e cte d s o th a t ,

if t h e pla te turn e d a rou n d t h e bolt t h e tool would s w i n g ,

a wa y from t h e commuta tor a n d n ot i n to i t Th e s crew of t h e .

41 2 A RM A T URE WI N DI N G A N D M OTOR R E P A I R

cr o f d wa
-
s s ee s too s ho rt to t a ke acut a cr o s s t h e comm ut a tor ,

there fore t e tool a

h h d to e re s et for ea
b - ch cu t Thi s wa . s a

li ttle tr oubl e s om e a s t h e tool h a d to be ta pp ed in to posi ti o n

wi th aha mme r Th e commuta . tor h a d grooves in i t a bout
54 i n c h d e e p re qu
,
i r i n g c o n si d e r abl e c utt i n g H ow e
. v e r t h e ,

j ob wa s sa ti s f a cto ri ly do n e wi th thi s a rra n ge m en t .

Th e ge n era t o r wa s di re ct co n n e cte d to a low s pee d hori zon ta

- l
ga s oli n e e n gi n e Whi le wor ki n g on t h e commuta
. to r t h e va lve s
were ta ke n out to pre ven t comp res si on a n d t h e tu rn i n g e fl ort
'

provi de d by al h p motor b e lt e d to t h e fly whee l Th e e l e c

- .
- .

t ri ca l equi pme n t of t h e pla n t co n s i s te d of t h e gen e ra tor a nd a

s tora ge b a ttery of 58 lea d cell s Thes e s uppli e d curren t for

.

t h e li ghts amotor dri v en i ce m a

,
- chin e l a u n d ry wa
,
ter-pump,

a n d ma ch i n e tools i n t h e ga ra ge .

Ca u s e of M o t or R e ve r s i n g i t s Di r e cti on of R o t a ti on on
Hi g h S pe e d . R L H e rv e y h a
—
. . s d es cri b e d t h e fo l lowi n g p e en

li a r p e rform a n ce of amoto r (E l e ctri ca l Wor ld J a n 20 1 9 1 7

, ) .
,

A 2 h p 2 2 0 volt d i re ct co n n e ct e d compoun d moto r d ri vi n g a

-
.
- -

ba n d sa w ha d b e en i n s e rvi ce for a ppr oxi ma te ly 1 8 mon ths

wi thout gi vi n g t h e s li ght es t trouble un ti l t h e ope ra tor
wa n t e d to wo r k t h e s a w a t i t s hi gh es t s p ee d whi ch wa , s oh

ta i n e d by us in g afie ld r h e os t a t Wh en a . ll of t h e res i s ta n ce

wa s cu t i n t h e fi e ld ci r cui t t h e motor s lowly ca me to astop a nd

st a rt e d i n t h e oppo s i t e d i r e cti o n Thi s wa . s t ri e d s e ve r a l

ti mes a ,
n d re s ult e d i n blowi n g t h e fu s e s mo s t of t h e ti me s .

Th ere could be but on e con d i ti on th a t would ca us e this re

v ers a l of di re cti on of rot a t i on n a mel y t h e compoun d wi n di n g
, ,

b ei n g i n oppos i ti on to t h e s hun t fie ld a n d ove r comi n g i t whe n

t h e s hun t fie ld w a s we a ken e d B y re ve rs i n g t h e compoun d

.

fie ld le a ds t h e tr ouble wa s r e move d Th i s moto r h a

. d b ee n i n
opera ti on for aye a r a n d ah a lf wi thout a n y i n d i ca ti on of
a n yt hi n g b e i n g wr o n g Th e br us h es a
. n d co m m uta to r were
i n e x ce ll e n t con di ti on wh i ch s p e a ,
ks wel l for t h e des i gn of t h e
ma ch i n e .

C h e ckin g C onn e cti on s of a n I n t er po l e M ot or Th e pol a.

—
ri ty

of t h e i n te rpole field coi l s s hould be t h e s a me a s th a t of t h e

pre cedi n g m a i n pol e s i n adi r e cti on a ga i n s t t h e r ot ati o n Th e .

pola ri ty of t h e i n t e r pol e fi e ld wi th r e l a ti on to t h e m a i n fi e lds

for both di re ct i o n s of rot a ti on of moto rs a n d ge n era tors i s
41 4 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

to a pply t h e curren t on ly momen t a ri ly to p re ve n t too hi gh

a n a rm a ture s pe e d .

Th e co n n e cti o n s for th i s t es t a re s ho wn i n Fi g 263 I f di r e c

. .

ti on of rot a ti on i s wron g i n te rcha ,

n ge t e rm i n a ls 3 a n d 4 or 1

a nd 2 Ha. vi n g s e cure d prope r di re cti on of rota ti on wi th t h e

s e ri e s co nn e cti o n i n se r t t h e s hun t fie ld a
,
n d op en t h e se ri es fie ld

a s s how n i n Fi g 2 63 . U pon s t a
. rt i n g up a gain a sa s hun t motor ,

t h e di re cti on of rota ti on s hould be t h e s a me a s it wa s wi th t h e

s e ri e s fie ld I f i t i s n ot i n t er ch a
.
,
n ge t e r mi n a ls 5 a nd 6 a nd

ma ke up pe rm a n e n t co nn e cti on s Th e corre ct pola

. ri ty of t h e

i n te rpol e s m a y th e n b e c h e ck e d w i th a c omp ass o r by b ri dg i n g

ama i n pol e a n d i n t e r pol e wi th a pi e ce of i ron b e a ri n g i n m i n d
,

th a t un li ke pole s a ttra ct a n d li k e pol es wi l l re pe l i t a n d ch e ck

i n g wi th t h e di a g r am s i n F i g 2 63 . .

He a ti n g of Fi e l d C oil s Tra ce d t o Wr on g Type of S ta rt in g

B ox .
—
Ou motors th a ta re d e s i gn e d for fie ld co n tr ol of s pe e d ,

E . C Pa . rh a m ha s po i n t e d out ( E lectri w l R ecord Fe b ru a ry , ,

1 9 1 9) th a t t h e shun t wi n di n g i s li ke ly to be li ghte r th a n th a t
of amotor whe re t h e s hun t wi n di n g i s to be subj e cte d co n ti n
u ou s l y to full op e ra ti n g volta ge Therefo re if t h e s hun t field
.

of s u ch ava ri abl e s pe e d motor i s co n n e cte d to full volta ge con

t i n u ou s l y i t will h e a
, t b e yon d t h e u s u a l t e mpe ra tu re gu a ra n tees .

I f t h e li n e volt a ge h a ppe n s to ru n we ll a bove n orm a l a s i t oft en ,

doe s t h e te mpera
, ture wi ll re a ch av a lue li a ble to in j ure t h e
i n s ul a ti o n a n d ul ti m a te ly to s hort ci r cui t t h e wi n di n g- .

Th e own e r of am a ch i n e s hop a t on e ti m e a s k e d th a t am a n

be se n t to fin d out why t h e s p e e d of h i s moto r w a s s o low a nd

why t h e moto r got so hot a fte r s e v era l hours of wo rk i n g A s .

th i s w a s a l l t h e i n for m a t i on obt a ina bl e t h e i n s pe cto r t ook a

,

voltm e t e r a nd a n a mme te r th a t could be us e d on e i th e r d i re ct

cu rr e n t or a lte rn a ti n g cu rre n t circui ts on ly to fin d out l a
- te r
,

th a t n o i n s trum en ts w ere r e q ui re d Th e motor i n qu es ti on .

pr ove d to be of t h e va ri a ble s pe e d field con trol type T h ere

, ,
.

wa s no na me pla t e on t h e motor but t h e type w a s i n f e rre d fr om

,

t h e typ e of res i s t a n ce box wh i ch h a d b ee n furn i s h e d wi th i t

but wh i ch wa s n ot b e i n g u s e d Th e moto r wa
. s b e i n g O pe r a t ed
a s aco n s t a n t s p ee d moto r on volt a th at a t
'

g e w s 1 5 p e r c e n .

a bove n or ma l Of cou rs e t h e m a
. x i mum s pe e d obt a in a bl e w a s

tha t du e to full field hot Th e field coi ls h ea . ted too mu ch but

 M E TH ODS US E D TO S OL V E SP E C I AL TR OUB L E S 41 5

di d n ot he a t s uffi ci en tly for thei r i n crea s e d re s i s t a n ce to g i ve

t h e s pee d re qui r e d I n o r d e r to b ri n g t h e s p ee d to t h e n e c
.

e ss a ry v a lue a nd a t t h e sa me ti m e re l i e ve t h e fi eld coi ls t h e ,

r es i st a n ce box wh i ch h a , d ma n y ta ps w a s co nn ect e d i n s e ri e s
,

wi th t h e fie ld coi l s a n d d i ff e r e n t t a p w i r e s t r i e d u n t i l o n e w a s

foun d th a t ga ve a pp roxi m a tely t h e p rope r s pee d A s t h e .

loa d of t h e motor w a s comp a ra t i ve ly li ght th e r e w e re n o ob

j e c t i o n ab l e fe a tures a tten di n g t h e s ta rt i n g of t h e moto r on a

we a ke n e d fie ld so t h e co n n e cti o n w a
,
s ma d e p e rm a n en t wi th

t h e u n d e rs t a n di n g th a t t h e ope ra tor would i mme di a te ly g e t a

sta rte r th a t wa s a da pte d to t h e work .

Sa f e Ope ra t i n g Te mpe ra t ur e of P ort a bl e De s k Fa ns .

A we l l kn own m a
-
n ufa ctu r er of f a n moto rs po i n t s out th a t
wa rm w e a th e r a lwa ys b ri n gs an umb er of compl a i n ts i n re
a
g rd to h e a ti n g of s m a ll motors Thes e compla . i n ts a re us u a lly
from de a le rs or us e rs who a r e po s s ess e d w i th t h e i d e ath a t if
t h e moto r body do es n ot f ee l n i ce a
-
n d cool to t h e h a nd the
,

W i n d i n gs a re i n i m m i n e n t d a n g e r of burn i n g out Th e l a
. tes t
sta n da rd i z a ti on rul es of t h e A me ri ca n I n st i tut e of E l e ct ri ca l
E n gi n eers p r ovi d e th a t i n moto rs wi th t h e cl a
,
s s of i n s ul a ti o n
us e d i n re li a ble m a kes of motors t h e te mpe ra ,
ture a s r e co rd e d

by athe rmome ter s hould be wi thi n al i m i t of 80 C Thi s

,
°
.

i s e qui va l en t to 1 76 F N o on e would ca r e to pl a ce h i s
°
.

ha n d i n co n t a ct w i th t h e f r a m e of amotor a t a n ywh e r e n e a r

tha t li mi t .

L e t u s sa y f o ,
r i n s t an c e th a t a
,
s m a ll moto r h a s a t e mp e r a
ture ri s e of 40 F wh e n op e ra °
. te d con ti n uous ly S u ch amot or .

opera ti n g on ada y wh e n t h e n o r m a l a i r t e mp e r atu r e i s

would re a ch a te mp e ra ture of on ly wh i ch would fee l on ly

comfo rt a bly wa r m to t h e h a nd Th e s a
. m e motor op e ra , ti n g
on am i d s umm e r da
-
y wh e n t h e th e r mom e t e r r u n s f r om 9 0
to wi ll a tt a i n at e mp e r a tu re b e twe e n 1 3 0 a °
n d 1 40 F .

A n y te mpe r a ture ove r 1 20 i s qui te un comfo rta °

bl e to t h e
tou ch a n d gi v e s ri s e to a la rm on t h e p a r t of t h e i n e x p e ri e n ce d

motor us er .

H owe ver amoto r wi th a s urf a ce t e mp e r a ture of 1 40 °

is i n n o da n g e r of i n j ur y f r om ov e r h e a ti n g a ,
n d moto r

us ers who ma ke compl a i n t of t h e h e a ti n g eff e ct un d e r s u ch

co n d i ti on s s hould be a dvi s e d to con ti n u e op era ti n g th e i r
41 6 A R M A TU RE WI N DI N G A N D M OTOR R E P A I R

ppa
motors un ti l i t is a re n t th a t t h e win di n g s a
re be i n g da
m
age d U n l ess the re i s s ome odo r of burni n g i ns u la
. ti on t h e ,

motor can n ot be co ns i d e r e d i n d a n ge r .

A n A dju st a
bl e S h un t for S e ri e s Fi e lds of E xci t ers . —
In
adj us ti n g t h e com poun d cha ra ct e ri s t i cs of three e xci ters for

para lle l ope ra ti on i n con j un cti on wi th aTir t i ll re g ulator i t ,

wa s foun d i m poss i ble t o g e t t h e n eces sa r y se ri es fie l d s hun t -

adj us tme n t wi th t h e s h un t ta ps pr ovi de d by t h e m a n ufac

Fro . 2 64 .
—
C o ns t ru c t i on of .
se ri e s -fie l d sh u n t i
s h ow n g bo w e d f orm a
t i on to
faci l i t ate ve n t il a
t i on .

t u re rs C ons e que n tly e a

. ch s hu n t wa s re pl a ce d by ave ry

si mpl e a n d ea s il y a dj us ta bl e shun t li ke tha t s hown i n Fi g 264, .

( S yd n e y F i s h e r ,
E l ectr i ca l W or l d , J un e 1 0,
B y m ea n s

of th es e t h e cha ra ct e ri s ti cs of t h e m a chi n es w e re m ad e pr a ct i

ca l ly i d en ti ca l Th e s hun t wa. s ma d e of s tri ps of G e rma n

ver slott ed to p ermi t t h e bow e d forma

s il ti on s hown R ough .

adjus tm e n ts w e re ma
d e by a dd i n g or r emovi n g s t ri ps a nd ,

fin e r a
djus tmen t obta i n e d by va ryi n g t h e cr o ss s e cti on of -
41 8 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

yi eld e d to p e rsua si o n .A sm a ll resi s ta n ce tub e co n n e cte d i n

t h e s hun t fie l d ci r cui t wa
-
s foun d i n t h e bottom of t h e fra me .

Whi l e thi s tube could n ot be rea ch e d for e x a m i na ti o n i t w a s ,

s u s p e cte d of b e i n g t h e ca use of t h e troubl e s o ajumpe r wa , s

co n n e ct e d a r ou n d i t . A n oth e r e ff o rt to s ta r t t h e moto r w a s

s u cce s s ful Th e moto r s pe e d w a

. s 3350 r pm wi th alin e.

volta ge of 5 75 Th e re si s ta
. n ce a ,
ft er b e i n g pa t che d wa s con ,

n e ct e d i n t h e field ci r cui t wh e n t h e s p e e d me a s ur e d 3 7 3 0 rpm .

A s t h e mo t o r w a s bu i lt f or 3 400 r pm a t 500 volts i t w a

. s ,

thought tha t t h e fa cto r y t e s t w a s ma de a t th a t volta ge a n d th e

re s i s t a n ce put i n t h e field to b ri n g up t h e s pe e d S i n ce how

.
,

e v e r t h e volt a
,
ge w a s 57 5a t t h e pl a ce of i n s t a l la ti on t h e s pee d ,

of 33 50 rpm w a . s h i gh e n ough a nd a s t h e re s i s ta n ce h a d op en
ci r cui t e d o n ce i t w a , s d e ci d ed to le a v e t h e r es i s t a n ce ou t t o

pre ve n t future tr ouble .

Wa y s t h at E n d -
p yl a V a ri a t i o n s S h o w U p T h.e —
p r i n ci p al
purpo s e of ha vi n g e n d pla - y in t he a r ma ture of amotor or of a
ge n e r a tor i s to kee p t h e b rus h e s from tra cki n g i n t h e s a me
pa th a n d th e r e by w e a ri n g a groove i n t h e commuta to r or i n t h e
coll e cto r ri n gs a s t h e ca se m a y b e T
. o p r e v e n t s u c h w e ar i n g
of grooves t h e a , rma ture en d th rus t cl ea
-
ra n ce s a re s o d i s pos e d

t ha t wh en t h e a rm a ture i s run n i n g i n i t s n orma l zon e wh i ch is ,

gove rn e d by t h e pull of t h e pole pi e ce s on t h e a -

rm a ture co re ,

t h e thr us t cl e a ra n ce s a t t h e two b ea ri n g s a re e qua l A s s umin g .

t h e co rre ct ge a r or p u ll e y a li gn m e n t to t h e con n e cte d loa d t he ,

a rm a ture wi ll n eve r ru n si d e wa y s fa r e n ough to kn o ck t h e

bea ri n g on e i th e r s i d e ; b e ca us e wh e n i t h a s ru n ov e r ace rta in

di s t a n ce t h e fi e ld w i ll pul l i t b a
, ck tow a rd a n d pa st th e m a g
n e t i c ce n t e r Th e s a
. me a cti o n w i ll th e n be r e pe a te d but in
t h e oppo s i t e d i re cti on I f howe ve r t h e e n d thr us t i s un
.
, ,
-

e qu a lly di s tri bute d for a n y re a s on or if t h e ma

, ch i n e a s a

whol e i s n ot le ve l kn o cki n g wi ll o ccur whi ch i n t h e ca

, se of

s ma ll hi gh s pe e d m a
,
-
ch i n es m a y t a k e t h e for m of s e r i ous

vi b r a ti on s th a t a re li kely to poun d down t h e bea ri n g

l i n i n gs .

E C Pa
. . rh a m (Gen er a l E l ectri c R evi ew J a n ua
, ry 1 9 1 6) h a ,
s

men ti on e d aca s e wh e r e fou r moto r s of fr a cti o n a l hors e power ,

wh i ch we re di re ct con n e ct e d to tool g ri n di n g whe e ls we re ,

i n s ta lle d a n d th r e e of t h e outfit s g a ve en ti re s a ti s fa cti on but ,

 M E TH ODS US E D TO S OL V E SP E C I AL TR OUB L E S 41 9

t he fourth on e vi bra t e d so ba dly tha t i t s hook t h e whole

s uppo rt i n g s tr u ctur e Th e r ot a ti n g e le m en ts of two of t h e
.

un i ts wer e then i n te r cha n ge d a n d t h e vi b r a t i o n s re m a ined

wi th t h e sa m e rotor S pi n n i n g t h e r ota .ti n g el e men t of
t h e troubl es om e m a chi n e i n a hi gh s p ee d l a the pr ove d -

t h e s ha ft t o be pe rfe ctly s tra

.

i ght C lo s e i n s pe cti on di s .

di s clos e d tha t t h e en d pl a y wa s n ot di s tri bute d on t h e f a

-
ulty
outfit i n t h e s a me m a nn er a s on t h e fa ultless on e s A l l .

vi bra ti o n w a s e li m i n ate d by loos en i n g t h e thrus t col la . r so

tha t t h e roto r when run n i n g coul d cen te r i ts e lf the n s ta rt i n g ,

t h e moto r a n d le tti n g i t s low a n d s top a n d th e n ti ghte n i n g ,

t h e colla r .

C onn e cti on s for Two 22 0 vol t M ot or s Wh e n Ope r a

- t e d on
440 V ol t s I t i s p ra cti ca
.
—
l to Ope ra te two 2 20 volt 7h p - -
.

FI G . 2 65 .
—
B el t a
r rang em ent f or t w o m o t ors op e r a t i n g i n s e ri e s a
nd dia
g ra
m
f or co n n e ct i n g t w o s h u n t m o t ors i n s e ri e s .

motors i n s eri es on 440 volts a n d s e cu re s a t i s facto ry re s ults ,

pr ovi di n g tha t t h e mot o rs a re a ppro xi ma te ly t h e s a me a s

re ga r d s w i n d i n gs a n d s pe e d I f t h e d ri v e i s by ab e lt a
. nd the

motors run a t t h e sa me s pe e d agood pla n i s to s e t t h e moto rs

wi th t h e pull e ys i n li n e a n d r u n as ho rt b e lt fr om on e to t h e

o t her Tha . t i s firs t b e lt t h e motors toge th e r by as hort b elt

,

a n d th e n put t h e re gul a r b e lt ove r t h e s ho rt b e lt a s s how n i n

Fi g 2 65 . A n othe r w a
.
y i s to c oupl e t h e two a r m a
tu r e s h a
ft s

t oge th er wi th as ui t a bl e couplin g a nd a tta ch t h e dri ve r p ul l e y

on on e of t h e a rm a ture s h a fts .

Th e co n n e cti o n s for two s hu n t woun d motors i n s eri es a - re

s how n i n Fi g 2 65 Th e co n n e cti on s for two compoun d woun d

. .
-

motors i n s eri es a n d t h e co n n e cti o n s for on e s hun t woun d -

.
42 0 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

motor a
nd one ompoun d woun d motor
c - in s e ri es i n Fi g .

266 .

In a of t h e motors i s hi gh er i n s pe e d tha
c s e one n t h e oth e r

on e i t m a
, y b e a dv i s a
bl e t o us e d i ff e re n t s i z e s of pull e y s so a
s

to se cur e t h e p r ope r s pe e d .

Fro 2 6 6
. .A t t h e l e f t , di a
—
g ra m for con n e ct i n g t w o com p ou n d m o t ors
n d, a
i n s e ri e s a t t h e ri g h t , se ri e s con n e ct i ons for on e s h u n t m ot or a
n d one

com p ou n d m ot or .

C ai n g M t rs wi t h C om pr
l e n o o e s s e d A ir - When usi n g com
.

presse d a i r to cl e a n out d i rt a n d dus t from mo t o r wi n di n gs

t h e p ress ure s hould n ot be h i g h er t h a n 1 00l bs ga uge Th e a

. . ir
ca n be a ppli ed by t h e us e of arubber hose a bout i n ch in
di a me te r fitte d wi th as ho rt pi e ce of i n ch i ro n pi pe to a
— ct

a s an ozzl e a n d d i re ct t h e a i r i n to t h e wi n di n gs s o a s to blow

ou t a ccumula t e d di rt .

M o s t mot o r wi n di n gs a re i mpre gn a t e d or pa i n ted wi th some

s o rt of i n s ul a t i n g va rni s h a n d thi s u s ua lly pres en ts s u ch a
s mooth s ur fa ce th a t a i r eve n a
, t ext re m ely hi gh v e lo ci ty i s ,

n ot li k e ly to li ft t h e e dge s n or t e a r t h e i n su l ati n g f a bri c I f .

t h e dus t tha ta ccumul a te s i n t h e motor i s of a n a b ra s i ve ch a r

a ct e r i t i s by a
,
l l odd s mo r e a d vi s a ble t o us e ahi gher pre ss ure
tha n m e n ti o n e d a n d g e t ri d of t h e dus t th a n to l e t t h e dus t pi le

up un ti l i t s t ops ve n ti la ti on of t h e wi ndi n gs a n d pe rh a ps e ve n
cu t s t h e i n s ul ati on .

Te s t in g ou t P h a s e rot a
- t i on Ma . n uf a
—
cture rs of a l t em a t ing
cu r re n t gen e r a t ors ge n e r a lly ha ve as ta n da rd di r e ct i o n of rot a

ti o n clo ckwi s e for e x a

—
,
m pl e h
a n d li ke wi se th e re i s a
—
dopted
a s ta n da r d d i re cti o n of ph a s e r ot ati on Thi s i s n e ces s a
- . ry ,

be ca use a lt e rn a t ors th a t a re to be opera t e d i n pa ra lle l mus t

ha ve thei r ph a se r ot a
- ti o n s t h e s a me Th e a . dopte d ph a se
42 2 A RM A T URE WI N DI N G A N D M OTOR R E P A I R

n oti ced tha t t h e upper ha lf of t h e m otor wa s mu ch hotte r th a n

t h e lower h a lf A n i n s pe cti on of t h e con n e cti o n s see me d t o

.

s how th a t the y were corre ctly m a de a n d th a t th ere were n o

grou n ds or ope n ci r cui ts The fu s es we re i n good con di ti on
.

a nd the a uto tra

- n s fo rm e r motor s ta r ter ope ra te d s a ti s fa cto ri ly .

