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College of Technology
Motors and Controls
Module # 3 AC Generators, Transformers, and AC Motors
Document Intent:
The intent of this document is to provide an example of how a subject matter expert might teach
AC Generators, Transformers, and AC Motors. This approach is what Idaho State University
College of Technology is using to teach its Energy Systems Instrumentation and Control
curriculum for AC Generators, Transformers, and AC Motors. The approach is based on a
Systematic Approach to Training where training is developed and delivered in a two step
process. This document depicts the two step approach with knowledge objectives being
presented first followed by skill objectives. Step one teaches essential knowledge objectives to
prepare students for the application of that knowledge. Step two is to let students apply what
they have learned with actual hands on experiences in a controlled laboratory setting.
Examples used are equivalent to equipment and resources available to instructional staff
members at Idaho State University.
Fundamentals of AC Generators, Transformers, and AC Motors Introduction:
This module covers fundamental aspects of AC Generators, Transformers, and AC Motors as
essential knowledge necessary to perform work safely according to national and local standards
on or around electrical power sources that are associated with motors and controls. Students will
be taught the fundamentals of AC Generators, Transformers, and AC Motors using classroom
instruction, demonstration, and laboratory exercises to demonstrate knowledge and skill mastery
of AC Generators, Transformers, and AC Motors. Completion of this module will allow students
AC Generators, Transformers, and AC Motors Module
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References
This document includes knowledge and skill sections with objectives, information, and examples
of how Motors and Control could be taught in a vocational or industry setting. This document
has been developed by Idaho State Universitys College of Technology. Reference material used
includes information from:
American Technical Publication Electrical Motor Controls for Integrated Systems, Third
Edition, by Gary J. Rockis and Glen A. Mazur, ISBN 0-8269-1207-9 (Chapter 7)
National Electrical Code International Electrical Code Series, NFPA 70TM, NEC 2008,
ISBN-13: 978-087765790-3
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KTO 3. 1.
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DESCRIBE three types of SINGLE PHASE AC MOTORS to include: ShadedPole, Split-Phase, and Capacitor motors.
KEO 3. 14.
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AC GENERATORS convert mechanical energy into electrical energy (the same way a DC
Generator does) by means of electromagnetic induction. AC GENERATORS are actually
referred to as ALTERNATORS because they convert mechanical energy into AC Voltage and
Current (Alternating Current) They are similar to DC Generators in that both generators have
Field Winding and an Armature that rotates in a magnetic field.
AC GENERATORS consists of a Field Winding, an Armature (Coil), Slip Rings and Brushes
as depicted in the below picture:
Field Windings are magnets used to produce the magnetic field in a generator. The
magnetic field can be provided by permanent magnets or by Electromagnets. Most AC
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An Armature (Coil) is the movable coil of wire that rotates through the magnetic field.
An Armature (Coil) may consist of many coils (similar to the armature in a DC
generator). The difference between the DC Generator and the AC Generator is:
o In a DC Generators Armature the ends of the coil(s) are attached to a
commutator.
o In n AC Generators Armature the ends of the coil(s) are attached to slip rings.
Slip Rings are metallic rings connected to the ends of the armature coils(s) and are used
to connect the induced voltage to the generators brushes. When the armature is rotated in
the magnetic field, a voltage is generated in each half of the armature coil. This voltage is
illustrated in the below sine wave of one revolution:
An AC Generator uses slip rings, which will allow the output current and voltage to
oscillate through positive and negative values. This oscillation of voltage and current
takes the shape of a sine wave. This is typical of the AC Voltage we have in our homes
and industry throughout the world.
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Brushes in an AC Generator are the sliding contact that rides against the slip rings and is
used to connect the armature to the external AC Circuit. As the armature is rotated, each
half cuts across the magnetic lines of force at the same speed. Thus the strength of the
voltage induced in one side of the armature is always the same strength of the voltage
induced in the other side of the armature. Each half of the armature cuts the magnetic
lines of force in a different direction. As the armature rotates in the clockwise direction,
the lower half of the coil cuts the magnetic lines of force from the bottom up to the to the
left, while the top half of the coil cuts the magnetic lines of force from the top down to
the right. The voltage induced in one side of the coil, therefore, is opposite to the voltage
induced in the other side of the coil. The voltage in the lower left half of the coil enables
current flow in one direction, and the voltage in the upper half enables current flow in the
opposite direction. This means the voltage and current alternates in both directions as is
why it is called ALTERNATING CURRENT VOLTAGE (AC Voltage).
Since the two halves of the coil(s) are connected in a closed loop, the voltages add to
each other. The result is that the total of a full rotation of the armature is twice the voltage
of each coil(s) half. This total voltage is obtained at the brushes connected to the slip
rings, and is applied to an external circuit.
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In the above picture, in position A, before the armature begins to rotate in a clockwise
direction, there is no voltage and no current in the external load circuit because the armature is
not cutting across any magnetic lines of force (O0 of rotation).
As the armature rotates from position A to position B, each half of the armature cuts
across the magnetic lines of force, producing current in the external circuit. The current
increases from zero to maximum value in one direction. This changing value of current is
represented by the first quarter (900 of rotation) of the sine wave.
As the armature rotates from position B to position C, the current continues in the
same direction. The current decreases from its maximum positive value back to zero.
This changing value of current is represented by the second quarter (910 - 1800 of
rotation) of the sine wave.
As the armature continues to rotate to position D, each half of the coil cuts across the
magnetic lines of force in the opposite direction. This changes the direction of current.
During this time, the current increases from its maximum negative value. This changing
value of current is shown by the third quarter (1810 2700 of rotation) of the sine wave.
As the armature completes its rotation to position E (position A), the current is
deceased to zero, thus completing one 3600 cycle of the sine wave.
KEO 3. 3.
The same principles of a single phase AC Generator are the same for the three phase AC
Generator except that there are there equally spaced armature windings 1200 out of phase with
each other.
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A Delta Connection is a connection that has each coil end connected end-to-end to form
a closed loop. In a Delta Connection, the three windings are all connected in series and
form a closed circuit. A Delta Connection appears like the Greek Letter Delta ().
A Wye Connection is a connection that has one end of each coil connected together and
the other end of each coil left open for external connections. A Wye Connection appears
as the letter Y.
NOTE
The reasoning for the Delta and Wye Connections will be addressed later in this
curriculum as it has to do with AC Power distribution systems and AC Power connections
to three phase motors.
SUMMARY:
AC GENERATORS convert mechanical energy into electrical energy (the same way a
DC Generator does) by means of electromagnetic induction.
AC GENERATORS consists of a Field Winding, an Armature (Coil), Slip Rings and
Brushes.
Field Windings are magnets used to produce the magnetic field in a generator.
An Armature (Coil) is the movable coil of wire that rotates through the magnetic field.
Slip Rings are metallic rings connected to the ends of the armature coils(s) and are used
to connect the induced voltage to the generators brushes.
Brushes in an AC Generator are the sliding contact that rides against the slip rings and is
used to connect the armature to the external AC Circuit.
A SINGLE-PHASE AC GENERATOR provides power through each complete rotation
of its armature within its magnetic field coils and produces one complete alternating
current cycle.
The same principles of a single phase AC Generator are the same for the three phase
AC Generator except that there are there equally spaced armature windings 1200 out of
phase with each other.
A Single Phase Generator has two leads providing power to the intended load.
A Three Phase Generator has three separate armature windings so there are six leads
providing power to the intended load.
There are two connections: Delta and Wye; the manner in which they are connected
determines the electrical characteristics of the generators output.
A Delta Connection is a connection that has each coil end connected end-to-end to form
a closed loop
A Wye Connection is a connection that has one end of each coil connected together and
the other end of each coil left open for external connections.