A l l of t h e co n n e cti o n s for t h e s t a r ter w i n d i n gs ch ecke d wi th t h e

di a gra m furn i s h ed wi th t h e motor .

T h e wi n d i n g w a s atwo ci r cui t d e ltaa

- rr a n ge m e n t a nd

t h e moto r h a d 1 6 pol e s . I n ch e cki n g ov e r t h e n umbe r of

poles i n e a ch of t h e two ci r cui t s i t w a s fin a lly foun d t ha t t he
wi n d i n g w a s d i vi d e d i n aho ri zo n t a l pla n e th rough t h e s t a tor ,

a n d th a t i n st e a d of each ci r cui t ha vi n g e i gh t poles t h e uppe r

.

ci r cui t h a d o n ly s ev e n a n d t h e low e r h a d n i n e pol e s . T hi s

ex pl a i n e d why t h e upp e r h a lf ra n hott e r tha n t h e low er . Th e
e l e ct r i ci a n ha d ma de ami s coun t wh e n co n n e cti n g up t h e
wi n di n gs wi th t h e re s ult th a
, t t h e lo a d wa s un e v e n ly di s t ri b

u t ed . Th e co n n e cti o n s w e re ch a n ge d s o th a t ea ch ci r cu i t

co n t a in e d a n e qu a l n umb e r of pole s a ,
n d t h e motor Ope ra ted
wi thou t t h e h e a ti n g tr ou ble p re vi ous ly e x p e ri en ce d .

S ta ll in g of Woun d R o t or I n ducti on M ot or E xpl a i ned .

A compl e t e op e n ci rcu i t i n t h e wou n d roto r of apolypha se

i n du ct i o n moto r wi ll p reve n t i t s s t a
,
r ti n g b e ca us e un d e r s u ch
co n d i t i o n s th e re ca n be n o se co n d a ry c u r r e n t . S u ch acom
p l e t e op e n c i r cu i t m a y b e ca u s e d by two of t h e r oto r b r u s h e s

b e i n g s o stu ck i n the i r hold e rs a s to m a ke n o con ta ct wi th t h e

colle cto r r i n gs . A n e x ce pti on mi ght obt a i n i n t h e ca s es of

fra ct i o n a l ho rs e powe r motors whi ch a re s o s m a ll tha t t he

roto r m a y s t a r t by v i r tu e of t h e e ddy c u r r e n t s i n du ce d i n

t h e r oto r la mi n a ti o n s H ow e ve r t h e t or que du e t o s u ch re
.
,

a ct i o n s could s up po r t n o lo a d Th e fun ct i on of e n e rgy ci r cui t

.

of are puls i on in du cti on s i n gl e pha -

s e mo t o r i s s i m i l a r to tha t of
t h e woun d ci r cui t s of t h e r oto r of a polyph a se i n du cti on

motor i n tha
,
t both a re t h e se a t of t h e i n duce d curre n t by
vi rtu e of whi ch t h e motor i s a bl e to do i t s duty Th ere fore
acompl e t e b r e a k i n t h e e n ergy ci rcui t of ar e puls i on i n du cti on
moto r wi ll re n d e r t h e mo t or un a
,
ble to s t a rt . Th a t a n in

compl e t e op e n ci r cu i t i n t h e e n e r g y ci r cu i t ,
m a y p r odu c e

d i ff e ren t re s ult s i s i llus t ra

,
t e d by t h e followi n g e x pe ri en ce .

A bu t ch e r compl a i n ed t h a t h i s moto r d ri v e n me a
- t gri n der
 M E TH ODS US E D TO S OL V E SP E C I AL TR O U B L E S 42 3

whi ch h a d b e en wo rki n g s a t i s fa cto r i ly for mo n th s w a s d e ve lop ,

i n g at e n d en cy to s low down wh e n co a r se s to ck w a s fe d i n to

t h e hopp er Wi th t h e fin e r s to ck t h e moto r a
. pp a re n tly c o ul d
,

do i t s wo rk a ll ri ght On op era. ti n g t h e moto r wi th t h e en d

cove r re mov e d vi ci o u s s pa
, r ki n g w a s s e en A t firs t th i s w a . s

thought to be ca use d by a rm a ture trouble but aclos e i n s pe c

ti on di s close d th a t t h e s pa rki n g wa s du e to t h e e n e r g y b r us h es

b ei n g stu ck i n t h e b rus h holders Th e b rus hes h a -

d wo rn so
.

s ho rt th a t t h e bru s h s hun ts were j a mme d i n to t h e bo xes a nd a

fe w mo re j obs of gr i n d i n g pr ob a bly would h a ve burn e d a nd

worn t h e b ru she s en ti re ly out of con t a ct wi th t h e commuta tor .

E ven wi th t h e a r ci n g t h e e n er g y curr e n t h a
, d b ee n s u ffi ci e n t
to s upport t h e li ghte r lo a ds a lthough a fte r i n s t a
, llin g n ew
brus hes i t b e ca
, m e e vi d e n t tha t t h e m otor h a d b ee n ope ra ti n g
a t re du ce d s pe e d a t a ll lo a ds .

Loos e B e a ri n g C a u s e d I n du cti on
M ot or t o Fa i l t o S ta rt H Wi l s on —
.

( P o w er, A ugu s t 5 1 9 1 9 ,
p a g e 23 1 ),

d es cri bes t h e fol lowi n g ex p eri e n ce

a ft er r epa i ri n g al a rg e th r e e ph a se -

i n du ct i o n moto r wh en a ,
n a tt empt
wa s ma d e to put i t b a ck i n to
s e r vi ce . On clo s i n g t h e comp e n s a
t or s wi t ch to t h e s t a rt i n g po s i ti o n ,

t h e motor f a il ed to s t a rt a lthoug h ,

i t wa s e vi d e n t f r om t h e s ou n d of

t h e ma chi n e th a t i t wa s g ett i n g
cur r en t th r ough i t s wi n d i n g Th e .

fi rs t thi n g th a t s ugges t e d i ts elf wa s

a n op e n ci r cui t s o t h e s t a
,
rt i n g com

p e n s at or w a s t e s t e d to s ee if t h e

curr en t wa s comi n g thr ough s i n gl e

pha se only I n ord e r to do thi s

.

qui ckly w e di s con n e ct e d t h e motor

,

l ea d a t t h e ma ch i n e a n d whi l e t h e
,
F
l f “ ti g
t
“
or o
‘

e n -C i r cui
S n

p
s wi t ch w a h eld on t he s ta
.

s rt i n g

posi ti on at es t l a mp w a s co n n ect e d a cr os s t h e diff e r e n t l ea ds ,

a s i n Fi g 2 6 7 Thi s s how ed cu rr en t on ea
. . ch ph a se a t a ,

redu ced volt a g e of ,c ou r s e W e th e n p.u t t h e s w i t ch o n t h e

4 24 A RM A T U R E WI N DI NG A N D M OTOR R E P A I R

r un n i ng posi ti on a n d t h e t es t

la mp bur n e d bri ghtly a cr o s s

ea ch ph a se s howi n g tha
, t the
motor wa s g e tti n g t h e cur r en t

a ll ri ght .

Th e rotor s e em ed to be ru b
bi n g ali ttl e on t h e s ta tor a s ,

i t wa s s om e wh a t ha r d t o tur n ,

s o t h e cl ea ra n ce wa s a djus t ed
by m e as of two d a
n r w bolts
-

on t h e b e a ri n g hou s i n gs T hi s . .

took s om e ti m e s i n ce wh en t h e ,

h ea r i n g s w e r e mov ed on e w a y
ali ttl e t h e rotor would bi n d ;
,

th en we wou ld s hi ft i t b a ck

s li ghtly un ti l fin a lly getti n g i t

i n to aposi ti o n wh ere t h e rotor
turn ed fr eely A n other a . t
t empt to s ta r t moto r m e t wi th

n o b e tt er r es ul t tha n t h e firs t .

Th e n ext s t e p wa s t o t ra ce out

t h e wi n di n g co n n e cti on s whi ch ,

wer e foun d to be a ppa r en tly

co rr ect . Th e wi n di n g b ein g
co n n e ct ed two pa ra lle l s t ar
ma d e i t s om ewha t compli ca t ed
to tra ce out H ow e ve r by.
,

looki n g to s e e if t h e con n ec
ti on s we n t un d er or ove r t h e
wi n di n g I woul d m a
,
rk a n

a rr ow on t h e gr oup of coil s to

s how t h e pola ri ty We wen t .

a r oun d e a ch ph a s e i n thi s wa y ,

s ta rt i n g wi th t h e outs i d e l ea d
i n ea ch ca se Th e a
. r r o ws on

ea ch gr oup poi n t e d a lt ern a t el y

i n oppos i t e d i r e cti o n s s ho w ,

i n g t h e con n e cti on s to be cor

rect a ,
s i n Fi g 268 . .
 426 A R M A T UR E WI N DI N G A N D M OTOR RE P A I R

t
ex en s i on Thi s difficulty ca
. n be ove rcom e by as y s te m pa t
e n t e d by P rofess o r A r n o i n whi ch t h e i n h e r e n t cha ra ct eri s ti cs

of thr e e pha se moto rs a

-
r e d e ve lope d from a s i n gl e-pha s e s ou rce

of supply .

Th e s ys t e m whi ch i s u se d ex t en s i vely i n A us tra

, l i a ca ll s for ,

t h e u s e of ath re e pha s e ma s te r moto r i n a

- ddi ti on t o t h e three
pha se pow e r moto rs T h e ma s t e r moto r i s a
. s ta n da rd ma chi n e

of ei th er t h e s qui rrel ca ge or woun d rotor typ e a

- n d t h e la- rg er ,

t h e b e tt e r Th e lower s i z e l i mi t of thi s moto r i s i n p ra

. cti ce

a bout 1 0 to 1 5 per cen t of t h e tota l loa

d con n ecte d to t h e s ys
.

tem a nd is a s t doubl e t h e si z e of t h e n e x t l a
t l ea rges t mo t o r .

FI G . 2 69 —
M e t h od of Op e r a
ting 3-p h a
se m ot or s fr om s i n g l e-p h a
se line
T h e four m ot ors t o t h e ri g h t a r e p ow e r m e t e rs , a n d t h e on e t o t h e l e ft 1s am ot or
w h i ch h a s i t s t h i rd ha s e c o n n e ct e d t o t h e t h i rd p h as e of al l t h e ot h e r m ot or s Th e m a
t e r m ot or i s s t a p
rt e c u p a s as p l i t -p h a a
s
.

s e i n d u ct i on m ot or n d ru ns li g h t .I t s fu n c t i o n 1 3
t o s u p pl y a u xil i a r y curr e n t t o t h e t h i rd p h a se of t h e ot h e r m o t o rs , a n d by t h i s m e a ns
t h e 3 -p h a ow e r m ot ors a r e g i v e n pra a
ct i c ll y t h e s a m e ch a ra ct e ri s t i cs a
s i f t h ey
p
se
w e r e ope r a t et fr om a3 -p h a se l i n e .

A ll moto rs i n cludi n g t h e ma
,
s te r moto r a r e co n n e ct e d to t h e
,

s i n gl e pha - se s upply m a i ns a n d t h e thi r d pha

, s es whi ch a re ,

n ot co n n e ct e d to t h e s ou rce of s upply a re con n e ct e d tog e th e r

,
.

Th e ma s t er moto r i s s ta rt e d up un d er n o lo a d wi th s peci a l
s ta rt e r s e qu i pp e d wi th a n a u xi l i ar y wi n d i n g s i m il a r to tha t
u s e d for t h e s ta r ti n g of s pl i t ph a s e i n du ct i o n moto rs
-
Th e .

ma s t e r moto r s hould a s a g e n e ra l rul e r un un loa ded a s a pha se

g i v e r . I t i s p e r m i s s i bl e how e v
,
e r to lo a d, t h e m as t er moto r

up to a bout 25 per ce n t of i t s n o r m a . l ra ti n g i n s p eci a l ca s es ,

but e ve n wh en t h e ma s t e r moto r i s ru n n i n g m echa n i cally

l oa de d i t m a , y b e e l e ct r i c a lly ov e rlo ad e d A n y of t h.e pow e r

motors b ecom es ama s te r moto r i mme d i a tely i t s loa d i s thro wn

 M E THODS US E D TO S OL V E S P E C I AL TROU B L E S 42 7

ofl , a n d i f t h e ma s t er m oto r ca n n ot pr ope rly p e r form i t s fun c

ti on as ma
,
ll unl oa d ed power motor m a y b ec om e ov e r lo ad e d
i n h elpi ng out t h e ma s te r motor .

Th r ough t h e volta ge i n du ce d i n t h e m a s t er mot or s thi rd

’

pha s e whi ch i s n ot co n n e cte d to t h e s upply m a

, i n s s u ch moto rs
,

a t fu ll s p ee d a re a bl e to s upply a uxi li a ry curr en t t o t h e lo a ded

moto rs du ri n g s ta rti n g a n d ov erlo a d peri ods A s lon g a . s the

ma s t er moto r i s r un n i n g t h e ove rloa d ca pa ci ty of t h e loa d ed

motors i s ra i se d a s comp a
, re d wi th pu re ly s i n gl e pha se i n du c
-

t o moto rs
i n a n
,
d t h e thre pha
e - s e moto rs a re a bl e to s ta rt

up from t h e si n gl e pha s e l i n e wi th p ra cti ca lly t h e sa me s ta rt

a
-

i n g to r que s th e y would ha ve whe n con n e cted to apolypha se

li n e S hould a
. ll t h e moto rs i n cludi n g t h e m a s t er moto r be
‘

loa ded to t h e s a m e e xten t i n p ropo rti on to thei r ra te d ca pa ci ty ,

n o cu rr en t would flow i n t h e thi rd pha s e co n n e cti o n s

-
A fte r .

t he m a s t e r m oto r h a s b ee n s ta r te d up t h e wo rkin g moto rs ca

, n

be s ta rted on e a fte r a n oth er a s r e gul a r s ta n da rd thr ee pha se —

moto rs Th e ga . i n i n e fli ci e n cy by ope ra ti n g t h e i n di vi dua l

motors a s th re e ph a se u n i t s i s p ra
— cti ca lly off set by t h e loss es
i n t h e ma s te r moto r s o tha t t h e ove rloa
, d e fli ci en cy of t h e
whol e i n s ta ll a ti on i s a bout t h e sa me a s tha t of as tra i ght s i n gl e
pha s e s ys t e m Th e n or ma
. l output of t h e power motors when
opera ti n g i n thi s ma n n e r is a bout 7 5 t o 80 per cen t of thei r .

s ta n da r d th re e pha s e ra
- ti n g .

A n A ppa r e n t Over l oa d Trou bl e Th a t wa s Tra ced t o a Defe ct

i ve Fu s e B l ock R L H e r ve y (E l ectri ca
—
. . l Wor l d J un e 2 4 , ,

1 9 1 6) re la tes t h e followi n g troubl e a t apl a ti n g pl a n t wh ere a

5 h p s i n gle ph a
- .
- se i n du ct i o n moto r from a
,
pp a,
re n t ov e rlo a d
co n t i n u e d to blow fu se s for se v e ra l da ys a n d th en re fu se d to

st a rt . Th e moto r h a d be en i n da i ly us e for si x ye a rs a nd the

re p a i rm a n ,a fte r ex a mi n i n g t h e e qui pme n t s a i d th a

, t n ew
bea ri n g s we re n e e d e d a s t h e r oto r w a s rubbi n g t h e s t a to r
la m i na t i o n s Th e s h a
. ft w a s a ls o cu t a n d gr oov e d whi ch ,

re qui re d i t to be turn e d down s o th a t t h e bea ri n gs could be

prope rly fitte d Af te r t h e motor h a. d b e e n re pl a ce d a nd in

s e rv i ce f or afe w d a ys t h e fuse s s ta rt e d blowi n g a ga in .

Th e r e p a i rm a n foun d on e of t h e b e a ri n g s hot wh i ch w a , s

ta ken ou t a nd ea s e d up
“
al i t tle A fe w da
”
. ys la te r a n oth e r

s hutdow n o ccu rre d Th i s t i m e t h e re pa

. i rm a n r e po rt e d th a t
42 8 A R M A T U RE WI N DI N G A N D M OTOR R E P A I R

the motor w a s ove rlo a de d a n d al a rg e r moto r wa

,
s re qui re d .

A s t h e pla n t wa s b e i n g ope ra te d e xa ctly a s it h a

d b ee n for three
yea rs wi thout as hutdown t h e ow n e r of t h e moto r w ould n ot
,

a cce pt t h e re po rt a nd a, s k e d tha t at h orou g h exa mi n a t i on

be ma d e to lo ca te t h e tr ouble .

Wh e n putti n g i n n e w re i n forced fuses i t wa s n ot i ce d th a t

t h e fu se cli ps a n d block h a d b e en q u i te hot for t h e y we re ,

di s colo re d a n d loos e Th e cli ps we re clo s e d up un t i l th e y

.

h eld t h e fus e t i ghtly A clos e e xa . m i na ti on of t h e motor a nd

s ta rt e r s how e d th e m to be i n firs t cl a ss co n di ti o n
-
An a mme .

t er w a s co n n e ct e d i n t h e li n e a n d t h e mo t or s t a rt e d wi th n o

loa d Th e curr en t ta
. k e n i n di ca te d tha t t h e wi n di n g wa s n ot

d e fe cti ve Th e lo a
. d of two bu ffin g whe e ls wa s th e n put on

a n d t h e n ee dl e of t h e 5 0 a m p m e t e r w e n t off t h e sca
-
. le A .

furt h e r e xa mi n a ti on of t h e fus e blo ck showe d two loo se

co n n e cti o n s I t wa. s t h e h ea t ge n era t e d by thi s hi gh con ta ct

res i s ta n ce th a t wa s ca us i n g t h e trouble wi th t h e fus es I t i s .

very p rob a ble th a t wh i le t h e rotor w a s r ubb i n g t h e s t a t or

t h e moto r w a s ta ki n g a n ex ce s s i v e cu r re n t a n d i n ju r e d t h e

fus e block Thi s i n s ta

. n ce s how s t h e n e e d of a ca re ful i n s pe c

ti o n of a ll wi ri n g wh en are pa i re d motor i s a ga i n co n n e ct ed
i n ci r cui t .

Ca u s e of N oi s e i n a Th r e e -ph a
s e M ot or Dri vi n g a
n E xh as t u

Fa
n .
—
freq ue n cy of t h e curre n t t ha
Th e t is a ppli ed t o t h e
st a tor of a n i n du ct i o n moto r i n comm erci a l Ope ra ti o n o r di n a r ,

i l y i s co n st a n t w i thi n n a r r ow l i m i ts i f t h e s pe e d of t h e p ri m e

move r to whi ch t h e cur r en t i s clue i s a s co n s t a nt a

, s i t s ho ul d

be . Th e fre quen cy of t h e cu rre n t th a t i s ge n e ra te d i n t h e

roto r of t h e moto r howe ve r v a , ri e s wi th t h e s pe e d of t h e roto r ,

b e i n g g re a tes t when t h e rotor i s a t re s t a n d le a s t wh e n t h e

r oto r i s Op e ra ti n g a t ma xi mum s p e e d Th i s i s b e ca . us e t h e
fre qu e n cy of t h e roto r curre n t de p e n ds on t h e di ff e re n ce of t h e
s p e e d s of t h e roto r a n d of t h e r ot a ti n g field I n other word s .

t h e fre qu en cy of t h e roto r cu rre n t d e pe n d s on t h e s li p of t h e

r oto r Th e pri n ci pl e of Op e ra
. ti o n of f re quen cy i n di ca tors of
t h e vi b r a ti n g type i s th a t t h e p en dul um p rope rti es of ea
,
ch

re e d a re s u ch th a t i t wi ll re s po n d syn chron o us ly to t h e i m
pu ls es of but on e va lu e of fre que n cy On t h e s a me pri n ci ple
.

i f ami s ce ll a n e ou s lot of pi e ce s of i ron a n d s t e e l be s ubj e cte d

43 0 A R M A TU R E WI N DI N G A N D M OTOR R E P A I R

so di s pose d tha t th e cu rr e n t s i n t h e m a i n s ta tor w i n din g a nd

in t h e s t a rti n g w i n d i n g s h a ll be ou t of pha s e w i th ea ch othe r .

A s t h e s ta rt i n g w i n d i n g i s i n te n d e d to be a cti ve for o n ly a

s e con d or mo re i t i s n ot pr opo rti on e d t o sta

,
n d co n ti n uous

a ppl i ca t i o n of t h e volta ge A ccor d in gly acen tri fuga

. l s wi t ch
,

tha t turn s wi th t h e rotor i s provi de d for a ,

utoma ti ca lly cutti ng
out t h e s ta rt i n g w i n d i n g a s s oon a s t h e rotor a pproa ch e s full

s pe e d . I f for a n y re a s on t h e s t a rt i n g w i n d i n g i s l e ft i n ci r cui t

for a ppre ci a bl e ti me t h e wi n di n g i s li ke ly t o be i n j ure d

,
.

I n ace rt a i n i n s ta n ce (E le ctr i ca l R ecord A ug ust 1 9 1 8) on e , ,

of these motors s toppe d afe w min ute s a fte r ha vi n g b een

s ta rt e d for t h e firs t t i m e a nd a s t h e ow n e r ex pre s s e d i t
,
t he ,

motor h a d n o mor e l if e i n i t Th e moto r w a s of t h e re s i s t a

”
. n ce

i n du cta n ce se lf s t a rt i n g typ e i n wh i ch t h e pha

-
,
s e s pl i tt i n g wa s

a ccompl i s h e d w i thout t h e u s e of a n y e xt e rn a l re s i st a n ce or

re a cta n ce E xa
. min a ti on of t h e motor di s close d t ha t i ts
fa i lure h a d b ee n du e to t h e ma i n s ta tor wi n din g bei n g i n
se r i e s w i th t h e a utoma ti c s wi t ch whi ch s hould ha ve i n clude d
on ly t h e s ta rt i n g w i n d i n g Th e moto r w ould s ta
. rt a ll ri ght ,

but t h e ope n i n g of t h e ce n tri fuga l s w i tch would cu t out t h e

ma i n wi n d i n g l e a vi n g t h e s t a
,
rt i n g w i n di n g co n n ect e d a cr os s

t h e li n e . I t de ve lope d th a t t h e motor h a d b e en bought a t a

low pri ce b e ca u s e i t wa s i n ba d co n d i ti on a nd ha d b e e n re
woun d by alo ca l r e pa ir m a n ; who di d 0 good j ob of w in di n g ,

but apoor job of con n e cti n g .

Ca u s e of On e M ot or Fa i l i n g t o S ta r t Wh i l e A n ot h e r w a s

R unni n g on t h e S a m e C i r cui t — At a n i n du s tr i a
. l pla n t wh e r e

44 0 volt thr ee ph a
-
, se -
60 cy cl e se r vi ce w a
,
- s use d to Op e r a te
motors of ma n y d i ffe re n t s i z e s ap ecul i a r t rouble w a
,
s e x peri

e n ce d by A C H e wi tt (E l ectr i ca
. . l Wor l d J a n 8 1 9 1 6) whe n,
.
,

on e of th re e fus e s w a s blow n on a fe e de r ci r cui t On e fee de r .

ci r cu i t s uppl i e d s om e four or fiv e moto rs on e of w hi ch wa ,

s

ra t ed a t 7 5 hp a n d t h e oth e rs a
. t 1 0 hp e a ch E a ch mo tor
. .

wa s e qu i ppe d w i th a kn i fe s wi t ch fu se s a n d sta rt i n g comp e ns a

,

t or a
,
n d t h e fe e de r ci r cu i t w a s fu s e d a t t h e d i s tri buti n g s wi t ch
bo a rd . Th e 7 5 h p moto r w a
-
. s de lt a co n n e ct e d whi le t h e
-
,

1 0 h p moto rs we re co n n e cte d Y ( Fi g
“
-
. .

Th e 7 5 h p motor w a
- . s ca rr yi n g a loa d of a bout 50hp On ly .

on e of t h e 1 0 h p moto rs wa-
. s i n u se a n d i t wa s d ri vi n g a
,
7h p -
.
 M E THODS US E D TO S OL V E S P E C I A L TR OUB L E S 43 1

l oa d a t t h e t i me t h e t rouble de ve lope d B ot h motors h a d .

be e n ru nn in g for a bout four hours whe n i t be ca me n e ce ss a ry

t o s top t h e s m a ll motor for afe w mi n u te s U pon t ryi n g t o .

ope ra te i t a ga i n i t re fu se d to s ta rt Th e e le ct ri ci a
n te s t e d
.

t h e motor fuse s wi th two 2 50 volt l a mp s in se ri e s wi thout

-
,

re movi n g t h e fu se s from t h e ci r cui t an d foun d the m good ,

.

Th e la mp te st se e me d to s how ho wever tha t t h e volt a

,
ge be ,

tween t h e mi ddle a n d e i the r out s i d e wi re wa s n ot a s hi gh

a s i t s hould be H e the n te s te d t h e fuse s on t h e 7

. 5 h p motor -
.

whil e t h e moto r wa s ru n n in g a n d foun d t h e s a me con di ti ons

r L eOds to O e
l i v r M a
nnm —
y

FI G . 270— C on n e ct i on s w h e n 1 0-h p m
. o t or fa
il e d t o st a
rt .

a
s w th
i t h e 1 0-h
p motor E vi de n tly some thi n g wa
. . s w ro n g,

a n d w i th re du ce d volt a ge be twee n t h e mi ddle a n d out s i de

wi res i t wa s na tu ra l to suppo se tha t the re w a s a hi gh resi s ta n ce -

co n n e ct i on s om e whe re i n th a t f e e d e r Th e l a rge moto r w a

. s

stoppe d a ,
n d t h e fu se s we re t e s t e d a s be fo re but th i s t i m e n o ,

volta ge a t a ll w a s foun d b e t we e n t h e m i ddl e a n d t h e out s i d e

wi re s The n t h e e le ctri ci a
. n t ri e d to che ck up t h e firs t re s ult s

by sta rt i n g t h e l ar ge moto r bu t si n ce i t wa
, s as qu i rr e l c a ge -

thr ee ph a
-
se i n du ct i o n moto r i t would n ot s t a rt on as i n gle

pha se ci r cu i t .

He n e x t te s t ed t h e m a i n fe e d er fuse s a
-
n d fo un d on e of th e m

ha d blown A n e w fee d e r fus e wa

. s put i n a n d e ve r ythi n g ,

s tarte d off a ll ri ght Th e r e du ce d volt a

. ge be tw een t h e m i ddle
a n d t h e outs i d e wi re s wa s ju s t on e ha lf of t he li ne volta
-
ge ,

or 22 0 volt s, si n ce t h e mi ddl e w i r e a moun te d to a50 pe r ce n t .

 AR M A T U R E WI N DI N G A N D M OTOR R E P A I R

ta
p on t h e win di n g of t h e l a r ge mo t o r wh e n i t wa s run n i n g

s i n gl e ph a-
se Thi s ca .s e s e e m e d qu i t e apuzzl e r a t t h e t i me ,

a n d i t wa s thought a t fir s t th a t t h e re du ce d volta ge on t h e
mi ddle wir e wa s be i n g ge n e r a t e d in t h e la r ge moto r H ow .

e ve r al i ttle s tudy of t h e co n d i t i on s soo n m a

,
de plai n t h e re al
re a s on as e x pla
i ne d .

Ca
use of S yn ch r on ou s M ot or Fa
i li n g to S t a
rt —
E . C .

Pa
rh a
m (P ower , J un e 24, 1 9 1 9 ) pl a
i n s t h e followi n g troubl e ex

wi th as yn chr o n ous moto r i n al a

rg e m i ll wh e n i t w a s sa
s n ece ry

to r epai r t h e wi n di n g whi ch h ad b een d a ma ged i n afire .

FI G . 271 —
. P ol e-p h a
se g r ou p s h o w n r e v e rs e d at X .

A c ompl et e s et of coils wa s a va i la
bl e a n d t h e r e wi n di n g wa s

don e by lo ca l r e pa i rm en A ft e r compl eti n g t h e j ob how e ver

.
, ,

con n e cti n g t h e moto r to i t s s our ce of pow e r f a i l ed to turn

t h e roto r a lthough i t h a
,
d sta rt e d v e r y p r omptly b efor e b e i n g

da ma g e d Hi gh er comp en s a
. tor t a ps w ere tri ed bu t to n o ,

a va il . A n ex p ert a lt ern ator wi n d er wa s ca ll ed from t h e

fa cto ry a n d fou n d th a t on e pol e pha s e group of co i ls h a -d b een
r e v e rs ed a s a t X Fi g 2 7 1 Th e i n t e r ch a
,
. n gi n g of t h e l ea
. ds
of thi s group a s i n Fi g
,
27 2 r es tor ed n o rm a . l sta rt i n g to r qu e
,
.

I t wi ll be n oti ced tha t by t ra ci n g ea ch ph a s e thr ough to t h e

s ta r co n n e cti o n i n Fi g 2 7 2 the a rr ows po i n t i n oppos i t e di r ec

.
,

ti on s on a dj a cen t pol e ph a s e group s whi ch i s t h e corr ect

-
,

co n di ti on I n Fi g 2 7
. 1 t h e wron g co n n ecti o n is i n di ca
. te d
by th r ee a dj a cen t a rr ow s po i n t i n g i n t h e s a
‘

m e di r ecti o n .

Th e exi s te n ce of s uch aco n d i ti on m a y b e p r ov e d by c on

n e ct i n g a mme t ers i n to e a ch ph a se con ductor a n d obse rvi n g

the i ta ke curren t s wh ile t h e rotor i s turn e d by ha

n n d ; are
434 A RM A TURE WI N DI N G A N D M OTOR R E P A I R

i t se lf produ ci ng further s pee d re du cti o n in ci den t t o t h e i h

cre a se oi t h e a moun t of moto r sli p .

E C Pa. r ha
. m (E l ectri ca l World J a n 1 1 9 1 6) ha , s re fe rre d to
.
,

s u ch as i tua ti on where a n Ope ra t or on a50-cy cle s ys t e m

s pe ci fie d i n or d e rin g a s ma
,
ll motor gen e ra tor se t a 60 -
,

cy cl e mo t or be ca use h e kn e w tha t ulti ma te ly h i s se rvi ce would

re q ui re 60 cy cl e Ope ra
- ti on I n orde ri n g t h e 60-cy cle se t
.

for te mpo ra ry 50 cy cl e ope ra

-
ti on h e h a d con si d e re d o n ly t h e
m et e r a nd ha
, d fe lt sa fe i n a s s um i n g th a t i t could s ta n d t he

la rg e r curre n t in ci de n t to ope ra tin g on t h e lowe r fre que ncy .

T h e sa fe ty of su ch a n a s s u mpti on w ould la r g e ly d e pe n d on how

n ea r ly t h e moto r would Ope ra te at i ts n orm a l ra t i n g u n d er t h e

pro s pe ct i ve loa d con di ti on s a n d w i th t h e p r ope r f re que n cy .

Th e po i n t of i n te re s t i n t h e prese n t i n s ta n ce howe ve r i s tha t , ,

wh e n t h e 60 cycle se t wa
- s put i n t o ser vi ce i t wa s foun d

i mpo s s i ble to m a i n ta i n t h e ge n e ra tor volta g e a t n o r m a l valu e

e ve n w i th t h e gen e ra tor fie ld rheos ta t re s i s ta n ce a ll cu t out .

I n or de r to g e t out of t h e di fli cu l t y i t wa s n eces sa r y to i n s t all

upon t h e gen e ra tor ase t of shu n t fiel d coil s tha t ha
- d ag rea te r
n um be r of a mpe re turn s -
.

A l tern a t in g curre n t mot ors a

- r e d e si gn e d a nd a re ra te d to
sta nd a re a son a ble de p a rture fr om th e i r volt a ge curren t a nd ,

fre que n cy s pe ci fica ti on s but be fore a

,
bu s in g the m w i th e yes
wi de Ope n i t would be a dvi s able for Ope ra tors to a s ce r ta in t h e
pe rmi ss i bl e li mi ts of a b n o rm al use .

S i m pl e R ul e s f or R e -conn e ct in g Al t ern t in g -curren t M ot or s a .

—
Th e re pa i r ma n s hould d e vi s e s i mple rule s tha t h e ca n re

me mbe r ea s i ly so a s t o be a ble to ha n dl e s i mple ch a n g es i n

motors wi thout ha vi n g to s tudy up t h e co n ne cti o ns or a s k his

n e i ghbor to e x pl a i n the m A fe w s u ch s ugges t i o ns a

. r e gi ve n

he r e a s us e d by M a uri ce S C le me n t (E lectri ca
. l R ecor d Octobe r , ,

1 9 1 8 ) for re-co n n e cti n g amotor to s ui t ch a n g e s in volta ge ,

s pe e d et c
,
For ex a
. mple if athree pha , se four pol e motor -
,
-

i s to be ch a n ge d t o two ph a se four pole a

-
t t h e sa
, m e ti m e-
,

r e ta i n i n g t h e sa me s pee d t h e g r oup i n g must be cha

,
n ge d .

A three ph a -
se four pole con n e ct i on h a
,
-
s 12 gr oup s ; tha t
i s on e gr oup to e a
, ch pol e of whi ch there a , re four and ,

four pole s to e a ch ph a se gi vin g 1 2 gr oups The refore t h e

, .
,

n umbe r of pol es m ul t i pl i e d by t h e n umbe r of pha se s g i ves

 M E THODS US E D TO S OL VE S P E C I AL TR OU B L E S 43 5

umb of gr oups B y thi s rul e atwo pha

.

t he n er . se four -
,

pole m a ch i n e h a
s e i ght g r oup s Th e n ext e le men t t o be .

ta ke n in to con s i dera ti on i s t h e n umbe r of coil s i n ea ch

group .

I n athree ph a se -
four pole m a ch i n e wi th 48 co il s th e re
,
-

would be four coi l s pe r gr oup ; wi th 36 slot s three co i l s per ,

gr ou p I n a48 coi l four pole three pha

.
-
, se ma ch i n e the re a
-
, re -

1 2 g r oups of four co i l s e a ch To ch a n g e th i s t o a .t w o pha se -

,

four pole wi n di n g wi thout cha

-
n g e of s p ee d t h e follow in g i s ,

t h e r ul e

(N umbe r of co i ls ) ( umber
N of pole s X P ha
s e s)

48 ( X 2)
4 6 .

There fo re t h e ne w groupi n g wi ll be rra

a n ge d wi th si x coi s l
pe r gr oup .

I n ch a n gin g t h e g r oup i n g of a3 6 co i l ma chin e from fou r -

pol th ee pha
e,
r - se to four pole two ph a - s e t h e res ult be com e s
,
-
,

atri fle puzzlin g a s it a
, ppa re n tly gi ve s four a n d on e h a lf -

co il s pe r group S in ce we k n ow th a
. t cutt i n g acoi l i n ha lf
to s ui t apa rt i cul a r gr oup i n g ca n n ot be do n e t h e g roupi n g of ,

co i l s w i ll be i n t h e followi n g o r de r : 4 4 5 5 4 4 5 5 , Th i s
, , , , , , .

me thod a ccoun t s for t h e ha lf coil s a n d w i ll be foun d to be

e ven ly ba la n ce d I f t h e ma
. ch i n e i s t o be cha n ge d fr om two

pha se t o t hree pha -

se s i mply re ve rse t h e ope ra
, t i on t h a t is
d es cri be d a bove .

For ge n e ra l de ta i l s for co nn e cti n g a ltern a ti n g curre n t motors ,

se e C h a pt er X I .

C ha n g in g 44 0 vol t M o o f r
- t r o 22 0 vol t Ope ra
- t i on Th e .
—

a ccomp ayi n gn i llus tr a t o s s how how a 440 volt 4 pol e

i n -
,
-
,

2 ph a
-
s e moto r w a s r eco n n ect e d for 2 2 0 volt Op e ra ti on by -

r e co n n e cti n g t h e co i l s i n p a ra ll el Th e di a gra m of Fi g 2 7
. 3 (a ) .

s hows t h e o ri gi n a l con n ecti on s of t h e moto r a n d Fi g 27 3 ( b) ,

.

i n d i cat es t h e conn ecti on a ft er t h e ne ce s sa ry a lt era ti on s h a d

b e en m a d e Th e ch a
. n ge s i n di ca te d i n t h e di a gra m Fi g , .

27 3 ( b) w ere ma
, de a s follow s :

Termi n a l X 1 wa s jo i n e d to t h e b e gi n n i n g of coil group

A1 a n d en d of gr oup A 4 Th en t h e b egi n n i n gs of groups A 3

.

a nd A 4 a n d en d s of A I a n d A 2 w er e con n e ct ed Term i n a l X2 .
43 6 A R M A TU R E WI N DI N G A N D M OTOR R E P A I R

wa
s joi n ed to t h e b e gi n n i n g a n d e n d of g roups A 2 a nd A 3

r es p e ct i v ely Th e B ph a . s e coil s w e r e con n ect ed i n as i m i la

- r

ma n n er .

Th e fo rego i n g a lterati on s gi ve v ery well di s tri but ed en d -

wi n di n gs whi ch a ,
r e co ns i d e r ed ess en ti al to obt a i n aun i fo r m
flu x di s t ri buti on ; but t h e i mp ed a n ce of t h e p a ra l l el ci r cu i ts
wi ll be ch a n g ed if t h e roto r r u n s off cen t er a s m a y h a pp e n ,

wi th aworm b ea ri n g thus ca usi n g ov erh ea

,
tin g On a ccou n t .

of t h e s ma ll a ir g a p u s u al ly fou n d i n a lt ern a t i n g cu rr e n t -

moto rs th ere i s s ma
,
ll p rob a bi li ty of thi s h a pp en i n g b eca us e
worn b ea ri n g s wo u ld ca us e t h e rotor to ru b t h e s ta to r b efore

Fro . 273 .
—
M ot or wi n d i n g be f ore a
nd a
ft e r ch a
ng i ng fr om 44 0 v ol t s t o 2 20
v ol t s .

it would bri n g a bout ov erh e a ti n g U n e qua l di s tri buti on

.

of curren t b etw e e n p a rall el wi n d i n gs du e to ach a n g e of i mp e d

an ce m a y b e a vo i d e d by co n n e ct i n g t h e c o i l g r oup s wh i ch ar e

di am etri ca lly oppos i t e Of cours e thi s ca . n n ot be do n e wi th

,

two pa rall el wi n di n gs if on e ha lf t h e n u mb er of pol es i s a

- n

odd n umb er .

M ul ti pl e C on n e ct i on Di a g r am f o r A -C M ot or W i n d i n g s . . .

Ma u ri ce S C l e me n t of You n gs town Ohi o m a

. k es u s e of t h e
, ,

di ag ram shown i n Fi g 2 74 a n d cl a i m s th a
. t i t sa ves ag re a t d ea l
of ti me in re con n e cti n g a lte rn a
- tin g curre n t motors (E l ectri ca - l
R ecord Fe bru a
, ry T h i s mult i pl e con n e cti o n w in d i n g
,

dia gr am ta ke s t h e pla ce of fou r d i a gra ms si n ce i t ca n be u se d ,

to show conn e cti on s for si n g le sta r si n g l e d elta pa ra ll e l s ta

,
r ,
43 8 A RM A T U R E WI N DI N G A N D M OTOR R E P A I R

ba la n ce d be fore the y a r e s hi ppe d e i ther i n m a chi n es or a s

ex t ra s
. S ome g o s o fa r a s t o ba la n ce r oto rs b e fore a nd a fter
i n s ta lli n g t h e coi ls a n d t h e hi ghe r s p e e d r otor s of t h e s l i p -ri n g

type m a y be b al a n ce d b e fo re a n d a ft e r i n s t a ll i n g t h e s l i p r i n g s .

M o s t of t h e b a la n ci n g w e i ght i s a ppli e d by forcin g le a d in to

pocke ts provi d e d in t h e core end pla te s for tha t purpose .

Th a t th e a bse n ce of t he se wei ght s m a y s e t up v i b r a t i o n s th a t

ca us e roughen i n g of t h e s li p rin g s a n d ult i ma te s pa rk i n g i s ,

proven by t h e foll owin g e x per i en ce

I n on e s hop (E l ectri ca l R ecord A ugu s t 1 9 1 8) a
, ,s li p ri n g motor-

ha d gi ven mu ch br us h a n d s li p ri n g t r ouble -
T u rn i n g of t h e
.

r in gs a n d ch a n g i n g of t h e ri n gs b r u s h es a ,
n d hold e r s h a d g i ve n
,

n o pe rm a ne n t re l i e f A fa . cto r y i n s p e cto r a t o n ce di a gn ose d

t h e ca use of t h e trouble a s vi b r a ti on whi ch n o on e h a
—
d su s
p e ct e d be ca u se i t w a s i n o n e of tho s e s hop s wh e r e e v e r yth i n g
th a t move s vi b ra te s He tes t e d t h e rotor i n ala
. the a n d foun d

tha t t h e s ha ft wa s be n t Th e s ha .ft wa s the n s t r a i ghte n e d

a n d i t wa s t hought t h a ta l l tr oubl e w a s a t a n e n d ; but n ot s o .

Th e ma ch in e ra n be t te r but th e re w a , s co n s i d e r a ble vi bra t i on

s t i ll th e re .

On que sti on i n g t h e ope ra t or t h e s t a ,

te m e n t w a s obt a i ne d
tha t t h e motor h a d r un a l l ri ght up to t h e t i me tha t it h a d
pa sse d thr ough afire a bout ayea r pr e vi ous ly Th e fire h a
. d
me l t e d out t h e be a ri n gs a nd h a d d e s t roye d e ve rythi n g i n t h e
na ture of in s ul a t i on ; a ls o i t h a d di s tor t e d t h e s ha ft a n d m e lt e d

t h e ba la n ce we i ght s a lthough n o on e h a d con s i d ere d t h e pos

s i bi l i t y of t h e l a st na me d con di ti o ns a
- t t h e t i me of re w i n d i n g -

t h e ma chi n e a n d i ns t a llin g n ew be a ri n g s T h e r oto r wa

. s se n t

ba ck to t h e f a ct o ry w i th ast a te me n t of i t s hi s tory a n d w h en

i t wa s re turn e d a n d r e i n s ta lle d t h e motor i n t h e word s of t h e

-
,

own er ra ,
n l i ke an e w m a ch i n e
”
P r oba . bly i t wa s an e w

ma ch i n e.

Ove rh e a
ting of a ce d t o a
n I n du ct i on M ot or Tra Va
ri a
t i on of
Fr e qu e n cy .
—
tha ta n i n du ct i o n motor i s n ot a
P rovi de d l re a
dy
ove rloa de d i t i s n ot con s i de re d a
,
bus i ve to ope ra te t h e motor
at l e ss th a n 1 0 pe r cen t ove r vol t a ge or a . t 1 0 pe r ce n t un de r .

fre quen cy M a n uf a
. c t ur e r s are ca re ful to s pe cif y howe ver , ,

tha t t h e moto r s hould n ot be ex p e cte d to s ta n d w i thout m a te

ri al i n cre as e i n he ati n g t h e con t in uou s a , ppli cat i on of 1 0 pe r
 M E THODS US E D TO S OL V E S P E C I A L TR OUB L E S 43 9

ce n t ove r volta
.
g e an d 1 0 pe r ce n t u n d e r fr e qu
. e n c y b e c a
,
u s e

both of these va ri a ti o n s a re i n t h e di recti on tha t ten ds to i n

cre a se t h e hea ti n g I f t h e a . mme te r of a n in du cti o n moto r

ci r cui t be obs e r ve d whi l e t h e moto r i s be i n g s t a r te d i t wi ll ,

be see n tha t whe n t h e mot or re a ches nea r ly n orma l s pe e d t h e ,

cu rren t d r ops s udd e n ly t o a va lue fa r be low wha t ex i s te d i mm e

di a t e l y p re ce d i n g t h e sudd e n drop I t is con ce i va . ble t h a t
ce rt a i n vol t a ge fre que n cy loa
-
d con d i ti on s m i ght exi st where by
-

t h e mo t or would be ope ra tin g ju s t on t h e hi gh s i de of t h e cri t

i ca l poi n t i n di ca te d U n de r thi s con d i ti o n t h e curre n t would
.

be a b n or m a ll y l a r ge .