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The effect of a power interruption on a load depends on the load and the application. If a power
interruption could cause equipment, production, and or security problems that are not acceptable,
an Uninterruptable Power System/Supply (UPS) can be utilized. An Uninterruptable Power
System/Supply (UPS) is a power supply that provides constant power needs when the main
power supply is interrupted. This is accomplished by a network of electronics and batteries such
that the incoming AC power from the main utility is used to convert the AC to DC to keep the
batteries charged and then it inverts the DC back to clean uninterrupted and filtered AC power to
which the facility that utilizes this UPS will not experience a power interruption upon loss of the
main utility power source. A large facility will also have a backup generator with a UPS to pick
up the emergency designated power in the event the UPS main battery(s) lose their ability to
keep their charge. For long power interruption protection (sustained), a combination of a
generator and a UPS are used. For short power interruptions (temporary), a UPS is used. UPS
batteries are generally sealed lead acid batteries.
AC Generators, Transformers, and AC Motors Module
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SUMMARY:
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SUMMARY:
Transient Voltages are normally erratic, large voltages or spikes that have a short
duration and a shout rise time.
Devices like Computers, Electronic Circits (TVs Mircro Wave Ovens Sound
Systems etc) require protection against Transient Voltages.
Protection methods usually include proper wiring to National Electrical Code
Requirements, to include grounding, shielding of the power lines, and use of Surge
Protectors.
A Surge Protector is an electrical device that provides protection from high-level
transient voltages by limiting the level of voltage allowed downstream from the Surge
Protector/Suppressor (more commonly called a Surge Suppressor).
Surge Suppressors power strips generally have and on off switch and a reset button.
When Surge Suppressors trip the power is removed from the loads and the device needs
to be manually reset to restore power to the loads.
If the Power Surge was high enough, it could actually damage the Suppressor and it will
not reset.
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KEO 3. 8.
Many TRANSFORMERS have a secondary coil that has an extra lead (tap) attached to it. A
Tap is a connection brought out of a winding at a point between its endpoints to allow changing
the voltage or current ratio.
Although Transformers are very efficient, they are not perfect. Not all energy delivered to the
primary side by the source is transferred to the secondary load circuit. There is a majority of
energy lost as heat in the transformer. There are three types of TRANSFORMER LOSSES in
an iron core transformer: Resistive Losses, Eddy Current Loses, and Hysteresis Losses.
Resistive Losses come from the resistance of the coil winding. When current passes
through the winding, the winding will heat up and lose energy that could have been
transferred to the secondary. These losses are inherent and cannot be minimized.
Eddy Current Losses come because iron is a fair conductor of electricity. This is due to
the varying magnetic field which induces a voltage in the secondary winding that also
induces small voltages in the iron core of the transformer. The small voltages produce
Eddy Currents, which in turn produce heat. This heat also represents a loss because it
does not useful work.
o Eddy Current Losses are minimized either by making the core of thin sheets
(laminations) which are insulated from each other, or by powered-iron cores
instead of solid blocks of iron.
o The insulation between the laminations of a laminated core break up current
paths within the core and reduces Eddy Currents. This same technique is used to
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Hysteresis Loses occur each time the magnetizing force produced by the primary side of
a transformer changes, the atoms of the core realign themselves in the direction of the
force. This energy required to realign the iron atoms must be supplied by the input power
and is not transferred to secondary load current.
o Hysteresis Loses are minimized by using High Silicon Steel and other alloys in
the construction of the core.
All three of these TRANSFORMER LOSSES make the typical iron core transformer hot when
operating under full load. The transformer may be too hot to touch based on its size and load, but
there should be no odor of burring insulation or varnish, or sings of discoloration or smoke.
Any one of these conditions indicates the transformer is either overloaded or defective and
service is necessary to correct and reduce damage, safety, or fire hazards.
SUMMARY:
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SINGLE-PHASE CONNECTIONS utilize only one of the three phases of power distributed by
the electrical utility. This Single Phase power is utilized throughout the world in residential
applications and smaller businesses that do not require three phase power. The following picture
depicts how Residential Electrical Power is provided by overhead 3-phase or lateral (underground) service as required by the National Electrical Code:
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THREE-PHASE CONNECTIONS utilize all three phases of power in the same manner where
each phase is Stepped-Down like it is with a single phase using three separate identical
transformers.