I n on e ca se a m i ll ope ra tor compla i n e d of t h e he a t in g of on e

of hi s la r ge r i n duct i on mo t ors He a dmi tte d tha
. t t h e mo t or
wa s ove rlo a d e d but t h e ove rloa
, d wa s con s t a nt a n d th i s di d

n ot e x pla i n why t h e h ea t i ng wa s s o mu ch gre a te r duri n g s ome

peri ods t ha n du r i n g othe rs Whe n ta .ki n g t h e moto r s pee d
duri n g ape ri od of ma xi mum loa d t h e i n s pector wa , s mu ch

s ur p ri se d to fin d tha t t h e s pee d w a s fiv e pe r ce n t a bove s yn

.

ch r on i sm .Th e mi ll ope ra tor s ta te d tha t ove r s pe e ds h a d ne ve r

b een n oti ce d but h e felt ce rta
,
i n tha t there were t i me s whe n
t h e s pee d wa s con s i d e ra bly un de r n orma l I n ve s ti g a t i on of t h e
.

en g i n e r oom e qu i pm e n t d i s clo s e d th a ,
ta t t i m e s t h e s te a m pres
s ure be ca me so l ow tha t i t wa s n e ce ssa ry for t h e e n gi n eer to

ope ra t e t h e o ve rlo a d va lve of t h e turb i ne i n or de r t o m a i n ta in

i t s s pe e d he n ce fre que n cy
, Th e tu r bi n e gen e ra
. t o r wa s e x ci t e d

from a n e n gi n e d ri ven e x ci t e r
-
t h e s pee d of whi ch wa
,
s n ot

ma t e ri a lly a ff e ct e d by t h e va ri at i o n s of s te a m pre ss ure A s .

t h e fre qu en cy of t h e se rv i ce a ppl ie d to t h e motor s de pe n de d

on t h e s pe e d of t h e turb i n e wh i ch s pe e d d e pe n d e d on s t e a
,
m
co n d i t i o n s wh i le t h e volta
,
ge of t h e s e rvi ce a ppli e d to t h e
motors de pe n de d on t h e turb i n e volta ge whi ch i n turn de
pen de d n ot o n ly on t h e turbi n e s pe e d but on t h e tur bi n e ex ci ta
ti o n whi ch w a s i n d e pe n de n t of s t e a m p r e s s u r e va ri a t i on s t h e ,

e xt re m e co n d i t i o n s of h i gh volta ge a n d low fre que n cy wh i ch ,

m a y h a v e obt a i n e d a t t i m e s ca n b e tt er
, b e i m a g i n e d th a n

e s ti ma te d A s t h e en gi n e r oom con di ti on s could n ot i mm e

.

dia te ly be rel i e ve d t h e duty oi t h e a,

buse d motor wa s l i ght e n e d

by re movin g afe w of t he conne ct e d ma chi nes tha t con sti tu te d

i t s l ea
d .
440 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

R el i ef for aHot Be a
ri ng —
In a
c se of ah ot M g, feed
ple n ty of hea vy oil loose n t h e n uts on t h e be a
,
r i n g ca p a n d
s la ck e n t h e be lt if on e i s use d I f n o re li ef i s s hown ta
. ke off ,

t h e loa d a n d ru n t h e ma chi n e s lowly un t il t h e s h a ft i s coo l

so th a t t h e bea r in g w i ll n ot fre e z e I f t h e be a
“
r i n g i s of
.

ba bbi tt exa m in e i t to see t ha t t h e oil g rooves a re s t i ll i n t a ct .

I f the y a re a n d t h e s u rfa ce of t h e h e a rin g h a s n ot bee n in jure d ,

re n e w t h e oil s upply a n d s ta rt t h e m a chi n e a ga in Wa tch .

t h e oil ri n gs to se e tha t the y a re re volv in g p rope rly a n d ca rry

in g ple n ty of oil t o t h e s h a ft A n e w ma . ch i n e or on e i n whi ch

t h e bea r in gs ha ve be e n rene we d should be run a t slow s pee d

f or a n hou r or mo re be fore t h e lo a d is a ppli e d i n orde r t o see
th a t t h e be a r i n gs a re p r ope rly a djuste d a n d wor k e d i n .

S ta t i c S pa rk s fr om B e l t s (I ns tructi on B ook We s tin ghouse ,

E le ct i c M fg . I t some t i me s o ccurs on be lte d m a

—
chi n e s ,

e s pe ci a lly i n dry wea t he r th a t cha

,
rge s of st a ti c e le ctri ci ty
of con s i de ra ble pote n t ia l on t h e be lt ca use d i s cha rge s to t h e

gr oun d I f t h e fra
. me of t h e m a ch in e i s n ot g roun d e d th ese ,

ch a r ge s m a y j ump to t h e a r m a tu r e o r fi e ld w i n d i n .g a n d th e n

to t h e groun d pun c tur in g t h e in sula

,
ti on Th e be lt a n d fr a
. me
ma y b e d i s ch a r g e d by pl a c i n g clo se t o t h e b e lt a t a po i n t n ea,
r

t h e ma ch in e pul l e y an umb e r of s ha
,
rp m e ta l poi nts li ke a
wh i ch a re ca I f t h e fie ld fra
,

comb , re fully gr ou n d e d . me i s
grou n de d there s houl d be n o d a
,
n ge r to t h e in s ul a ti o n .

Ra ti n g s of A -C G e n era. . t or s I n t h e ca s e of as
.
-
i n gle pha
- se

g en e r a to r t h e ra
, tin g in kvai s e qua l to t h e produ ct of a
. mpe re s
a n d volt s .

For at w o ph a - se g e n e r a tor t h e ra tin g in kva i s e qua

,
l to .

twi ce t h e outpu t of one pha se whe n th e lo a d i s ba la n ce d .

For ath ree-ph a se ge n e ra tor t h e tota l ra t in g in kv ai s e qua l .

t o t h e output of on e pha s e mult i pl i e d by T ha t is the ,

re a d i n gs or a mpe re s a n d volts for on e ph a s e t i me s is

e qua l to t h e kva ra .tin g of t h e ma chi n e when it ca rri es a
,

ba la n ce d lo a d .

Al t e m a i
t n g curre n t M
- ot or P ha -
s e ro a
t t i on (I n s tructi on B ook,
We s t i n ghous e E le ct ri c M fg I n or d e r tha t t he .
—

alte rn a ti n g curre n t wi rin g con n e cti on s be twe en t h e motor

-

an d i t s s up ply ci r cu i t m ay be c o rre c t ly m a d e to obt ai n a g i ve n

di rect i on of rot a ti o n i t i s n e ce s sary, to k n ow t h e ph a s rot a

e -
 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

S iz e s of M ot ors Th e N a ti on al E l ectri ca
Fu s e s for A .
-Cl .
—

C od e do es n ot s pe ci fy t h e s i z e of wi re whi ch s ho ul d be us ed to
co n n ect up a n y gi v en moto r , n or do es i t gi ve t h e s i z es of

sta rt i n g a
n d ru n n n g fu s es to be us ed A commi tt ee of t h e
i

S QUI R R E L -C A GE TH PHA S E
RE E - I ND U CTI ON M or on s E qm r p mn wxrn
'

A UTO-S T A R TE RS

0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

0 0 0 0 0 0 0

West ern A s s o ci a ti o n of E l e ctri ca l I n s p e ctors h a s compi l ed t h e

a ccompa n yi n g t abl e ba s ed on t h e cod e r ul e s whi ch gi v e thi s i n

form a ti o n for si n gl e-pha s e two ph a se a n d thr e e ph a s e moto rs

,
- - .

E x ce r pt s f rom t h e re port a n d t h e recomm en d a ti on s for three

ph a s e moto rs follo w

N o co n si d era ti on wa s gi v en t o l i m i ti n g t h e volta ge drop a t

t h e motor M oto rs wi tho u t a s t a rti n g d evi ce a
. n d tho s e

op era ti n g a t l es s th a n 6 00 r p m r e qui re i n t h e m a j o ri ty of. . .

,

ca s es on e si z e l a
, rg er Wi r e or ca bl e tha n the ta bl e ca ll s for .
 M E THODS US E D TO S OL VE S P E C I A L r RoUB L E S 443

Th e wi res in t h e ta bl e a r e ca l culat ed for two a n d on e h a -lf

ti mes t h e ful l loa d curren t of motors up t o 3 0-a m p ra
. ti n g
a n d f or t wi ce t h e full lo a
- d curren t of la rg er moto rs .

W e r
i r o ca bl s zes r oth t yp es of co t uous duty
e i f o er n i n -

i n du cti o n moto rs s hould be b a s ed on t h e foll o wi n g m ul ti pl es

of t h e ful l loa-
d curr en t : S qui rrel ca - ge moto rs up to 75 hp . .

wi thout s t a rt ers ,
th re e ti m es full loa -
d curr en t ; s qui rr el ca ge
-

moto rs wi th s ta r d elt as t a
- rt i n g s wi t ch on e a
,
n d ah a lf ti m es
full lo a
- d curr en t ; woun d rotor motors wi th resi s ta
- n ce i n r otor ,

on e a n d a t en th ti m es full lo a - d curr en t a ,
n d s i n gl e ph a
- se

re puls i on moto rs up to 1 5 h p . twi ce a

, ,
n d s i n g l e ph a
~ s e moto rs

wi th s pli t pha
-
s e s ta rti n g t h ree ti m es full -loa
,
d curren t .
 C HA P T E R X V I I

M A C HI N E E QU I P M E N T AN D T OOL S N E E DE D I N A
R E P A I R S H OP

Th e work tha t come s to t h e a ve ra l t i a l re p ai r s hop

a
g e e ec r c

va r i e s fr om t h e re-w i n d i n g afa n motor t o t h e ove r h a uli n g n d

r e w i n d i n g of l a
- r ge s t a ti o n g en e ra tors I n t h e la tte r ca se th e .

work mu s t i n t h e ma
, j ori ty of ca se s be do n e a t t h e lo ca ti o n of
,

t h e ma chi ne a n d ca ll s for more port a bl e tools t ha n ma ch i n e

e qu i pm e n t . To m e e t t h e re qu i r e m e n ts of wo r k be twe e n the se
l i mi t s i n siz e of ma ch i ne th e r e i s n e e d e d a fa i r ly we ll e qu i ppe d
ma ch i ne s hop M o s t m ot or re pa
. ir a nd a rm a t u re w i n d i n g
work ca n be p r op e rly h a n dl e d i f t h e follow i n g e qu i pm e n t i s

a va ila ble :
La
the .

C oi l -w i n di n g la
t h e h ea
ds .

Sha
pe r , or u n d ercu t t in g a
tta
ch m e n t for l a
the .

Dri l l pr e s s .

Ba n d sa w .

E m e r y wh eel .

P ort a
bl e h a
nd cr a
ne .

C ha
i n bl ock .

We l d i n g ou t fit .

Vi ce s .

C oi l - pu l li n g m ach i n e .

C oil -
tapi n g m a
ch i n e .

Ba
n din
g m a
ch i n e or t e n s i on d e v i ce for l a
the .

In a onl y on e la
c se the i s a va i la
ble thi s s hould be l ar g e en ough

to a ccommod a t e ag ood s i e d a rma t u re a n d ha ve as pre a dz

be t we e n he ad a n d tai l po s t of a bout 60 i n ch es Th e s h a per .

an d ba n d saw a th e r s pe ci a
re r a l ma ch i n e s for are p a i r s hop
but ve ry u se ful Th e form e r s e rve s a
. s ar a pi d a
nd a ccur a te
me thod for un der cutt in g t h e m i caof acommuta t or Th e .

444
446 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

FI G 2 7
. 6 .
—
Dri ft s used by a
rm a
t ure wi n ders .
( N um bers refer t o t ypes a
nd
u ses . a
p ge

A R M A T UR E Wa mas HA N D’
Toons ( Fro . 275)

Name of t ool
 R E P A I R S HOP E QUI P M E N T A N D TOOL S

Da
m s USE D BY A R M A TU R E Wa n ns ( Fro 2 7
6).

r t i cu l a
Pa r u s es

C oi l s li d e rs or g u i des . For s l i di n g t op s i des of coil s i n t o s l ot s .

Di fie re n t s i z es of fib e r s l ot dri f t s . F or dr i v i n g coi l s i n t o s l ot s Th e y va ry .

i n wi d t h a n d l e ng t h a ccor di ng t o s i z e

of s l ot .

8. 4 a
nd 5 Fi ber coi l s h a
pe rs . Th e c u r v ed s ur f ces a a
re us e d to sh a
pe
e n ds of c oil s .

Fi be r coil d ri ft t a
pe r e d For li ft i n g t ig h t coil s in sm a
ll m a
ch i n es .

Sm l l m et a
a l coil l i ft e r For li ft i n g t i g h t coi l s ou t o f s l ot s .

C ent er p u n ch For m a k
r i n g l oca t i on a n d p i t ch of c oil
wh en s t r i p p i ng a rm a t ure .

9 , 1 0, 1 1
a
nd 12 L ea
d l ift ers For dr i vi n g s ol de r e d e n ds ou t of com

m ut a
t or nec k s wh e n s t r i pp i n g a
rm a

t ur e .

1 3 , 1 4, 1 5. M et a
l dr i f t s For se a
t i ng coil a
t e rm i n l s i n co m m u t a
t or
1 8 , 1 9 , 2 0, k
nec s .

21 a
nd 22

16 Or di na ry d i v i de rs For l ayi ng ou t fi ber coll a rs .

1 7a
nd 2 3 Tee s l ot dri ft s For p a rt l y cl ose d s l ot s t o dri v e coi l s

d ow n i n s l ot s .

De vi ce for S h a i
p gn I n s u l a
t i n g C e l l s of A rm a
t ur e S l ot s .

For sha pi n g t h e fish p a per in ma kin g ce l ls for arm a ture a nd

s ta tor slots t h e cell s ha per s ho wn i n Fi g 2 77i s ve ry use fu l . .

I t con s i s t s of two pi e ce s of wood hi n ge d toge the r s o th a t the y

wi ll ma ke an ea t 90 deg fold Th e pe rma
- n e n cy of t h e cor re ct
. .

fold ma ker i s i n s ure d by me a n s of a ,

l a — 16r
5
! m e ta
" m
l s t ri p a
“
tta ch e d to t h e wood s lot .

Th e cel l s h a pe r i s use d by i n se rtin g

api e ce of fish pape r i n t h e open in g
3
3 be t we e n t h e two blo cks of wood whi ch ,

Fm 27
. 7 D i.
—
f o i s t h e l e n gt h of t h e s lot plu s tw i ce t h e
e v ce r

ll of
hei ght a n d who s e wi dth i s t h e w i dth
ce s

of t h e slots Th e m e ta l s tr a
i ght-e dge .
,

whi ch i s a dj us ta ble by mea n s of w i n g n u t s a llows t h e pa pe r ,

t o be folde d so a s to be m a de t h e he i ght of t h e slot .

Tool f or C u tt i n g C e l l Li ni n g a t Top of S l ot For cut t in g t h e —

proj e ctin g i n sul a ti on of a n a rm a ture slo t a fte r t h e coi ls h a ve

be e n a s se mble d t h e tool s hown i n Fi g 2 7
, 9 i s re comm e n d e d by .

Ma uri ce S C le me n t (E l ectri ca
. l Wor l d Oct 1 2 T hi s ,
.
,
 RE P A I R S HOP E QUI P M E N T A N D TOOL S

be in g to out ati gh fit t in g coi l wi thout da

l if t ma
u
- gi n g t h e
i n sula ti on .

Th e wi re s cra pe r i s very si mmy ma de a n d ve ry econ o m i ca

-
l ,

beca use i t e li mi n ates t h e use of akn i fe whose lif e i s s hort on ,

a ccoun t of t h e rough tre a tme n t a cco r de d i t Th i s d e vi ce i s .

ma de of s pri ng me ta l 1 2 i n ches by i n ch by ,
i nch Th e .

knife e dges ca - n be sh a r pe n e d by m e a n s of afil e a n d t h e tool

used i n de fini te ly A se ct i on t h e s hape of are ct a

. n gle is cu t

from t h e me ta la t t h e ha n dle e n d gre a tly i n cre a s i n g t h e s p ri n g

,

e fle ct of t h e d e vi ce
'

For d ri vi n g fibe r w e dge s betwe e n t h e t op of aco i l a nd t h e

la m in a ti on overha n g i n g clo se d s lot s awe dge dri ft ma de of

-
, ,

api e ce of tool stee l ei ght i n ches by five i nches by ,

i nch ,

ov wh ch i s fitte d aloose fit t i n g stee l s lee ve M 6 in ch thi ck

er i -
, ,

i s ve ry con ven i e n t Thi s i s u s e d by in se rti n g t h e fibe r we dge

.

a bout M i nch i n to t h e s lot ; the n wi th t h e dri ft p ull e d ba ck i n t o

,

t h e s lee ve t h e s lee ve i s fi tte d ove r t h e we dge whi ch i s dri ve n

, ,

i n to t h e pr o pe r pla ce t h e s l ee ve hold i n g t h e w e dge i n pos i t i on

,
.

R e pa t Ca
i r Tool s t h a d e fr om Ol d a sa
n be M a H ck - w B la
de s .

S e v en tools tha v e b e en m a
t ha ck a
d e from old h a w bl a
d es -s

FI G . 2 82 .
—
S ev e n a
rm a t u re r e p a
i r t ool s m ade fr om ol d ha ck -s a
w bl ade s t h a
t
are us e ful a r ou n d am o t or re p air be n ch .

an d fou n d u s eful i n t h e r e w i n d i n g of motors a re s hown i n -

Fi g 2 82 . A sma ll wooden ca
. s e t o s tow a wa y these tool s ca n

be ma de a s follow s : C u t out two p i e ce s of a n y s ui tabl e h a

rd

wood e i ght i n ches lon g on e a n d on e h a lf i n che s wi de a

,
nd -

54 in ch th i ck . T he n
of on e of these pi e ce s on t h e fla
t si de
out se ve ra
l groove s l a llow aha
rge e n ough to a ck sa w bl a
, de -

to fit in i t s nugly Th e two pi e ce s s hould the n be n a

. i led
45 2 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

toge the r so tha t t h e gr oove s will be be twe en both pi e ces .

When athi r d p i e ce of wood e i ght i n che s lo n g on e i n ch wi de

, ,

a nd M i n ch th i ck is n a i l e d on as a bo t tom p i e ce t h e ,

ca se i s re a dy for t h e tool s .

Whi le e a ch of t h e tool s ca n be u s e d for s e v era l d i ff e ren t

Ope ra ti on s afe w of t h e mo st i mport a
, n t use s a re a s fol lows :

To ol s on e two a n d five (fr om t h e ri ght ) a

, re use d mos tly i n

ta p in g co i ls Tools one a . n d two a re use d to be s t a dva n ta ge i n

di ggi n g st ra y drops of s olde r out of t h e win di n g of as ta tor
a ft er t h e conn e cti on s h a ve be en sold ere d Tools four a n d six
.
,

whi ch ha ve both e dge s of t h e V s ha r p en e d to akn i f e e dge -

,

a re ve ry we ll a da pte d to cutti n g in sula t i on a n d s cra pin g wi res

or le a ds N umbe r se ve n i s use d to dri ve we dge s in to t ig ht
.

s lots .B y se tti n g t h e sa w t e e th on t h e we dge a

- n d po un d i n g

on t h e b e ve l e d e n d w i th aha mme r t h e tee th a r e ma ,

de to
gr i p t h e we dge a n d d ri v e i t to i t s p rope r pl a ce .

S pe ci al C oi l wi n di n g De vi ce
- For wi n d i n g coi l s of pra
.
—
ct i

ca lly a ny s ha p e t h e s pe ci al d e vi ce s hown in Fi g 2 83 h a s b een .

FI G . 2 83 .
—
Fr a
m e w or k for u se i n w i n di n g di fl e re n t sh a
p es of a
rm a
t u re coil s .

d evis ed by Fr a n k H u s ki n s o n ( E l ectr i ca l Wor l d J uly 2 7 , ,

I t co n si s ts of a
n i ro n fr a m e work h eld tog eth er wi th four bolts
s hown a t B B y loos en i n g t h e n ut s of th es e bolts t h e two
.

outs i d e m emb ers ca n be a djus t ed for a n y wi dth of co i l n e e d ed .

To g i ve t h e co i l t h e p rop e r s h ape di s ks s u ch a s ma rk ed C a
,
re

cl a mp ed on t h e pi e ce D a n d t h e la tt er i n s e rt ed i n t h e s lot s
'

ma rk e d A i n t h e fr a m e Th e V i e w a .t E s hows how th es e
di s ks a pp e a r wh en t h e bolt D i s i n i t s p r op e r pl a ce i n t h e f ra
me .

Wh en fo rmi n g t h e coi ls t h e wi r e i s wou nd a r o un d s i x of t h e

bolts or p egs a n d b e tw e en t h e d i s ks mou n t ed on th e m .

454 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

S t ea
dyi n g B ra ce for R e pa i ri n g S m al l M ot ors Th e d e vi ce —

s how n i n Fi g 2 84 h a
. s b e e n d e vi s e d by M a uri ce S C le me nt .

( E l ectri cal R ecor d, De ce mbe r ,

1 9 1 8) f or pa i ri n g fa n u se in re

motors or othe r s m a ll mo t ors when it i s n e ce ssa ry to re move

t h e w in di n g of t h e s t ator fr om t h e f ra me To remove these .

wi n d in gs from t h e fra me t h e l a mi n ati on s must be re move d

wi th t h e w in d i n g When on ce re move d i t i s very d i ffi cult
. .

t o wor k on i t a s it h a s at e n de n cy t o r ol l a wa ya l l t h e ti me .

Thi s b ra ce i s co n st ru ct ed a s follows : A blo ck i s cu t a s

s hown a n d bolt ed to t h e b e n ch On e en d of al en g th of .

ri bbo n copp er wi re a bout M 6 i n ch thi ck a nd i n ch wi d e i s

th en scre we d to t h e en d of t h e blo ck a n d pa ss ed ov e r t h e Wi n d

i n g whi ch s et s i n t h e cu t out port i on of t h e blo ck Th e oth e r .

en d of t h e copp e r ri bbo n i s h e ld down by m ea n s of awi n g

n u t pl a ced b etw e en t h e bolt s A l ea th er stra p is a

. rr ag ed
n
from on e si d e of t h e block over t h e copp er ri bbon a
,
n d fa s t en ed

to abu ckl e on t h e oth er s i d e Thi s i s at en si on st ra

. pa n d ta kes
t h e sl a
ck out of t h e copp e r r i bbo n .

Te n si on B l ock For U s e Wh e n B a ndi n g A rm a A tool

'

t ur e s .
—

i s s hown in Fi g 286 wh i ch h a . s b e e n d e v i s e d by M a uri ce S .

FI G . 2 86 .
—
T e n si on bl o ck for
. use w h e n wi n d i n g a
rm a
t u re s .

C lem en t (E l ectri ca l Wor ld Oct 1 2 1 9 1 8) for b a

,
. n d in g a
,
n a rm a

tu re i n asm a ll r e p ai r s hop wh ere ab a n din g la the i s n ot a vail

a ble B y u se of t h e de vi ce t h e a
.
.
rma ture ca n be b a n d e d on a n

o rdin a ry w i n d in g s t a n d wh i ch i s s e cure ly f a s t e n e d to t h e fl oor

or w or k b e n ch When th i s de vi ce i s use d a
. bou t on e foot of
s tout l i n e wi t h a hook a tta ch e d to on e e n d i s m a d e fa s t to t h e

r i n g on t h e t e n s i o n blo ck a n d hook e d to a n e ye bolt whi ch i s -

s et i n t h e fl oo r for th a t pur pose Th e s pool of b a . n d i n g wi r e

i s pl a ce d on as m a ll s ta n d b e s i d e t h e e y e bolt a n d t h e w i re i s -

pa ss e d b e t w e e n t h e two blo ck s a t t h e re a r e n d th r ough t h e

hole i n t h e firs t wi re gu i de ove r t h e te n si on cur ve a n d th rough

 RE P A I R S HOP E QUI P M E N T A N D TOOL S

t he o d wi re gu i de hole a
se c n n d th e n to t h e a r ma ture Th e .

ten si on can be re gulate d by t h e win g n u t place d a t t h e for ward

uppe r e n d of t h e blo ck B y s cre wi n g down t h e wi n g n u t

.

both s i de s of t h e blo ck a r e b r ough t n e are r tog e th e r thus .

7B ra
ss ri ve t s

FI G . 287.
—
A rm at u r e sl i n g m a
de u p of dou bl e -p l y l e a
t h e r be l t i n g .

n a
rr ow i n g te n s i on curve ove r whi ch t h e wi re mu s t pa
t he ss .

Th i s in cre a n d wh e n ap i pe w r e n ch
s e s t h e t i ghtn e s s of t h e b a

ca
n be u se d to re vol ve t h e a r mat ure .

Fro 2 88
. .
—
M e t h od of u s i n g ar 0p e sli n g in ha
n dl i n g a
rm a
t u re s w i t h ac a e r n .

Arm a
t ur e S l i n g .
—
For h a hea vy a
n dh n g r ma t ure s in re pa ir
s hops a s l in g i s s om e t i me s u s e d i n s t e ad of li ft i n g by m e a n s of a

rope a t ta ch e d t o t h e en d s of t h e s h a ft as a ba le h a n dl e for t h e
45 6 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

cr a n e hoo k Th e s li n g pre ve n t s t h e pos si bili ty of S pri n g in g

.

t h e s ha ft A sli n g wh i ch ca
. n be u se d for ha n dli n g sm a ll
a rm a ture s i s s hown in Fi g 287 I t i s con str ucte d of api ece
. .

of double ply be l t in g a bout i n ch th i ck 1 0 i n che s wi d e a nd ,

fee t lon g provi de d w i th tria n gle s ,

of s te e l ba r for t h e hook of a s hop

cr ane .

de vi ce whi ch
P i ni on P ull er .
—
A
ca n be m a de up a s s how n i n Fi g .

28 9 i s co n ve n i en t for r e movi n g
pin i on ge a r s fr om motor s h a fts wi th
out in j ury B y ma k i n g t h e he a . d
s u ffici e n t l y lon g a n d p r ov i d i n g hole s

a t s ui t a ble di s ta n ces ; p i n i o ns of
d i ff ere n t s i z e s ca n be re move d by

f m am t
ro haft o or a dj us t in g t h e e n d p i e ce s
s .
.

C oil -wi n di n g M a ch i n e s I n Fi g —
.

290 ade vi ce i s s hown whi ch do e s n ot re qui re t h e u s e of fo r ms

whe n win din g a rm a
ture coi l s I t con s i s ts of a na dj us ta
. ble me ta l
fr a ws whi ch m a
m e wi t h j a y b e cl amp e d i n v ar i ou s po s i t i o n s s o

as to m a ke aform ove r whi ch t h e wi re ca n be woun d i n t o t h e

FI G . 2 90
.
—
Seg ur a rm at u re coil w i n d e r f or w i n d i n g h a
i r -p i n l oop , obt u s e l oop
an d re c t an g ul a
r l oo p coil s .
( E l e ctri cal M an uf a
ct u r e r s E qu i p m en t C om p a ny ) .

With t h i s d e vi ce l oop s f r om 3 i n ch e s t o 3 6 i n ch e s c n a be w ou n d B y m ea ns of t h e
a a 2 92 ca
.

d e r s h ow n i n Fi g 2 9 1 t h e c oi l s h p e s s h ow n i n Fi g n be f or m ed f r om t h es e
s
p re . .

oop s .

sha pe of t h e coi l de s i r e d J a ws a r e pr ovi d e d for for m i n g ha

. ir
pi n loop co i l s t h a
t i s co i l
, s w i t h pa
, ral lel si d es a
n d cur ve d en ds .
458 A RM A TURE WI N DI N G A N D M OTOR R E P A I R

F m 2 92 .
—
. C oil s th ta ca
n be sh a
pe d on t he s p re a
der s h ow n i n Fi g . 29 1 .

(1) C l oop . 3 w i r es wi d e wi t h 5 t u rn s t h a t can be s p rea d a s s h own i n

$
om m on 2»
a 5 -c oxl
g r ou p 3 wi res w i d e , w oun d 5 wi r es v e r t i cal a
n d s pi r a l s h ow n f or m ed i n 4 )
$;
3
5 ar ec t a ng ula r 1 00 3 wi r e s wi de . 2 t ur n s o f 6 w i r es t h a t ca n be s h a pe d t o m a e } k
8-coi l bu n dl e (7 ) O t u se l oop . 5 t ur ns 3 wi r es wi d e t h a t ca n be f or m e d a s s h ow n i n
n d s p re a k
n E i ck em e y e r c oa k
. ,

( 8) a d t o m ae a Ri bbo n cop pe r coil f or m ed i n t o

.

l li e
hai r -p i n l oop by ba r be n d e r ( Fi g 2 9 3 ) a
. nd sh ap ed i n c oi l s p r eader .

FI G 2 93 — T op vi e w of
. . aS e g ur r be n de r for s h a
ba p i n g a
rm at ure coil s m ade
of cop pe r s t ri p from to i n ch t hi ck by an y wi dt h u p t o 1 “ i n ch .

( E l ectr i ca
l Ma ctu r sr s E qu i pm ent C om pa
n ufa ny ) .
 R E P A I R S HOP E QU I P M E N T A N D TOOL S

Fi
( g . then a
Ta
pe is che d by ha
tt a nd a n d t h e rota ti n g
e le m e n t whi ch ca pe wi n d s i t s ym met ri ca
rri e s t h e s pool of t a lly
a bout t h e bun dle of wi re s formi n g t h e coi l .

FI G 2 9 4 — S e g u r a
. . rm a t ure coil -t a pi n g m achi n e .

( E l ectr i cal Ma ct u r er s E qu i p m en t C om pa
n uf a ny ) .

Fro 2 95 P or t abl e com m u t a t or s l ot t i n g m a ch i n e t h a t w il l h a n dl e a rm a

—
. .

t u re s u p t o 1 8 i n ch i n di a E l i S i l i C a y )
m et er .
( e ct r c er v ce S u pp e s om p n .

C om m ut a
t or -s l ot ti n g a
n d Gri n di n g M achi n e s I n Fi g 29 5
—
.

is how acomm u ta
s n to lottin g outfit -
r s . Th i s ma chi n e con s i s ts

of afra
me i n whi ch t h e commutat or is he ld ei ther be fore or
46 0 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

af te r t h e comm uta tor h as be e n pl a ce d on t h e a r ma ture a nd ,

arota ti n g di s k saw moun t e d on sli de s w hi ch a re pa ral l e l t o t he

di re cti o n of rota ti on of t h e di s k Th e r ota t i n g sa
. w i s d ri v e n
by be lts or othe r s ui t a ble m ea n s of t r an s m i ss i o n fr om t h e

sour ce of powe r Th e gui d e or fra

. me upon whi ch t h e sa w is
moun ted i s a dju sta ble a cco r d i n g to t h e d i a
meter of t h e com

E m . 296 .
—
C om m u t at o r s l ot t i n g m a ch i n g t h a
t ca n be a ttach e d t o a n da
st a rd

e ng i ne lat he.
( E l ectri c S ervi ce S u p p l i es C om p a
.ny )

mut a tor to be worke d on a nd a fter t h e corre ct he i ght a n d d e pth

of t h e cu t ha ve b e e n a s ce r ta i n e d t h e fr a me i s cl a
,
mpe d firmly
i n po s i ti on Th e ope ra
. t o r th e n s t a rt s t h e s a
w a n d move s i t

forw a r d on i t s g u i d e by m e a n s of a l eve r s o th a t i t com e s i n t o

,

co n t a ct w i th t h e commut a tor thu s cutt in g aslot Th e a

,
rm a .

ture i s move d t hrough as pa ce co rre s pon d i n g to t h e wi dth of a

si n gl e ba r a n d t h e sa
, w is a g ai n b r ought fo r w ar d cutt i ng
46 2 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

ma chi ne is esse n t ia l ly ala the a n d ope ra tes i n t h e sa me ma nn er

a s a n y othe r m a chi ne for g rin din g a ci r cul a r s urf a ce .

Arm a t ur e ba
- n di ng M a chi n e Thi s ma
.
—
chi n e us ua lly con
si st s of as ui t a ble s ta n d wi th bea r in g s upon whi ch t h e a r ma

t ure sh a ft res t s a
,
n d some me a ns for r o t a ti n g t h e a r ma ture by
me a ns of abe lt ch a,
in or gea r d r i ve fr om a l i n e sh aft or from
a n i n d i vi dua l motor A ba. n d wi re te n si on d e vi ce s i mi la r to t h e

te n si on de vi ce e mploye d for wi n di ng coil s i s in cor pora te d i n t h e

ma chi n e or i s bu i lt a s ase pa ra te m a ch in e wh i ch m a , y b e a t
ta ch ed t o t h e a rm a ture s t a nd Wi th a
. n a r ma ture i n pos i ti on ,

t h e ba n d wi r e i s att a t se ve ra
ch e d a l po i n ts thr oughout t h e len gt h

F m 2 98
.
—
. A ma
chi n e e q u i p pe d s o th t a coil - wi n di n g , ba n di n g a
nd g ri n di n g
a
Op er t i on s m a
y be p e r f orm e d o n i.t

of t h e a r ma ture on e a
, t each e n d a n d on e or more a t e qual dis
ta n ce s be twe e n t h e en d s a n d t h e ma
, chi n e i s s t a rt e d Th e r o .

ta t i on of t h e a rm a ture ca use s t h e wi r e to be wra ppe d a bout t h e

a rm a ture t h e ten si on de vi ce a
,
n d gu i d e l a yin g t h e wi re s e ven ly ,

to awi dth whi ch i s de term in e d by t h e se ttin g of t h e gui de .

C om bi na t i on M a chi ne s A —
combi n a t i on coi l wi n di n g -
,

ba n din g a n d gri n d in g ma chi n e i s s hown in Fi g 2 98 Thi s . .

ma chi n e comb i n es in to on e t h e followin g tool s :

,
a
( ) a b an d
i n g ma ch i n e w i th ase lf con ta - i n e d t e n s i o n ca rri a ge for t h e
ba n d w i re d e s i g n e d t o h a
, n dl e l a rge or s m a ll ra i lwa y l ocom o ,

ti ve or s ta t ion a ry a rma ture s ( b) acommuta tor slotti n g m a

ch i n e w i th i n d e pe n d e n t moto r d r i ve ; ( 0) a commuta tor gri n din g
ma chi n e w i th i n d e p en d e n t motor d ri ve ; (d) acommut a t or
 R E P A I R S HOP E QUI P M E N T A N D TOOL S

c utting or turning a t ta chmen t ; ( e) afie ld a nd a rm a ture coi l

pla te moun t e d on t h e ma i n s p i n dle s ui ta ble for a ll cl a s s es of

hea vy form coi l win di n g T hi s m a . c hi n e close ly rese mbl e s a

la rge powe r la the but is provi de d wi th t h e s pe cia la tta chm e n ts

for pe rformi n g t h e work a bove outli n e d A fte r a

. n a r ma ture
ha s ha d t h e co il s pla ce d i n t h e s lot a n d t h e l ea d s s old er e d to t h e
commuta tor i t m a ,y b e pl a ce d i n th i s m a ch i n e a n d t h e wo r k
compl e t e d w i thout r e movi n g t h e a rm a ture fr om t h e ma ch i n e
.

Th e b a n di n g a tt a chm e n t i s ca pa ble of he a vy duty t h e rota

,
ti on
be i n g un de r con t rol of t h e ope ra t or
. Wh en t h e ma chi n e

i s stoppe d i t a utoma t i ca lly lo ck s a n d pr e ve n t s s l a ck i n t h e

ba n d w ir e du e to b a ck i n g mot i o n of t h e a r ma ture U n i form

.

ten si on i s se cure d by ate n si on de vi ce moun te d on t h e fee d

ca rr i a ge a n d t ra ve lin g wi th i t Th e fe e d ca
. rr i ag e is mov e d
a lon g by mean s of ara ck a n d p in i o n a n d p i lot whee l a nd is

a djusta bl e vert i ca lly in or out .

Th e s lott in g a t ta chm e n t i s s upporte d by a bra cke t cla mpe d

to t h e ta il s to ck s pi n dle a
- n d i s r e move d by loo se n in g two ca p
s cr e w s . Th e comm uta tor truin g or grin d in g a tta chm en t

con s i st s of at ra v eli n g g ri n din g whe e l s uppor t e d from t h e ta il

s to ck a n d moto r d r i v e n . Th e ca s t i n g wh i ch s uppo rt s t h e two

r od s ca rr yi n g t h e gri n d in g wh e e l a n d t h e i n d e pe n d e n t moto r

a re a dj usta ble a lon g two othe r s te e l r od s proj e cti n g ba ckwa rd

fr om t h e ta i l sto ck a n d b r i n gi n g t h e g ri n d in g wh ee l p a ra lle l
to t h e fa ce of t h e commut a tor The s e r ods a
. re a dj us ta ble i n
or out to s u i t t h e l e n gth or lo ca t i on of t h e commu t a tor a
,
nd

t h e g ri n d i n g wh ee l i s move d a lo n g by me a n s of t h e s cre w a nd

ha n d wh ee l C utti n g i s don e i n both d i re cti on s of tra

. ve l of
t h e whe el P owe r i s a
. ppli e d e i ther thr ough belt a n d pull e y

from acoun te rs ha ft or by a n i n d i vi du a l mot or dri ve wh i ch

ma y re a d i ly b e i n s t a ll e d . T h e c o n t r ol i s by m e a n s of a c lut c h
whi ch i s ope ra te d by at rea dle run n in g t h e full len gth of t h e
ma ch i n e . Th e m a chi ne i s p r ov i d e d w i th two ch a n ge s of

s pee d alow S pee d for b a

,
n d in g a n d co i l w in d in g a n d ah i gh

s pee d for commut a tor cuttin g gri n din g a

, n d t u in g
r . T h e

hea d s tock i s pr ovi de d wi th acoi l wi n d in g pla - te to whi ch m a y

be a t ta ch e d for m s for w i n d i n g co i l s of va ri ous s i z es a n d sha pe s
,

upon t h e sa me prin ci pl e a s t h e i n d e pe n d en t co il w i n d in g-

ma chi n e s d es ig ne d t o do th i s wo r k o n ly
,
.
466 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

a
of e ch s ys t e m a
re of the s a
me si z e, t h e foll owi n g i s t h e rel a
t i on s hi p of
the coppe r re q u i r ed .

S ys t e m .

2 Wi re , a
si ng l e-ph se or di re ct cu rr en t
3 Wi re i l ph as e or di re ct cu rre n t
s ng e -
,

4 Wi re , si n g l e-ph a se or d i rect cu rren t

4 Wi re , t w o-ph a se .

4 Wi re , t h r ee-ph a s e w i t h n e u t ral
3 Wire , t h ree -ph a se De l t a

Cl a
ss ifica
t i on of Wi re Ga
ug e s. —
Wi re g a re kn own u n de r a
u g es a va
ri e t y

a
of n m es s o a a
t h t i t i s i m port n t t o kn ow t h e di fier en ce wh e n con di t i ons
'

re qu i re a a
t h t t h e v l u es of on e g u g e s h l l be con v ert e d in t o t h ose of an a a
ot h e r . Th e foll ow i n g is cl s s i fica aa
t i on of g u g es by n m es n d u s es a a a
B rown 8: S h a rpe ( B dz S ) A m er i ca n Wi r e Ga u g e (A
. W . . .

N e w B ri t is h S t an da rd ( N B S ) B r i t i s h , I m pe ri a l , E n g li s h L e g a
. l . .

S tand a n da
nd S t a rd Wi re Gau g e, a n d i s va ri ou s l y a bbrevi a te d by
S W G a
. . nd I W G. . . .

m Ga
B i rm i n g h a u g e (B W G) S t u bs , Ol d E ng li s h S t a nd
. . and .

I ron Wir e Ga ug e .

R oebl i n g Wa
s h bu rn M oen , A m eri ca
n S t ee l a
n d Wi r e C
’
os . I ron
Wi re Ga ug e .

L on don Ol d E n g li s h (n ot Ol d E n g li s h S t a n da rd) .

A s afu rt h er com pl i ca t i on
B irm i n g h a m or S t u bs I ron Wi re Ga u g e i s n ot t h e s a me a s S t u bs
’ ’

S t ee l Wi re Ga uge .

U es of V a
s r i ous Ga ug es — B dz S Ga u g e — Al l form s of r ou n d w i r e u s ed
. . . .

for e l ect ri ca l con du ct ors S h ee t coppe r , br a ss a n d Ge r m a

. n s i l v er .

U S S Ga
. . ug e .
— S h ee t i ron a n d s t ee l L eg al i z ed by a ct of C on g ress , .

Ma rch 3, 1 893 .

B W Ga
. ug e
.
—
Ga l va n i z e d i ron w i r e
. N orw a y i r on w i r e . .

A m e ri ca n S cr e w C o s Wi r e G a N u m ber ed s i z es of m a ch i n e a
’
ug e —
. nd

w ood screw s , pa rt i cu l arl y u p t o N o 1 4 i n ch ) . .

S t u bs S t ee l W
’
i re G uga e — Dri l l r od .

R oebl in g dz T r en t on I r on a
— n d s t e el w i re Te l e ph on e a n d t el e .

g r ap h w i re . 1

N .B S .
— Ha rd d ra
. wn coppe r Tel e ph on e a n d t e l eg r ap h w i r e. .
 APP E N DI X

Drr rE E E N cn BE TWE E N Wm E GA U GE S
470 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

power , n ot for t h e per cen t l oss i n t h e lin e of t h e pow er a

. t t h e g e n er a t or ;
a nd t ha t E i s t h e pot en t i a l a t t h e en d of t h e l i n e a n d n ot a t t h e g en e ra t or .

Wh en t h e pow er fa ct or ca nn ot be m ore a ccu r a t e l y de t e rm i n ed , i t m a y

be a ssum ed t o be a s foll ow s for a ny a l t e rn a t i n g sys t e m opera t i ng u n der
a ver a g e c o n di t i ons : I n c an d esce n t li g h t i n g an d s yn ch ro n ous m o t o rs ,

95 per ce n t ; li g h t i n g a
. n d i n du ct i on m ot ors t og e t h er , 85 per cen t ; i n du c .

t i on m ot or s a l on e , 80 pe r cen t .

I n con t i n u ous cu rre n t , t h ree-wi re syst e m s , t h e n eu tr a l wi re for feede rs

s h oul d be m a de of t h e sect i on obt a in ed by t h e form u l afor ei t h er of t h e
ou t s i de wi res . I n bot h con t i n u ous a nd a l t e rn a t i n g -cu rre n t sy s t e m s , t h e
n e u t ra l condu ct or for se con da ry m a in s a n d h ouse w irin g s h ou l d be t a ken
a s la rg e a s t h e ot h e r con du ct ors .

Th e t hree wires of at h ree-ph a se ci rcu i t a n d t h e fou r wi r es of at w o

ph a se ci rcu i t s h ou l d be m a de a l l t h e sa m e si z e , a n d ea ch con du ct or s h oul d

be of t h e cross—sect i on g i v en by t h e firs t form u l a .

GE NE R AL WI R I N G DA T A FO R FOR M UL A F OR DI RE CT AN D A L TE R N A TI N G

cU R RE N r
'
C I R C U I rs —
'
25 AN D 60 C YC L E S

Val u e of B f or for m ul a( p ag e 468)

 A P P E N DI X

GE NE R A L WI R I N G D A TA r OR FOR M UL A r OR DI RE CT AN D Am n N A TI N O

C UR R E NT C IR U
C rT s — 60 A N D 1 25 C r ow s

R esi s t
Val ue of B f or f orm ul a( u s e 4 68)
A re a Wt lb a
n ce
ba
.

w ire re Oh m s
ct r

35
6C
.

g
“
H ft °

A m per e s i n A l t ern ti ng -curre nta C ircui ts The foll owi ng t a

.
— bl es g i ve
t he a m m res pe r l ea d wi re pe r ki l owa t t for si ng l e-ph a se a n d t h ree-ph a se

ba la n ced l oa ds Th e si n g e ph a
. l - se t a bl e ca n be u se d fo r t wo ph a
- se

ba la nced l oa ds by u s i n g acu rre n t va l u e corres pon di n g t o t wi ce t h e s t a t ed

p o te n t i a
l o f t h e ci r cu i t or b y d i vi d i n g t h e c u rr en t v a l u e a t t h e p o t e n t i a l
of t h e ci rcu i t by t w o Th a t i s , ea
. ch wi r e Of at wo-ph a se ci rcu i t ca rri es

on e-h a lf of t h e cu rren t i n di ca t ed a t t h e l oa d s peci fied Th ese t a. bl es

s h ow t h e va l u e of t h e cu rren t a t powe r fa ct ors va ryi n g from u n i t y t o

7 0 pe r cen t . Th e power of a n y ci rcu i t i n ki l ow a t t s ca n , t h e refore , be

com pu t ed by di vi di n g t h e r ea d in g of t h e a m m e t e r by t h e t a bu la t e d va l ue
corres pon di n g t o t h e m ea s u red powe r fa ct or a n d v ol t a g e o f t h e c i rcu i t .

Th ese va l u es a re correct on l y for aba la n ced l oa d (a n d t h e re i s g e n er a lly

asl ig h t u n ba la nci n g of t h e l oa ds on t h e ph a ses ), bu t t h e t a bl e is u se fu l i n
com pu t i n g t h e si z es of w i re r e qu i red for t ra n s m i ss i on pu rpos es .

Thi s t a bl e wa s deri v ed from t h e fol l ow i n g form u l a s :

a
For si n g l e-ph se ci rcu i t s : A m peres per wi re wa t ts (vol t s X
pow er fa ct or ) .

a
For t hre -ph se ci rcu i t s : A m peres per wir e
e
t ot a l wa t t s : (v ol t s
bet ween wi r es X
pow e r fa c t or X V 5) .

For t wo-ph a se ci rcu i t s : A m m res p e r w i r e t o t al w a t t s (v ol t s

be t wee n wi res of on e ph a s e X pow e r fa ct or X

In m a ki n g t h e com pu t a t i ons t h e n u m be r of w a t t s wa s a ssu m ed a s

1 000, a nd t h e a m per es w ere com pu te d for v a ri ous v a l u es of em f t o a .

472 A RM A TU R E WI N DI N G A N D M OTOR R E P A I R

su fi ci ent num ber of deci m a l pl a ces t o i ns u re accu ra cy Th e t a bl es w ere

.

t h en ext en ded by m u l t i pli ca t i on a n d di vis i on I f d es i red , t h ese t a

. bl es
ca n be fu rt h er e x t en d e d t o cov e r v ol t a
g es ou t si de of t h e i r li m i t s by u si n g
r va
a a
t h e t bu ll u es corre s pon di n g t o pot e n t i a
ls of on e -t en t h (or 1 0 t i m es )
t he d es i red pot e n t i l , a ca
re a
bei ng u s ed t o shif t t h e deci m l poi n t in t h e
pr op e r di rect i on .

Th e v a
l u es for i n t e rm ed i a
t e pow e r f a ct ors ca n be a pproxi m a te d from
the ta
bl es . For l ow er power fa ct ors , t h e v al u e of t h e cu rre n t for un i t y
pow e r fa
ct or a
c n be di vi ded by a l pow er fa
ct u a ct or of the ci rcu i t or
m ul t i pli ed by t h e r e ci proca
l of t hi s pow er f ct or a .

S I N GL E -P R A sE C I R C U I TS -
A M PE RE S F OR ON E K I L OW A TT AT D I FF E R E NT

P OWE R FA C T O R S
Q

P ow er fa
ct or i n pe r ce n t .

TH RE E - PH A S E C I RC U ITS -
A mp E RE s PE R WI R E FOR ON E KI L OW A TT AT

D I F FE R E NT P OW E R FA C T OR s

P ow er fa
ct or pe r ce n t .
 47
8 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

ta
l M ot or Da
Ge n era Th e foll owi n g t a
— bl e g i ves t h e h ors epowe r, v ol
ta g e a n d s pe e d of s t an d a
rd m ot o rs a t v a
ri ous f re q u en ci es f or t wo a
nd

t h r ee -
ph a s e op e ra t i o n :

V OL TA GE ,
HOR sE P OWE R AND S PE E Ds or S TA N DA R D M OTO R s

n o, 2 20, 440, 550 1 , 2 , 3 , 5,

1 1 0, 2 20, 440, 550 2 , 3 , 5, 7 1 200
2 20, 5 50 2, 3, 1 200
2 20, 550 1 , 2, 800
1 1 0, 2 20, 440 1 , 2 , 3, 1 500
1 1 0, 2 20, 440 1 , 2, 3 , 750

S TA N DA R D P OTE N TI A L s r OR wnrcn S KE L E TO N FR A M E M OTOR s ARE

WOUN D
V ol t s

S ta
nd wil l deve op cons i d era
m ot ors bl y m ore t orque t h a
l n t ha t g i ven
a t ed s peed a
t t h e ra nd vol t a e
g , s o t h a
t t h ere is am pl e m a rg i n t o carry fu ll

l oad or t e m pora ry overl oa ds u n der ordi n a ry va ri a

t i on s of vol t a ge .

Th e m a xi m u m ou t pu t of a n i n d uct i on m ot or v a ri es wi t h t h e s qu a re

of t h e v ol t a g e a t t h e m o t o r s
’
t e r m i na , l bu t m ot ors wil l g i v e t h e i r ra t ed
ou t pu t e v en wi t h a drop of 1 0 per ce n t in t h e vol t a .
,ge a s t h ei r m a xi m u m

ou t put i s g rea t l y i n excess of t h e r a t ed v a l ue

. A t t h e l ower pot e n t i a l
t h e e ffici en cy a n d powe r f a ct or wi ll be i n crea s ed a t l i g h t l oa ds ; t h e fu ll
l oa d va l u es h ow ever a
, ,
re u s u a l l y s om ew h a t l ower .

Tra ns f orm e r R a t i ng for Al t ern a t i n g current M ot ors

- .
—
For t h e l a rg er

m ot ors t h e ca p a c i t y o f t h e t r a ns f o r m e r s i n k il ow a t t s s h ou l d e qu a l t h e ou t
pu t Of t h e m ot or in h p . Sm a l l m ot ors s h ou l d be su ppli ed wi t h a s om e wha t
la rg e r t r a n s f orm e r ca p a c i t y , es p e c i a l l y ,i f a s i s d e s i ra b,
l e t h e y a re expe ct ed

t o ru n m os t of t h e ti m e ne a r f u l l l oa , d or even a t s li g h t ov erl oa d Tra

. ns

form e rs of l ess ca p a c i t y t h a n t h o s e g i v e n i n t h e f o ll o w i n g t ab l e s h ou l d
n ot be u se d even W h en a m ot or i s t o be ru n a t on l y pa rt i a l l oa d .

For t h e ope ra t i on of i n du s t ri a l m ot ors from t h ree-ph a

,
se s ys t e m s t h ree ,

s i n g l e ph a
-
s e u n i t s or on e t h r e e ph a - s e u ni t a re recom m e n de d a l t h ou g h
, ,

if d es i r ed t wo s i n g l e ph a
,
-
s e t ra n sf orm e rs m a y b e u se d . Th e u se o f
t h e t h ree ph a-
se t ra nsform er g rea t l y redu ces t h e spa ce re qu i red a nd m a kes
48 0 A RM A T URE WI N DI NG A N D M OTOR REPA I R
t h e wi ri n g very si m d e, w hil e t h e onl y dva
a nta
g ga
e i n ed i n u si n g t h ree
si n g l e -
ph a
se t r a
nsf orm ers r a
t h er th a
n at h ree -ph a
se t ra
ns form er is t h a
t
in the a
c s e of on e a
trns form e r bu rn i n g ou t , the ot h er .
t wo m a
y be u s ed t o
ope r a
te t h e m ot or a
t redu ced l oa d .

R A TI N Os or TR A N S FOR M E RS R E QUI R E D F OR I N D UC TI ON M OTO R S

t t s p e r t ra
Kil owa ns f or m e r

R ATING OF T R A N S FOR M E R S FOB TH R E E A N D TW O-PH A S E I N D U C T I ON

M oTO R s ON V A R I OU S C I R C UI TS
s e t ra
S i n g l e -p h a n s f orm er v ol t a
g es

l l o-v ol t m ot or 2 20-v ol t m o t or

i
SIZ E OF W I RE s FOR S I N GL E - PH A S E M OTO R S
2 2 0 v ol t s
482 A R M A TU R E WI NDI NG A N D M OTOR REPA I R

4
1
4
1
4
1
4
1
4
1
4
1
2
1
0
1
8 8 6 6 4 v oc a
l — l o c o

oo oo co m
g v
4 4 4 4 4 4 4 2 2 o
e no fi fi co
1 1 1 1 1 1 1 1 1

O M Q w 00 fi oo h

-i c c c c c c
v -i v -i v -i v-Q v-i

4
1
4
1
4
1
4
1
4
1 w QD QD QD Q ‘ C O N -I Q
v Q O

c
O C
o

” m w c
fl
rti
e
fi
fi
fl
ca
am m v
io n t
4
—n
m
et »
w h
no
fi g- v-
-4
‘
-
v s v-i v s v I -i
v -i
v

a
c c o o o m c m c m c c o c o o o o o c
ew “ . no “ ap o o to
N
s s s g
F 1 N le n: IQ
fi fi fi m m m m e' n
484 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

WI R I N G D A TA '
I OR D I RE C T-C UR R E NT M OT OR S , 1 1 5 V OL TS

7
00000

‘
Wh e n fu se s i z es e x cee d a
m m es , ci rcu i t bre a
k er s a
pp ov e d
r

t y pe s h ou l d be su bs t i t u t e d .
486 A RM A TU R E WI N DI N G A N D M OTOR R E P A I R

WI R I N G DA TA FOR DI R E -
CT C UR R E NT M OTO R S , 5 50 V oL T s

WI R I N G DA T A FOR I N D UC TI ON M oTOR s — S I N GL E -R R ASE —

l 1 0 V OL T S ,
AL L FR E Q UE NC I E S, S TA N D A R D S PE E DS
 A P P E N DI X

W I RI N G DA TA FOR I N DUC TI ON M OTOR s— S I N GL E -P II

A SE — 220 V OL T s ,
FR E QU E NC IE S , S TA N D A R D S P E E DS

WI R IN G DA TA FOR I N D UC TI ON M OTOR s TII R E E P E A S E

— - —
l 1 0 V OL T S ,
FR E QUE NC IE S , S T A N D A R D S PE E D S

Wh en fu se si z es e x ceed 600 a
In peres , ci rcu i t bre a
k ers of a
pprov ed

t ype s h oul d be subs t i t u t e d.

488 A RM A TUR E WI N DI N G A N D M OTOR R E P A I R

Wm m o DA TA FOR I ND U C TI ON M OTOR s — TR R E E -P R AS E — 220

AL L FR E QUE N C IE S, S T A N D A R D S PE E DS

H orse p owe r
st a
rt i n g

a
m p e r es

Wh en fu g;
1g
iz es e xce ed 600 a
m peres , ci rcu i t brea
ke rs of a
pproved
t yp e s h ou ld be s u bs t i t ut ed .
49 0 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

el em en t devi ce t o preven t ope ni n g wh en t h e st a

rt er h a
n dl e is t h rown t o
the r u n n in g pos i t i on . Wi t h ou t t hi s t i m e e l e m en t t he ci rcu i t-bre a
ke r
wh e n con n e ct e d a s j us t des cr i be d m u s t be ca l i bra ,t e d for t w o or t h ree
i
t m s t e h e r at d u
e f l l l a
o d c-
u r r e f
nt o t e h m ot o r I f t h e ci r c u i t - br e a ke r
.

m u st be e ff e ct i ve i n t h e s t a r t in g pos i t i on i t m us t be pr ov i ded w i t h a t im e
e l em e n t a n d be ca li bra t e d for f rom t h r e e t o fiv e t i m es t h e r a t e d fu l l l oa d -

cu rr e n t ; wi t h t h i s ca l i bra t i on n o prot e ct i on wi l l be a fiorded from con t i n

u ou s ov e rl oa d s wh i ch m i g h t work i n j u ry .

For M otors C a rr yi n g aU n if or m L oa d Th a t i s m ot ors dri vi n g li n e

—
,

sh a f t s fa
,
ns m a ,
ch i n e t ool s or a ny m a , ch i n es w h i ch g i v e t h em afa i rl y
u n i for m l oa d ca rryi n g m a
,
x i m u m con t i n u ou s r a t e d ou t pu t a t l ea s t pa rt

of t h e t i m e a n d poss i bl y f u l l ra t e d ov e rl oa
-
d for s h ort pe ri od s I n g e n e ra l .
,

t h e ov e rl oa d pr ot e ct i on for s u ch m ot ors S h ou l d h a ve a n orm a l ca l i bra t i on

e qu a l t o 1 2 5 per ce n t of n orm a . l fu l l l oa d m ot or cu rr en t -
If n o st a n da rd .

ci r cu i t br e a
- ke r i s lis t e d for t h i s r a t in g t h e n e x t l a r g e r l is t e d s i z e s h ou l d
,

be u se d . A ci rcu i t br e a ke r s e l e ct ed i n t h is m a
- n n e r w il l h a ve a m a xi m u m

ca li bra t i on a t l ea s t t w i ce f u l l l oa d cu rre n t -
Wh e re ove rl oa ds g r e a
. t er
tha n 2 00 pe r ce n t Of n orm a . l cu rr en t a r e re g u l a
rl y e x pe r i e n ced for pe ri ods

n ot e x ce ed in g t w o s econ ds a t i m e e l e m e n t de vi ce s h ou l d be a
, d d ed t o t h e
ci r cu i t bre a
-
ke r For h e a. v y ov e rl oa ds fre qu e n t l y r e cu rr i n g a n d con t i n u

i n g for peri ods of fiv e S e co n ds or l on g e r t h e ci r cu i t br e a ke r S h ou l d h a

,
ve -

am a x i m um ca l i bra t i on Of a t l ea s t 1 0 pe r ce n t i n e x cess of t h e m a .xi m u m

cu rr e n t .

For M otors S ta
rted a
nd S toppe F qu en t l y
d re a—
n es el e M ot ors on cr ,

va t ors pu m ps a
,
i r com pres s ors Or ot h e r a
, pp ar at u s r e q u i ri,
n g f r e q u e n t
s tart i n g a n d s t oppi n g s h ou l d h a v e ci r cu i t br ea
, ke r s w i t h aca l ibra t i on -

of a t l ea s t 2 5 pe r ce n t in e x ce ss Of t h e m a
. x i m u m cu rr e n t a ct u a l l y r e qu i r e d
by t h e m ot or du ri n g a n y con t i n u ou s pe ri od of m or e t h a n five s e con d s .

A t i m e e l em e n t d ev i ce S h Ol l l d be s u pp l i e d t o ca t e r ov e rl oa
r e for g re a
‘
ds
la
s t in g l e ss t h a
n fiv e se con ds .

B e l ti n g .
—
R u bbe r be l t s s h ou l d a
lwa
y s be k e pt fr e e from g r a
e s e or

a
ni m a
l Oi l s If t h e y sl i p, m oi s t e n t h e i n s i d e of t h e bel t w i t h boil e d
.

l i n s e e d Oil .S om e fin e ch a l k , s pr i n kl e d on ov e r t h e Oi l , w i l l h e l p t h e be l t .

L en g th of B e ta A d d t h e d i a
t —
m e t e r of t h e t w o p u l l e y s t og e t h e r , m u l t i

p y l b y t h re e a n d on e -s e
v e n t h ,
d i v i d e t h e p r od u ct b y t w o , a dd t o t h e

qu ot ien t t h e di st an ce be t w ee n t h e cen t e r of t h e sh a ft s , a n d t h e p rodu ct

wi l l be t h e re qu i re d l en g t h .

OR DI N A R I L Y A C C E PTE D E QU I V A L E N TS OF BE L TI N G

2- pl y R u bbe r—
L ig ht l ea
s in g l e
t h er .

3 pl y R u bber
- —
M e di u m s in g l e l e a t h er .

l
4 py
- R u bbe r—
He a vy s i n g l e l e at h er .

5 pl y R u bbe r
- —
L i g h t dou bl e l e a
t h er .

6 pl y R u bbe r
- —
M edi u m dou bl e l e a t h er .

7pl y-
R u bbe r —
He a vy dou bl e l e a
t h er .

- l
8 p y R u bbe r —
fi i pl e l e a
t h er .
 A P P E N DI X

Th e t h i ckn ess of rubbe r be l t i n g i s u su a ll y fig ured a t Mo i n ch per pl y .

H ors epower Tra ns m i tted by B e lt i n g —

On e-i n ch s i n g l e be l t m ov i n g a
. t
ave l oci t y of 1 000 ft per m i n u t e e qu a . l s on e h ors e pow er On e-in ch .

d ou bl e be l t m ovi n g 7 00 f t pe r m i n u t e e qu a . l s on e h ors e powe r Th e .

h ors e pow er Of a n y be l t e qu a l s i t s ve l oci t y i n fe e t pe r m i n u t e , m u l t i pli e d

by i t s w i dt h a n d d i vi de d by 1 000 for s i n g l e , a n d by 7 00 for dou bl e be l t s .

Th e fol l owi n g t a bl e is bas e d on s i n g l e be l t s r u nn i n g on pu l l e ys of e qu a l

di a m e t e r , re v ol vi n g a t 1 00 rpm Th e pow er t r a ns m i t t e d a
. t ot h e r s pe eds
is i n di rect proport i on For dou bl e be l t s , m u l t i pl y by t e n -s eve n t hs
. .

H OR S E P OW E T R A N S M I TTE BE
'

R D BY L TI N G

W idt h of be l t i n i n ch e s

44 65 8 7 1 09 1 31
51 76 1 01 1 2 7 1 53
58 87 1 16 1 45 1 75
65 98 1 31 1 64 1 97
73 1 09 1 45 1 81 2 18
80 1 2 0 1 60 2 00 2 4 0
. 8 7l
'
. 31 1 75 2 18 2 62
9 5 1 42 1 89 2 36 2 83
1 02 1 5 2 2 02 2 53 3 05
1 09 1 64 2 19 2 73 3 29
1 16 1 74 2 32 2 91 3 48
1 24 1 85 2 4 7 3 09 3 70
1 3 1 1 96 2 62 3 27 3 92
1 3 9 2 07 2 76 3 45 4 14
1 45 2 1 8 2 91 3 64 4 36
1 6 0 2 40 3 2 0 4 00 4 8 0
3 50 4 4 0 5 2 0 7
3 80 4 70 5 70 7
4 10 5 10 6 10 8
4 40 5 4 0 6 6 0 8
4 70 5 80 7 00 9
4 90 6 20 7 40 9
5 20 6 50 7 80 1 0
5 5 0 6 90 8 3 0 1 1
5 80 7 30 8 70 1 1
6 10 7 60 9 20 1 2
6 4 0 8 00 9 6 0 1 2
6 70 8 4 0 1 0 00 1 3
7 00 8 80 1 0 4 0 1 4
720 9 00 1 0 9 0 1 4
7 80 9 80 1 1 8 0 1 5
8 80 1 0 80 1 3 1 0 1 7
9 6 0 1 2 00 1 4 4 0 1 9
. 1 0 4 0 1 3 00 1 5 6 0 2 1
1 1 40 1 4 2 0 1 7 00 2 2
1 2 2 0 1 5 2 0 1 9 40 2 4
49 2 A R M A T UR E WI N DI N G A N D M OTOR R E P A I R

B e l ting R ul e s .Th e power t ra

-
ns m i tt ed by abe l t depe n ds u pon i t s

wi dt h a n d i t s t h i ckn e ss a n d t h e s pee d a t w hi ch i t t ravel s Hen ce i t i s .

cus t om a ry (a s m e n t i on e d un de r H orsepowe r Tra ns m i t t e d by B e l t i n g

to e xpress ans m i t t i n g ca
the t r p aci t y a s t h e s pe e d i n f ee t pe r m i n u t e

re qu i re d by a bel t on e i n ch w i de t o t ra n s m i t on e h orse pow e r For si n g l e .

or l i g h t d ou bl e be l t t h i s e xpre ss i on i s u s ua
, ll y g i ven av a l ue of a bou t
700 a , n d for h e a vy dou bl e be l t a pp r oxi m at e l y 4 50 Th u s a do u bl e b e l t .

fou r in ch es w i de ru n n i n g a
, t 2 2 50 ft pe r m i n u t e wil l t r a n s m i t 20 h p
. .

R ou g h l y , be l t s pe e ds s h ou l d n ot ex ceed one m il e pe r m i n u te t hi s s peed i s

g i ve n w h e n t h e di a m e t e r of e i t h e r pu ll e y i n i n ch es m u l t i pl i e d by i ts r pm .

e qu a ls ( D X rpm .

M i ni m u m di a m et e r of pu l l e ys for l On g l i fe of h ea vy be l t s

For dou bl e be l t s .

For dou bl e be l t s , e x t rafle x i bl e

For d ou bl e 3-pl y be l ts
hp
Ordi n a
.

ri l y , wd x
“

r pm . P
wh e re w w i dt h bel t , d
Of m e t e r of pu l l e y (bot h in i n ch es ), a
di a nd

P be l t s t re s s pe r i n ch w i dt h Sa fe v a l u e s for P a
. re a
s f oll ow s

S i n g l e be l t s , above 4000 ft per m i n , 33 l b ; be l ow 4000, 46 l b ; m a

. . x . . .

s t r ess n e v e r ove r 50l b Dou bl e bel t s , 40t o 7

. 01b ; 3-pl y be l t s , 7 0 t o 95 l b . .

Wi t h s t a n da rd cons t ruct i on a n d n orm a l bel t s t ress , t h e s t res s on t h e

sh a ft a n d be a ri n g s i s w i t h i n s a s l on g a
f e li m i t s a s d e x cee ds w To fin d
a
.

l en g t h L (l en g t h ) of be l t w h en t h e pu ll ey di m e t e rs D d a n d t h e di s t a
n ce ,

A be t wee n ce n t ers a r e kn own , u s e t h e form u l a

L (D +d) + 2 A
To de t erm i n e dis t a
n ce be t w e e n pu l l e y cen t e r s u s e t h e form ul a
A K (D d)
wh e re t h e al u e of t h e cons t a
v n t K ra n g es fr om 3 t o 4 bei n g ag ood ,

av e ra g e v a l u e w h e n t h e d i a
m e t e r D i s fr om 4 t o 6 t i m e s t h at o f d .

Th e fol l ow i n g pre ca u t i ons s h ou l d be obs e rv e d

a Th e for m ul adoes n ot a
.
p p l y w h e n p u l l e y s ar e of n e a
r l y t h e s am e

di a m e t e r ; i n t h is ca s e t h e dis t a n ce s h ou l d be g re a t e n ou g h t o a ll ow s om e
be l t s a g .

b As ag en era
. l ru l e t h e di s t a n ce A S h ou l d n ot e x cee d 2 5 ft i n a n y ca se . .

R ul e s f or P u l l ey S i z e s Th e f ol l owi n g form u l a
.
—
ca n be u s e d t o ca l cul ate
s i z es of pu l l e ys for m ot or dri v es
D X N
n

D Di a m e t e r Of dri v e r .

d Di a m e t e r Of dri ve n pu l l ey .

N R e vol u t i on s pe r m i n u t e of d r i ve r .

n R e vol u t i on s pe r m i n u t e of d r i v e n pu l l ey .

S pe e d of P ull e ys .
—
Wh en t h e di a m e t er of t h e dri ve n pu l l ey is g i ve n ,
to fi nd i ts num ber Of re volu t i on s p roceed s fol l ows : a
M ul t i pl y t h e di a
 A P P E N DI X

( 9 ) A voi d a l d r i ve s
ve r t i c .

( 1 0) Al l ow asi de cl e a ra n ce for ch ai n (pa ral l el t o axi s of s prock et s a

nd

m ea s u r ed from n om in a l wi d t h of ch a i n ) e qu al t o t h e pi t ch .

(1 1 ) M a x i m u m li n ea r ve l oci t y for com m er ci a l s erv i ce 1 200 t o 1 600 ,

f ee t per m i n ut e .

H OR S E PO W E R T R A N S M I I TE ' ‘
D BY S TE E L S HA FI ' ‘
IN G

R e vol u t i o ns p e r m i n ut e

H OR S E P OW E R T R A N S M I TT E D BY S I N G L E R O PE S
( Worki n g str a
in 200d w h e re d i s
’
di a m e t e r of r ope )

Dia
m e te r of r op e i n i n ch es

Sm a l l es t s h e a
v e , di a m et e r ,
i n ch e s.

A l l ow a bl e w ei g h t , t e ns i on 5
80 00
. 1 1 0 00
.
750 . 00

N OT E —
T h e h ors e p ow e r d e cr e a
s es w h e n t h e v e l oci t y is a
bov e 5 500 f e e t on a
ccou n t
of ce n t ri fu g al f or ce .
4 98 A R M A TUR E WI N DI N G A N D M OTOR R E P A I R

S om e Ha
n dy R ul e s

D ia m e t er of a ci rcl e X C i rcu m fe re n ce .

Ra di u s of aci rcl e X C i rcu m fe re n ce .

S qu a re of t h e r a d i us of aci r cl e X A re a .

S qu a re of t h e di a m et er Of aci r cl e X Ar e a .

S qu a re of t h e ci r cu m fe re n ce of a ci rcl e X A re a .

Ha l f t h e ci rcu m fer en ce Of aci rcl e X by h a lf i t s di am et e r . re a .

C i rcu m fe ren ce of acir cl e X Ra di u s .

S qa re root of t h e a re aOf aci rcl e X Ra di us .

C i rcu m fe r en ce of aci rcl e X Di a m et er .

S qu a re r oot a t h e a re a of aci rcl e X Dia m e te r .

Di a m e t e r of a ci rcl e X S i de of i n s cribe d e qu i l a t e ra l t ri a ng le .

Di a m e t e r of aci rcl e X S i d e Of a n i ns cri be d s q u a re .

C i rcu m f e r e n ce Of aci r cl e X S i de of a n i n s cri be d s qu a re .

C i rcu m fe re n ce of aci rcl e X S i de Of a n equ a l s qu a re .

Di a m e t e r Of aci rcl e X S i de Of a n e qu a l s qu a re .

Ba s e of a t ri a n g l e X by M t h e a l t i t u de Ar ea .

M u l t i pl yi n g bot h di a m et e rs a nd 7 .85 4 t og e t h e r Ar e aof a n e l l i ps e .

S u rfa ce of a s ph er e X by Of i t s di a m et e r S ol i di t y .

C i rcu m fer en ce of as ph e re X by i t s di a m et e r S u rf a ce .

S qu a re of t h e di a m e t e r of as ph e re X S u rf a ce .

S qu a r e Of t h e ci r cu m fe r e n ce Of a s ph e r e X Sfll rf a ce .

C u be of t h e di a m e t er of as ph e r e X S ol i di t y .

C ube Of t h e r a di u s Of as ph ere X S ol i di t y .

C ube of t h e ci rcu m fere n ce of aS ph ere X S ol i di t y .

S qu a r e r oot of t h e su rf a ce Of as ph e re X Di a m et e r .

S qu a re root Of t h e s u rf a ce of a s ph e r e X C i rcu m fe re n ce .

C ube root of t h e s ol i di t y of as ph e re X Di a m et er .

C ube root of t h e s ol i di t y Of as ph e r e X C i r cu m fe re n ce .

Ra d i u s Of as ph ere X S i de of i ns cri be d cu be .

S qu a r e root of ( P5 of t h e s qu a re of ) t h e di a m e t er of as p h e re S i de
of i n s cri be d cu be .

A re aOf i t s ba s e X by 3 4 of i t s a l t i t u d e S ol i d i t y o f a c o n e o r py r a m i d,
w h et h er r ou n d , s qu a re or t ri a n g ul a r .

A re aOf on e of i t s s i de s X 6 t h e s u rf a ce Of a cu be .

A l t i t u de Of t ra p e z o i d X 56 t h e s u m of i t p a r a l l e l s i d es A r ea .
502 I N DE X
Ba
s k et coi l s for i n du ct ion m ot ors , B rush es (cont )
1 95 l oca
t ing a
c u s es of t rou bl es , 33 7
B e l t s , poor j oi n ts i n ca
us e sp a
rk i n g l oc a
t i ng e l e ct ri c a
l n eu t ra
l for ,

Of brus h es , 3 94 332
h ors epow e r tr a
n s m i t t ed by , pi ck i ng u p copp e r , 3 43
49 1 p r ess u r e Of , 3 34
p ul l e y s i z es for, 492 s p ecific r es is t a
n ce , 33 5
r ul es for us e of , 492 t erm s us ed , 334
s p eed of pul l eys for, 492 t oo l ow brus h pr ess u r e , 33 7
st a
t ic sp a
rk s from , 44 0 q a
une u l a ir g aps , 3 39
t rou bl es du e t o t en s i on Of , 39 1 wron g ch ra
a ct e r i s t i cs of, 341
B en ch st an d for w i n di n g d . c . B rus h es for un dercu t com m u t a
t or ,

a
rm at ur es ,
447 3 22
Bl a
ck e ni n g of com m u t a
t or B rush -h ol der, a
dj us t m e n t Of r e c a
r em e dyfor , 3 43 t i on t yp e, 406
B ori n g ou t en d Of com m u t a t or , 3 1 3 h ea
t i n g of , 407
B raci n g wi n di n g s of t u rbo-g e n er a m ki n g a
a dj u s t m e n t s of , 329
t ors , 2 2 8 B rus h es s et i ncorr e ct l y , 404
of la
rg e ac
. .
g en erat ors , 2 2 3 w ron g s e t t i n g Of , 405
B r ea
k-down t es t for t u rbo-g en er a B rus h s h u n t s , l oos en i n g of , 3 44
t ors , 2 2 9 B rus h s t u ds , h ea
t ing Of , 403
B ri dg i n g com m u t at or ba rs 2 58 , B u rn ed ar t i n g w i n di n g
ou t s t 42 9 ,

B rus h es , a dj u s t i n g a n d corr ect i n g B u rr ed com m u t a tor ba rs t roubl es ,

t rou bl es (8 e s a l so t abl e r es ul t i n g from ,

402
Of con t en t s for C h a p t e r
C
X I I I ), 3 2 6
a
djus t m ent of brush -h ol ders , Ca l cul a t i ng wi ri n g ci rcu i ts , for
32 9 m ul a for, 468
an g l e for s et t i n g Of, 33 3 C en t i g r a de a n d Fa h r en h ei t t em
bl ack eni n g Of, 3 43 p er a
t u r es , e qu iv 9 1 en t
a
c us es of r api d we a
r of , 3 3 1 va
l u es , 49 9
ca
us es a
nd r em edi es Of C ha
i n w i n di n g , conn ect i ng of , 48
t rou bl es , 3 4 1 C ha
i n driv es :
ch ec ki n g s et t in g , 3 34 ca l cul a t i n g s i z e of ch a i n , 493
chat t eri n g Of ,
r e m e dy for, 344 da ta for, 494
con t act drop , 3 34 p i n i on s a n d s p rock e t s fo r ,
4 93
cu rr en t de ns i t y , 33 5 C ha
n g es i n d c m ot ors (s ee a
. . lso
e ff e ct of d ef ect i v e fiel ds , 3 3 9 ta bl e of con t ents for
fit t i n g or g r i n di n g -i n , 3 2 6 C ha p t er X ), 2 3 7
fri ct i on of, 3 3 5 C ha
n g es i n s p ee d of d c m ot or, . .

g l ow i n g , 3 3 5 23 7
ha r dn ess , 33 6 air g a ps , 2 42
h ea t i n g of, r e m e dy for , 3 43 brus h es , 243
h on ey com bi n g , 3 35 conn ect i ons to com m u t a
t or,
i n corr e ct t h i ck n ess of, 3 40 2 43
i n corr ect s p a ci n g , 33 8 Op er a
t i ng v ol t a
ge , 23 7
i n ert i aof, 33 6 wi n di ng w a
v e to l a
p, 248
 I N DE X

Ch a
ng es in du pl ex wa
v e wi n di n g , C oil s (cont ) :
2 52 i ns ul a
t i on for i n du ct i on m oto r
conn e ct i ons of coil s , 244, 253 coil s , 1 64, 1 67, 1 70
C ha
n g es i n i n du ct i on m ot or w i n d k i n ds of insul a
t ion for ,
1 53
i ng s (s ee h ea di ng , proc ed m ic ains ul a
t i on for , 1 7
3
u r e w h en r econn ect i n g i n p i t ch es Of d . c .
, 7
duct i on m ot ors ) p i t ch es Ofac . .
, 37
fa ct ors l i m i t i n g , 286 pl a ci n g on a rm a
t ur e 1 1 0 ,

pr act i ca l m et h ods for, 26 1 r e m ov i n g from d c a rm a tu r e . .

,

r econn ect i ons fr equ ent l y 57

m a
de 272 , r ep ai ri n g da m a
g es t o 1 7 4 ,

C ha
n g i n g 440 v ol t m oto r for 22 0 sh a pi n g e n d con n ec t i o ns 7 0 ,

v ol t op er at i on , 43 5 ta bl e for conn e ct i n g 1 1 0 ,

C ha
ng ing s t a r t o d el t a conn ect i on , t es t v ol t a g e for i nsul a t io n of ,

41 175
C ha ra ct e ri s t i cs of brush es , 34 1 t hi ck ness of insul a
t i on for ,
1 63
C h ord f a cto r, m ea ni ng of , 2 69 t yp es a n d sh ap es Of 3 ,

C i rcu i t -br ea k ers for m ot ors , 489 w i r e, s t rap an d ba r w oun d , 34

C l ea ni n g m ot ors wi t h com pr ess ed C oil r a is in g t ool 449 ,

a ir , 42 0 s p r ea d e r 457,

t roubl es du e t o i m m op e r ta p gin m ac h i n e 4 57 ,

cl e a n i n g , 37 6 ta
pi n g n eedl e, 44 9
C l ea ni n g s l o t s , s ol u t i ons for, 1 40 wi n di n g dev i ce, 452
by fil i n g , 1 40 C om a
m u t t or
C oi l t h row, 7 , 7 0 act i on Of 1 ,

C oil a n d com m u t a t or i ns ul at i on , bl a ck en i n g of r em edy for

, , 3 43
t es t v ol t a g e for , 175 br i dg i n g ba rs of 2 58 ,

com p ou n d
for pl u g g i n g of , 3 04
a
ppl y i ng i nsul at ion on , 1 63 conn e ct i ons for l a p w in di n g ,
con n ect i ons wi t h dea d coil s , 98 1 02
cl a
ss i fica
t i on Of , 5 con n e ct i ons for w a
v e w in d

for l a
rg e d a rm a
t ur es 7
. c7
.
,
i n g , 1 04
for ra
il wa
y m il l an d c
,r a
n e fla
t s pot s on , r e m edy for , 3 42
m otors , 90 i m prov is e d m et h od t o t u rn ,
for ac
. . w i n di ng s , 1 41 41 1
f orm s for m a
k ing , 1 40 i nsu l a
t i on of con n e ct i ons t o, 76
i ns er t i n g i n op en s l ot s , 69 l oca
t i ng firs t conn ect i on to
i n s ert in g t h r ea d ed-i n t yp e , 6 0 for l a
p w i n di n g, 1 01
i ns ert i on i n r a il w ay a rm a
t u res , l oca
t in g firs t conn ect i on to
94 for wa
ve wi n di n g , 1 05
i ns ert i on i n l a
rg e ( 1 . c . a
rm a m a
k i n g conn ect i ons t o, 1 01
t ur es , 8 1 nu m ber Of ba rs , 2 4

i ns ul a
t i n g for op en sl ot s , 67 l
p gg g
u i n Of , 3 95
i ns ul a
t i on for di fi er en t v ol t p oor s ol de ri n g , t rou bl es re

a
g es 1 64, , 1 65 , 1 67, 1 68 s ul t i n g , 3 96
i nsu l a
t i on for d . c. coil s , 1 64, r econ n e ct i ng wi t h de a
d coi l ,

1 65, 1 68 25 2
504
“

I N DE X
C om m u t a
t or (con t ) C om m ut at or r epa
,
irs t o ( cont )
r econn ect i n g du pl ex w a
ve t e m pora ry cov e r for 3 1 0 ,

wi n di n g s , 2 52 t es t for Oil s a t e d m i ca
t u ra ,

r ep ai rs t o 3 01 , 32 0
r ep ai r ed u n der di fficul t i es 3 97 ,
t i g h t e ni n g up ba
rs , 3 06
sa n dp a p eri n g h ol d er for 400
, ,
t ool s for u n d ercu t t in g m ic a .

s eas oni n g a n d g r i n di n g 1 48 ,
320
sol d er i n g coil l e a ds to 1 44 ,
t roubl es from hi g h m i ca , 30
1
s parki n g a t brus h es of 3 4 1 ,
t urni n g dow n s u rf a
c e Of , 3 09
ta bl e for conn e ct i n g coil s t o ,
u n d ercu t t i n g m i ca
, 32 0

C om pr ess ed a
ir p r ess u r e in a
cl e n

t rou bl e f rom bu rr ed ba
rs , 402 ing m ot ors , 42 0
t roubl es i n , 3 01 C on ce n t r a
t e d a c w i n di n g , 2 7
. .

u n d e r cu t t i n g of,32 0 C ha i n or s pi ra l a c w in di n g , . .

u n dercu t t i n g wi t h el ect r i c dr i l l , 27
400 C on du ct or or i n du ctor , 3
v ol t a
be t w ee n ba
ge rs Of , 24 C onn ect i n g coil s Of d c a rm a
. t ur e
.

wi n di n g p i t ch for 6 , i n pa ra ll el , 244
C om m u t at or, r ep a i rs t o (s ee a lso C onn ect i n g coi l s Of d c a rm a
. t u re
.

a
t bl e of con t e n t s to C h a
p i n s eri es , 2 53
t er X I I ), 3 01 C onn ect i ons t o com m u t a t or (s e e
ba k i n g of, 3 07 ta bl e Of con t e n t s for
bl ack eni n g of i n s pot s , 3 2 0 C ha p t er I V) .

bor i n g ou t e n d of , 313 C on t a ct drops for bru s h es , 3 3 4

brus h es for u n d e rcu t com m u C on t roll e r , dru m t yp e, ov er h a ul

a
t to r , 3 2 2 i n g of, 3 5 5
bu rn ou t b e t w een ba rs , 3 03 C os t Of m a k i n g r epa i rs , 346
a
c us es of e xc es s i v e w ea r, 3 1 8 es t im a t i n g of, 3 47
ca
us es of t rou bl es i n , 3 01 C u t t ing ou t coil s Of d 6 w a ve
. .

copp er for ba
rs , 3 1 9 wi n di n g , 1 09
fini s h in g u n d ercu t s l ot s , 3 22 of i n du ct i on m oto r wi n di ng ,

m a
ki n g a
m ic n i t e en d ri n g s , 2 88
318
m ic aus e d i n , 315
a i ns ul a
m i c ni t e x
t i on for 3 1 7 , D ea
d coil s
p ec a
r u t i on s wh e n t i g h t e n i n g , conn e ct i ons of coil s wi t h , 98
317 w a
v e w i n di n g wi t h , 1 08
r efill in g , 3 1 1 D ev ic e for de t ect i n g f a ul ts i n ac . .

r em e di es for h ig h a
nd l ow wi n di n g s , 2 3 2
ba rs , 3 02 Di ag n os i s of m o t o r an d g e n e r a
t or

r e m ov i n g ba rs a n d m i ca , 3 04 t rou bl es (s ee a ls o t a bl e
r e m ov i n g g r ou n ds , 3 0 8 Of con t en t s for C h a p t er

r epa i r i n g bu r n e d ba r , 3 05 X V ), 3 7 6
r e pl a ci n g bu r n e d ba r, 3 0 6 Di ag ra m s for conn ect i n g i n du ct i on
sh a p n g m i c ae n d r i n g s , 3 1 6
i m ot or wi n di n g s , 2 92
e m pl e t for m a ki n g m i ca com bi n a
‘
t i on s ch em e for
ri n g s , 316 s ev er a
l t ypes , 436
506 I N DE X

Dry in g ou t in s u l at i on of i n du c Form ul a
s a
nd rul es for d . c .

t i on m o to rs , 1 83 win di n g s :
i ns ul a
t i on t es t w h il e , 1 84 for c l cul a
a t in g w i ri n g ci rcu i t s ,

i nsul a
t i on r es is t a
nc e wh il e , 46 8
1 85 for poss i bl e s y m m et ri ca l win d
Du pl ex w a
v e w i n di ng , r econn e c ing s , 2 1
t i on of , 2 52 lap ( m u l t i pl e or p a
r a ll e l ),
1 1
m ul t i pl e x l p, 1 5 a
E
m ul t i pl ex wav e (s er i es-p a
ral
l n eu t r a
E l ec t ri ca l , l oca
t i on Of , 33 2 l e l ), 1 9
E l em d c wi n di n g , 3
e n t Of . . wav e (s e ri e s or t w o circu i t ) 1 7 ,

E n d con n ect i ons Of coi l s Fr a m es for m a k i n g coil s 1 40 ,

app ea r an c e i n l a
p an d w a
v e Fr e qu en cy ch a ng e r econ n ec t i on ,

(1 . c . w i n di n g s , 1 0 of i n du ct i on m ot or for , 2 76
i ns u l at i on be t w e e n , 63 e ffect of d ecr ea
s e on i n du ct i on

sh a p i n g Of i n d c w i n di n g , . . 70 m ot or-g e n er t or , 43 3 a
t h i ck n ess Of i ns ul a
t i on for, 172 Fri ct i on of br us h es , 33 5
E nd ri n g s f or com m u t a
t or , 316 Fr i c t i on cl ot h bl a
n k e t for com m u

E nd l
p ya of a rm a t u r e 41 8 ,
ta
t or e n d con n ec t i ons , 76
E ng i n e t y p e g e n er a t or i ns p ect i on ,
Fu s e bl ock d ef ect i v e , t roubl e du e
Of , 371 t o, 42 7
E qu al iz er ri n g s for d . c. wi n di n g s , Fus es , s i z es for ac . . m ot ors , 442
22 d . c . m ot ors ,484
us e on m ul t i pol a
r m a
ch i n es ,
a
c us es Of bl owi n g of , 3 89
1 20 s ta
r t i n g ac . . m ot ors , 48 7
E qu i pot e n t i a
l con n ect ors or e qu a
l
iz e rs ,
21
E st im a
t ing cos t of re p a
i rs , 3 47
G ea
rs , d a
tafor, 496
F
G e n er a
t or, en g i n e t yp e , ov e rh a
ul

Fa
il u r e Of m ot or to st a
rt ,
43 0, 43 2 i ng Of , 371
Fi e l d coil s G e n era
t or u s ed a s m ot or 241
a dj u s t a bl e s h u n t for 4 1 6 ,
G en er a
t ors , rg e ac
la .

h ea t i n g of 4 1 4 ,
ba
r a
n d conn e ct or w i n din g for ,

i ns u l a t i on of 1 7 6 ,
21 7
t es t for d ea d coil s 1 3 6 ,
coi l s for p a
rt i a
ll y cl os ed sl ot s ,

t es t for r ev ers ed conn ect i ons , 21 0

1 36 coi l s f or op e n sl ot s , 212
Fi el d cu rr en t in d . c .
g en er a
t ors ,
con n e ct i n g coil s Of , 22 1
473 di a
m on d coi l s for , 2 1 9
Fl a
t S pot s on com m u t a
t or ,
r e m ed y dou bl e w i n di n g s for, 2 2 1
for , 3 42 g l ow i n g Of br us h es , 3 3 5
Fl oor st a
nd for wi n di n g (1 . c . i ns u l at i on Of coil s for , 2 1 4
rm a
a t ur es 75 ,
i ns er t i n g s h ov ed t h rou g h coi l s ,

Form for r e cor di n g w i n di n g da

ta 21 5
of di s m a rm a
n t l ed a t u re ,
la
p a
nd w a
v e con n ec t i ons for,
58 21 4
 I N DE X
Ge ne ra t ors , l arg e a 0 ( con t ) . . . I n du ct i on m ot ors ( con t ) .

br a ci n g h e avy w i n di n g s of, 2 23 i ns er t i ng n ew coil i n , 2 03

t es t i n g wi n di n g s of , 2 2 1 Op en S l ot s , w i n di n g of , 2 01

Gr i n di n g com m u t a
t or ,
1 48 Op er a t ed on di ff er e n t v ol t ag es
Grou n ds i n d c wi n di n g s :
. .
an d fr e qu en ci es 2 84 ,

ca u s es of, 1 3 0 ov erh a ul i n g of 36 3 ,

l oca t i n g dea
d g r ou n ds , 1 3 3 p ar t i a
l l y cl os e d s l ot s w i n di n g ,

t el eph on e r ec e iv er t es t for,
1 35 ph a
s e wou n d s e con d ry , a 2 09
t es t s for , 1 3 1 proce du r e w h en con n e ct i n g

G rou p i n g coi l s Of i n duct i on m ot or coi l s of n ew w i n di n g , 2 88

wi n di n g , 2 8 9 r econ n ect in g for ch n g es a in
O dd n u m ber coil s p er g r ou
p, 5 4 v ol a
t g e , fr e qu en cy , ph a
se

pr oc edu r e for, 35 a
nd S p ee d , 272
s qu i rr el cag e s econ dary ,
2 07
t e s t i n g w i n di n g s of , 2 02
2-ph a
s e st a
t or, w i n di n g of , 2 02
Ha
l f-coil ed a
nd w h ol e-coil e d ac
. .
w i n di n g sm a l l s i z e s 1 92 ,

w i n di n g s , 3 0 w i n di n g w i t h ba sk e t coi l s 1 9 6 ,

Ha
n d t ool s for rm a
a t ur e wi n de rs , wi n di n g w i t h di a m on d coi l s ,

445 1 99
Hea t i n g Of brus h s t u ds , 403 I ns p ect ion a nd ov erh a
ul in g of

Hea
t i ng Of m ot or or e n er a
t or u t o s ta
a r t ers - 3 51
g , ,

r e m edi e
s for , 3 43 com pou n d d . 0
. m ot or , 3 58
a
c u s edby poor s ol d e r in g , 3 96 d . 0
. m ot or s t a
r t e rs , 3 49
'

ca
u s e d by ri a
va t i on of fr e dr u m t yp e con t r oll ers , 3 55
-

qu en ey ,
43 8 e ng in e t y p e g e n er t or , 3 71 a
h ot st a
t or coi l s , 391 i n du ct i on m ot or, 3 63
Hol d e r for an d pa
s p e r i n g com m u s i n g l e -ph a
s e m ot or ,
3 68
ta l -r i n 3 66
t or 400 s ip g m ot or ,
,

Hon ey com bi n g Of brus h es , 3 3 5 I ns p ect i on a nd r ep ai r Of m ot or

ls t a r t ers m o t ors a
l

r e m edi es for , 3 43 ,
n d g en

Hoods for a rm a t u r es , 99 era t ors 3 45 ,

m aki n g of, 1 45 cos t Of m a k i n g r ep a i rs 3 46 ,

Hot bea ri n g , rel i ef for , 440 es t i m a t i n g cos t of r e p a irs 347 ,

I ns ul at i on f or
ao . . coil s , 1 64, 1 67,
1 70
coi l s a
n d s l o t s k i n ds ,
Of , 1 56
I m pr eg n a
t in g pou n ds
com (s ee a
l so coi l s u s e d i n op e n s l ot s , 67
va
r ni s h es ), 1 76 coil s a il waOf
y mro t ors 9 2 ,

I n du ct i on m ot ors com m u t at or con n e ct i ons 76 ,

bas k et coi l s for, 1 95 cor e Of r ail w a y a r m at u r e s 9 3 ,

coil i n s ul a
t i on for, 1 63 , 1 6 7
, d . c . coi l s , 1 6 4, 1 6 5 , 1 6 8
170 di ff er en t v ol ta
g es , 1 63 , 1 6 4,
con n e ct i n g coi l s of , 2 05 1 6 5 , 1 66
di a m on d coi l s f or, 1 98 e l e ct r i c a
l prot e ct i on ,
1 55 , 1 56
i ns ul a
t i on of s l ot s , 1 95 en d con n e c t i on s of coi l s, 63
508 I N DE X

I n s ul a
t i on for (cont .
) ti ng m a
I n sul a t eria l s ( con t ) .

fie l d coil s , 1 7
6 p r ess p a h n ,
1 5 4
form ed coi l s , 1 63 ra w h i d e fiber, 1 60
h i g h t e m p era t u r es , 1 55 r ed rop e pa
p e r, Oil ed , s h e l

la rg e ( 1 c a
. rm a
. t u r es , 79 la
ck ed , a
nd v a
rni s h ed ,

m ech a n i ca
l prot ect i on , 1 53 1 61
Op en s l ots , 69 a
s h e ll ck e d bo n d p a p e r 1 6 1 ,

p a rt i al l y c l os e d sl ots , 61 t es t v ol t a
g e t o us e 1 7 5 ,

p h a s e c oi l s 1
, 72 va rni s h es a n d com pou n ds ,

s l ots , t hi ck n ess n eed e d, 1 63 176

I ns ul a
t i on from copp e r to copp e r, a
v ul c n i z ed fibe r, 1 54
bet w ee n coil s , 1 7 2 I ns u l a
t i on r es is t a
n ce , a
m e s uri n g
I ns ul at i ng m a t eri als Of, 1 85
t r ea t e d cl ot h s , 1 56 m eg g er t es t for , 1 85
cot t on ta
p es a
nd cl ot h , 1 56 v ol t m et e r t es t for , 1 84
E m pi r e cl ot h , 1 56 I n t e rpol e m ot or, ch e c ki n g con

Koba k cl o t h , 1 56 n ect i ons of , 41 2

a a
oil ed c n v s , 1 58
Oil ed cot t o n dri ll , 1 58
Oil e d m usl i n , 1 58

Ja pa n m us l i n , 1 57
Kn ock in a rm a t ur e caus ed by
Ja p an d u c k ,
1 57
ba
n d w i r es 395
var ni s h e d c a m bri c , 1 57
,

va rn is h ed s il k , 1 5 7

pr ess bo a r ds ,
fi b res a n d p a
p e rs ,

1 58
a
s bes t os p a per oil e d a
nd La W i n di n g ra
(m ul t ipl e or pa ll e l )
, p
va rn i s h ed 1 62 ,
com m u t a
t or conn ec t i ons for ,
dry i n g ou t , 1 81 1 02
expr ess p a
r ch m en t a
p p er , co nn ect i n g doubl e l a y e r for

e xpr ess pa
p er, s h e ll a
ck ed ac . . m a
chi n e , 47

a nd v a r n is h e d 1 6 1 ,
f or d . arm a
c . t u r es 9 ,

fis h p a p e r 1 54,
for m ul a s a n d rul es for d c . .

h orn fibr e J a p
,
a n n e d O il e d , , arm a t ur es 1 1 ,

s h el l ack ed a nd v a rn i s h ed , g r ou i
p gn c o il s i n a c m a
ch i n e . .
,

1 59 35
l ea
t h e roi ds , 1 6 0 m ul t i pl e x, form u l a
s for, 1 4

m a nil a a
p p e r 1 55 ,
re qu ir e m ent s of, 1 03
m i ca 1 5 5
,
us e on arm a
d t u r es
. c .
,
115
m i ca f or coi l s 1 7 3 ,
us e in a0 m a
.chi n es 1 1 6
.
,

m i ca pa p er a n d m i cacl ot h , v e rsus wa
v e, 1 1 2

1 55 v s m ul
. t i pl e wa
ve ( s eri es -p r aa
l
a
m i c n i t e , 1 55 l el ), 1 1 9
m ic a r ta f ol i u m 1 6 2 ,
wa
ve a
nd l a
p for a0 . . m a
pr ess boa r d O i l ed J s p a
,
n n ed , , ch i n es , 28
s h el l ack ed a nd v a r n i s h ed , La
y in g Ou t a
nd conn ect i ng ac
. .

1 59 w i n di n g s , 3 5
51 0 I N DE X

P i t ch ofd c coil s
. . P r ocedu re w h en r e con n e ct in g

d e fin i t i on Of , 6
fron t a n d ba ck , 7 dou bl e ci rcu i t s t a r t o s in g l e

f ul l an d fr a ct i on a l, 7 cir cu i t -d e l t a ,
28 7
i n w i n di n g s p a c es , coil s i des efi ect Of hi g h a n d l ow v ol t a ge
a
n d s l ot s 7 ,
on Op er a t i on , 283
s h or t -pi t ch or s h or t cor d, 7 fa ct ors l i m i t i n g ch a ng e in
Pi t ch of ac . . coil s n u m be r of pol es , 28 6

eff ect fr a
c t i on a
of l p i t ch , 3 8 g rou pi n g coi l s , 2 89
full a n d fr act i on a l , 37 p h as e a n d v o l t a g e ch an e
g , 2 78
P l u g g i ng com m u t a t or, 395 poi n t s t o con s i der, 2 7 2
fil l i n g com p ou n d f or , 3 04 r e conn ect i ons fr e q u en tly
P ol a
ri t y Of ac
. . coil g rou ps , 40 m a
de 27
2 ,

P ol e ph a
se g rou ps Of i n du ct ion aa
r e rrn g in g ph as e co il s, 278
m ot or w i n di n g , con n ec t S cot t or T-conn ec t i on , 2-ph ase

i ng Of, 290 t o 3—ph as e , 2 69

P ol yph a
se w i n di n g s , con n e c t i ons t es t i n g r econ n ect ed m otor , 2 82
for , 43 w i n di n g d i a
g r a
m s for di ffer en t
P ot en t i a
l pi t ch , 23 p ol es a
n d ph a
s es , 2 95
P r ess u r e for brus h es , 3 3 4 P roc e du r e w h en w i n din g a . 0.

P rocedu r e w h e n conn ec t i n g coil s m a

ch i n es

Of i n duct i on m o to r w i n d i n du ct i on m ot or s econ d a
ri es ,

ins 2 07
con n ect i n g pol e p g a
- h s e - r ou s
p , i n du ct i on m otors wi t h p a r

2 90 tia l l y cl os e d s l ot s , 1 94
cons t ru ct i n g con n ec t i n g di a i n du ct i on m ot ors wi t h Op e n

g ra
m s, 2 92 s l o ts , 2 01
g rou p i n g coi l s , 2 89 la rg e ac s t a
. . t ors , 2 1 0
nu m ber pol es from coil t h row , r e pu l s i on -s t a rt m otors , 1 9 0

293 sm a l l s i n g l e -ph a s e m ot ors , 1 86

p ci n g ph a
l a s e coi l s , 2 9 1 sm a ll pol y ph a s e m ot ors , 1 9 2

wi n di n g di a
g ram s for d i ff er e n t st a
t or Of ac. . t urbo-g en er a
num ber pol es a
nd ph a
se ,
t ors , 223
29 5 P roc edu r e w h en wi n di n g d . 0.

P roc edur e w h en r e con n e ct i n g in m ch i n es (s ee a

a l so h ea
d
du ct i on m o t ors , 2 7 2 i n g di r e ct cu rr e n t a
rm a

ng es i n v ol t a
ch a g e on l y , 2 75 t u r es ) :
ch a
ug a in ph as e on l y , 2 76 ba
n di n g rm a
a t ur es , 1 46
ch a
n g e i n fr e qu e n cy 2 7 8 ,
a
cl e n i n g arm a t ur e s l ot s , 1 40
ch a
n g e i n n u m be r of pol es 2 8 2 , conn ect i n g coil s to com m u t a
ch a
n g e in sp e ed 27 3 2 82 , ,
t or, 1 01
ng e i n r es is t a
ch a n c e Of s qu i r cu t t i n g ou t coil s of wa
ve

r e l ca g e rot or 2 8 0
-
,
w i n d i n g , 1 09
cons t ru ct i n g con n e ct i n g di a i ns ul a
t ing coi l s , 1 64 , 1 6 5 , 1 68
g ra m s 2 92 ,
la
rg e rm a
a t u r es 77 ,

cu t t i n g ou t coi l s , 288 op e n s l ot s , 66
de a
d e n di n g coi l s , 277 p t ia
ar lly cl os e d s l ot s , 60
 I N DE X

P rocedu re w h en w i n di n g R ec onn ect i n g i n du ct i on m ot ors

rail w a
y ,
m i l l a
n d cr an e rm a
a fa
ct ors l im it ing ch a
ng e in
t ures , 90 n u m ber of pol es , 2 86

rot a
ry con v ert ers , 88 ph a
se a n d v ol t ag e ch a
ng e , 278
s t ri ppi n g 03 ol d w i n di n g , 1 3 9 ph a
s e i ns ul a
t i on 2 7 1 ,

3 -wi r e g e n e r a
t ors , 89 poi n t s t o co n s i de r befor e r e con
P rog r ess i v e w av e w i n di n g , 1 07 n e ct i n g , 2 62

cu t t i n g ou t coi l s Of , 1 09 r e rr aa
n g i ng ph a
se coi l s , 278
P ull eys , ru l es for s i z e Of , 492 S cot t or T-con n ect i on , 2-p h a
se

s p eed of , 492 to 3—ph a

s e , 26 9

ta
bl e Of poss i bl e r e con n e c
R
t i ons , 2 66
Rat in g of ac
. .
g en e r a
t ors , 440 t es t i n g r econ n ect ed m ot or , 2 82
R econ n ect i n g d . c . w i n di n g wi t h d e d a en ded coi l s 2 77 ,

2 40 v ol t s l a
p t o 1 2 0 v ol t s l a
p, R e en t r a n t , d e fin i t i on of, 1 4

243 R el i ni n g s pl i t b e a ri n g s , 1 5 1

240v ol t s w a
v e t o 1 2 0v ol t s l a
p, R e m edi es f or t r oubl es in d . 0 .

2 48 m a
ch i n es , 380
bri dg i n g com m u t a
t or ba
rs , for bru s h t r ou bl e s ,
258 R e m ov i n g Ol d coil s from (1 . c .

conn e ct i n g coil s in s e r i es , 2 53 a
rm a
t u r es , 57
con n ec t i n g coil s in pa
ral l el , R ep a
i ri n g :

2 44 au to st a rt e rs 3 5 1
-
,

r e conn ect i n g wi t h on e dea

d coi l s d a
m a g e d w h i l e w i n di n g
coil , 2 52 arm a t ur e 1 7 4 ,

r econ n e ct i n g du pl e x wi n di n g s , com pou n d ( 1 . c . m ot ors , 358

252 cos t Of , 3 46

ta
bl e for con n e ct i n g coi l s to d . 0 en g in e
. t y p e g en e r a
t or , 3 71
com m u t a
t or , 246 d c m o t or s t a
. . r t e rs , 3 49

a
t bl e f or r e wi n di n g coi l s , 2 45 dru m - t y p e con t rol l e rs , 3 55
R e con n ect i n g i n du ct i on m ot ors es t i m a t i n g cos t of , 3 47
( a
l
s ee
s o t a b l e Of con t e n t s i n du ct i on m o t or, 3 63
for C h a p t e r X 1 ) 2 6 1 ,
s i n g l e ph a s e m ot or , 3 68

ch a
n g es p o ss i b l e i n e x i s t i n g s l i p r i n g m o t or, 3 6 6

w i n di n g , 2 72 R ep a ir s h op e q u i p m e n t :
ch n g es fr e q u e n t l y m a
a de 27 2 , ba n di n g d ev i c e , 86

n g e i n v ol t a
(

ch a g e on l y 27 5 ,
f or t es t i n g d c w i n di n g s , 1 3 8
. .

n g e i n ph a
ch a s e on l y 2 7 6 ,
fl oor s t a n d for a rm a t u r es , 75
ch a
n g e i n f r e q u e n cy 2 7 8 , m a ch i n es a n d t ool s , 444

ch a
n g e i n n u m be r p ol es 2 82 ,
R ep a
i r s h op m e t h ods f or r e w i n di n g

ch a
n g e i n s p ee d 2 7 3 2 82 , ,
d . c . a t u r e s (s e e a
rm a l so
n g e i n r e s is t a
ch a n ce Of s qu i r ta
bl e Of con t e n t s for
r e l ca g e r o t or 2 8 0 ,
C ha
p t e r I I I ), 56
cu t t i n g ou t coil s , 288 R epa
i r s h op m e t h ods f or r ew i n di n g
ch ord fa
ct or , m a e ni n g Of, 2 69 a0 ma ch i n s (s e e a l so
. .
e
di a
g r a
m s f or ch a
n g es in con tabl e of con t e n t s for
nec t i o ns , 2 6 3 C ha p t e r V I I I ) 86
1 ,
51 2 I N DE X

R ep ai rs t o com m u t a
t or Ro t a
ry con v er t e rs , w i n di n g of, 88
ba k i ng of com m u t at or, 3 07 ba
n di n g Of, 41 0
bl a ck e ni n g Of com m u t a to r , R ul es forac w in di n g s
. .

in s pots , 3 20 a
rr a
ng e m e n t of coil s , 51
bori n g ou t en d of, 3 1 3 ch ec ki ng ph a
se r el a
t i ons h i p ,

brus h es for u n der cu t com m u 52

a
t t or, 3 22 conn ec t i ons f or coi l s Of di ff er
burn ou t bet w een ba rs , 3 03 en t w i n di n g s , 43
a
c us es of e xc ess iv e w ea r, 3 1 8 g rou i
p gn co i l s, 35
ca
us es Of t roubl e i n , 3 01 i n di c a
t ing pol a
ri t y Of coi l

c opp er us e d for ba rs , 3 1 9 g r oups , 40

fin is h i n g u n dercu t S l ot s , 3 22 r econ n ect i n g i n du ct i on m o

a
m ki n g m i ca ni t e en d ri n g s , t ors , 43 4
318 R ul es for d c w i n di n g s
. .

m icau s ed i n 3 1 5 ,
for poss i bl e s y m m e t r i ca
l wi n d
m ican i t e i n su l a
t i on for 3 1 7 ,
i ngs , 2 1
pr eca
u t i ons w h en t i g h t e ni n g ,
lap ( m u l t i pl e o r p a
r a
ll e l ), 1 1
317 m ul t ipl e x l a p, 1 5
refil l i n g of at or 3 1 1
com m ut ,
w av e (s e ri e s or t wo cir cu i t ) 1 7 ,

re m ov i n g rs a
ba n d m i ca3 04 ,
m ul t i pl e x w a v e (s eri es pa ral -

r e m ov i n g g r ou n ds , 3 08 l el ), 1 9
r em edi es for h i g h a
n d l ow ba
rs , R ul es , g en e r al , 498
3 02
r epai rin g bu r n ed ba r 3 05 ,

r epl a ci n g burn e d ba r 30 6 ,

sh a p i n g m i c a e n d r i n g s 3 1 6 ,
S ea
s on i n g a
nd g r i n di n g com m ut a
t e m pl et for m a k i n g m i cari n g s ,
t or, 1 48
316 Sha
p i n g i ns ul a
t i n g cel l s for s l ot s ,

t e m por a r y cov e r for , 3 1 0 448

t es t for oi l s a a
t u r t ed m ic , 32 0 a S i n g l e -ph a
s e m ot ors

t i g h t en i n g u p ba
rs , 3 06 conn e ct i on s for w i n di n g s Of ,

t ool s for u n d e rcu t t i n g m ic a,

1 91
3 20 dis t ri bu t i on Of m a in a nd st a
rt

t roubl es from hi g h m ica , 3 01 i n g w i n di n g s , 1 8 8

t u rn i n g dow n su rf a
ce , 3 0 9 i ns ert i ng sk ei n coi l s i n s l ot s ,
u n d e r cu t t i n g m i c a3 2 0
,
1 87
u n de r di fficul t i es , 3 97 i ns u l a t i on for sl ot s Of , 1 86
R et rog r ess iv e w av e w i n di n g , 1 07 t es t i n g w i n di n g s Of, 1 92
cu t t i n g ou t coil s of , 1 09 w i n di n g of by h a n d, 1 9 0

R ev e rs a
l of s p ee d of m otor w h il e w i n di n g for Odd f r e q u e n ci es ,
ru n mn g , 4 1 2 1 91
R e v e rs ed coi l s i n d . c. w i n di n g wi ndi n g r epul s i on st a
rt t yp e ,
ca u s e of , 1 3 1 1 90
t es t for wi t h b a
r m a
g n e t ,
1 31 wi ndi n g S k ei n coi l s in , 1 86
t es t for w i t h pacom
ss 1 32 ,
S i n g l e -ph a
se m ot or , Ov e r h a
ul i n g

R op es , h ors epow e r t ra
ns m i t t e d by , Of, 3 68

49 5 S i n g l e v s m ul t i pl e wi n di n g s , 1 1 8
.
 I N DE X
Te st i n g , e qu ipm ent for , 1 38 Tr a
ns f om er r a
t i n g for ac . . m ot o rs ,
T es t i n g i n du ct i on m ot or win di n g s 47 8
for : Troubl es i n a0 m a .ch i n es ,. a
c us e s

d evi ce for d et ect in g faul t s , 23 2 a n d r e m edi es :

e xpl or i n g w i t h acom p ass , 236 l fa

du e t o el ect r i ca ul t s , 388

g r ou n ds , 23 1 du e t o m ech a ni cal a dj us t
i m prop er g ou p
r conn e ct i on , m en t s , 38 7
234 fus es bl ow i n g , 3 89
op en circui t s , 23 4 h ot s t a t or coil s , 3 9 1
ord er i n m a ki n g t es t s , 23 5 i n w i n di n g s of , 3 87
r ev ers a
l of coil s or g rou ps , 2 33 i n duct i on m ot or t roubl es , 3 86
s h ort —ci rcu i t s , 23 1 rot or wi n di n g s , 3 92

us e of wro n g n um ber coil s , 2 3 4 s pa rk i n g a

t s l i p ri n g s , 3 9 3
wron g n um b er of pol es , 23 5 st a
t or w i n di n g s , 3 92
Th r ea
d d in
e -
co i l , 60 s y n ch ron ou s m ot ors , 388
i ns er t i on i n s l ots ,
61 t ens i on Of be l t s , 39 1
Th r ee-ph a
se m ot ors , r econn e ct i on t es t i n g for g r ou n ds , 3 9 0
for (s ee r econn ect i on Of Troubl es i n d c m ot ors n d g en er
. . a a
i n d uct i o n m ot ors ), 2 6 1 t ors , a
c u s es of

Thr ee-ph a se m ot ors on S i n g l e al d ef ect s 37

e l ect ri c 9 ,

ph as e l i n es ,
425 expos u r e t o a ci d fu m es a nd

Th ro w of coil s , 7 , 7 0 gas es 3 7 7 ,

Ti g h t eni ng com m u t at or ba rs 3 06 , lack Of i ns p ect i on an d r epl a

ce

Tool s us e d
by rm a
a t u r e wi n d e r : m en t s , 3 7
8
ba
n d wi r e t e n s i on bl ock , 454 l a
ck of p p
r o e r a
cl e ni n g , 376
ba
n di n g m a ch in e , 46 0 op e r a
t ing t e m p e ra
t u res too
ba
r be n d e r for coi l s , 458 hi g h , 3 78
coil r a
is er , 449 ope ra t i on i n da m p pl a c es , 3 77
coi l s pr e a
der ,
4 57 r e m e di e s for, 3 8 0

coil tai
p gn n ee dl e, 449 Troubl es i n com m u t a t or, caus es of ,

coi l tai
p gn m a
chi n e , 45 7 3 07
coi l wi n di n g d ev i c e , 452 wi t h brus h es , r e m edi es for ,
coi l w i n d er for l a
t h e , 456 341
com bi n a
t i on m a
c hi n e ,
462 w i t h h i g h s p ee d m ot or, 41 7
drif t s , 44 8 Tu rbo-g e n e r a t or
f or cu t t i n g c ell l i ni n g , 448 bra ci n g w i n di n g s of , 2 2 8

for S h a i
p g n i ns u l dt ing cell s , 448 br e a
k-d ow n t es t for , 229
ha n d t ool s , 445 coi l s for , 2 2 3
l ea
t h e r s l i n g , 455 con n e ct i n g w i n di n g s , 228
m a
de fr om h a
ck s a
w bl a
d es , i ns ert in g coi l s i n , 22 7
45 1 i ns ul a
t ion f or coi l s Of, 2 26
p i n i on p u l l e r , 456 f or m i n g coi l s for, 22 5
r op e sl i n g , 4 55 t es t i n g w n din g s of, 226
i

s l ot t i n g a
n d g r i n di n g m a
chi n e ,
U
459
st e a
dyi n g bra
ce , 454 U n d ercu t t i n g m ic aw i t h st nda
a rd

wir e s cr a
p er , 449 t ool s , 3 2 0
 I N DE X

Un der cut t in g m ic awi t h h a

n d t ools , Wa
ve win di n g ( con t .
)
3 23 us e i n a0 . . m ach i n e s 1 1 8 ,

w i t h por t a
bl e el e ct ri c dril l , 400 us e on d . c arm a
. t u r es ,
1 17
v e rsus la
p, 1 1 2
Wedg e dr iv er 6 2 ,

Va
rni s h es a
nd i m pre g n a
ting com Wh ol e-coil ed a
nd ha
l f-coil e d ac . .

pou n ds wi n di n g s , 3 0
ba
ki n g a
nd a
ir - dry in g v a
rn Win di n g d ach i n e s
. 0 . m
is h es , 1 7 8 ha v i ng pa rt i al l y cl os e d sl ot s 6 0 ,

ch a
ra ct e r i s t i cs Of , 17
8 ha v i n g op e n sl ot s 66 ,

cl a s s es Of 1 7 6 ,
la rg e a rm at ur es 7 7 ,

cl e a r a n d bl a ck v a rn i s h es 1 7 7 , r ot a ry con v er t e rs 88 ,

s ol v en t ch a rt f or 1 78 , 3 w ir e g e n e r a
- t o rs 8 9 ,

ta bl e of u s es 1 7 7 ,
ra il w a y m i ll a n d c,
r an e m ot ors ,

V ol t a g e ch an g e r econ n ec ,
t i on of 90
i n du c t i on m ot or f or , 2 75 Wi n di n g a0 . . m a
ch i n e s

V ol t m e t e r t es t f or i n sul a t i on r e i n du ct i on m o t ors w i t h op en

s is t a
n ce ,
1 85 sl ot s , 2 01

V ol t a
g e to us e i n t e s t i n g i ns u l a i n du ct i on m ot ors w i t h p a
r

t i on , 1 7
5 tia
ll y cl os e d s l ot s , 1 94
i n du ct i on m ot or s econ d ri es , a
W 2 07
Wa
ve w i n di n g ( s e ri es or t w o-ci r la
rg e ac . . st a
t ors ,
210
cu i t ) r e pu l s i on st a
rt des i g ns , 1 90
com m u t a
t or con n e ct i ons for, S i n g l e- ph s e m ot ors , a 1 86
1 04 sm l l pol y ph a
a se t y p es , 1 92
cu t t i n g ou t coi l s Of , 1 09 st a
t or Of ac. . t u rbo-g en e r a
dea
d coi l s i n , 1 08 to rs , 22 3
du pl e x w i n di n g , 2 52 Wi n di n g da t an ee de d t o du pl i ca te
f or a0 m a
. ch i n es , 4 1
. a n Ol d w i n di n g 57 .

f or d arm a
. ct ur es
.
,
16 Wi n di n g di a g r am s f o r a c m o t o r s . .

s a
form u l a n d m l es for d . c . d ev el op e d di a g r a m ,
co m p a r e d
arm a t u r es 1 7 , w i t h ci rcl e s ch e m e , 53
g rou pi n g coi l s in ac . . m a f or di ff e r e n t pol es a n d ph a s es ,

ch i n es , 3 5 2 95
la
p a
nd w a
ve for a0 . . m a s im p l e ci r cl e di a
g r a
m , 39
ch i n es , 28 Wi n di n g p a
r t s a
n d t erm s, 2
l oca
t in g fir s t con n e ct i on to Wi n di n g p roc e du r e f or d . c .

com a t or f or 1 05
m ut , a
rm a
t u r es (s e e h ea
di n g
m u l t i pl e w a
v e vs l a D ir e c t C A rm a
“
p 1 1 9 .
, u rr e n t

m u l t i pl e x form ul a s,
for ,
19
p rog r e ss i v e a
nd r et rog r ess i v e , Wi r e s cr a p er , 449
1 07 Wi r e s i z e for m ot or s e rv i ce s , 47
3
r econ n e ct in g wit h d ea
d coi l , d . c . m ot ors , 48 1
2 52 m ot or l ea
ds , 474
r e con n e ct i n g 24 0 v ol t s t o 1 2 0 3-ph a
se m ot ors , 48 2
v ol t s , 2 48 Wi r e t a
bl e h ow t o r e m e m ber
, ,
465
re qui r em en ts of ,
1 07 Wi r e g au g es cl a
s s i fica
t i on of,,
466
It m a
y be kep t
FOU R TE E N DA YS
TWO C E N TS wi ll be cha rg ed
la
y t h e book i s ke p t ove r ti m e
.