The following pictures depict: Transformer Secondary Tap, Centered-Tap, configurations to
obtain a variety of different voltages:
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o To check for open circuits in coils, the resistance of each coil is checked. The
winding is open and the transformer is bad if any coils show an infinite resistance
reading.
o To check for short circuits between primary and secondary coils, the resistance
needs to be checked between primary and secondary coils. If an infinite resistance
is not found between the primary and secondary coils, the coils have shorted and
the transformer is bad.
o To check for coils shorted to the transformer core, the resistance needs to be
checked from each coil to the core. This check is good if the resistance is infinite.
If there is a continuity reading from coil to core, the transformer is bad.
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SUMMARY:
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Single Phase Motors are commonly used in residential applications for AC Motor
Driven appliances such as: Forced Air Furnace Fans, Air Conditioners, Washing
Machines, etc. Single Phase Motors include: Shaded-Pole, Split-Phase, and Capacitor
motors.
KEO 3. 13.
DESCRIBE three types of SINGLE PHASE AC MOTORS to include: ShadedPole, Split-Phase, and Capacitor motors.
Shaded-Pole motors are a Single Phase AC Motor that uses a shaded stator pose for
starting the motor as depicted in the picture below:
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Split-Phase motors are Single Phase AC Motors that include a Running (main winding)
and a Starting Winding (auxiliary winding). Split-Phase motors are AC motors of a
fractional horsepower, usually 1/20 to 1/3 HP. They are commonly used to operate washing
machines, oil burners, and small pumps and blowers.
o A Split-Phase motor has a rotating part (rotor), a stationary part consisting of the
running and starting winding (stator), and a centrifugal switch that is located
inside the motor to disconnect the start winding at 60% to 80% of designed full
speed.
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When the Split-Phase starts, both the Running and Start Windings are connected in
parallel. The Start Winding is used to jump start the motor and then is disconnected by
the centrifugal switch at 60% to 80% of full speed. When the motor is turned off, the
centrifugal switch returns to its normally closed position (at approximately 40% of its full
speed), ready to be used for starting the motor again.
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A Capacitor-Run Motor is a Split-Phase AC Motor with the start winding and the capacitor
connected in series at all times which does not have a centrifugal switch, giving this motor
medium staring torque and somewhat higher running torque than a capacitor start motor as
the capacitor continually charges and discharges while the motor is running.
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A Capacitor Start-and-Run motor (used to run refrigerators and compressors) uses two
capacitors with one used to start the motor, and the other one used as a capacitor to allow the
motor to continue operating as a Capacitor Run Motor. This motor uses a larger capacitor to
start the motor and a smaller one to run it.
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A Capacitor Start-and-Run motor has more running torque that a capacitorstart motor or a capacitor-run motor.
SUMMARY:
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THREE PHASE AC MOTORS are the most commonly used motors in industrial applications.
Three Phase Ac Motors are used in applications ranging from fractional horsepower to over 500
HP. Three Phase Ac Motors are used in most applications because they are simple in
construction, require little maintenance, and cost less to operate than Single Phase or DC
Motors. The most common Three Phase Ac Motor is the Induction Motor.
The Induction Motor is a motor that has three sets of Rotor Coils with each connected a
different phase of the three phase power. These composite windings are the Phase A, B,
and C of the three phase power. An Induction Three Phase Motor is illustrated below
with different colors per phase in the Rotor and in the Voltage Sine Wave:
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SINGLE VOLTAGE THREE PHASE MOTORS is a motor that operates at only one
voltage level. They are less expensive to manufacture than Dual Voltage Motors, but are
limited to locations having the same voltage as the motor.
o Common Single Voltage Three Phase Motors ratings are 230, 460, and 575 VAC.
Other ratings include 200, 208, and 220 VAC.
o All Single Voltage Three Phase Motors are wired so that the phases are connected in
either a (Y) or a () configuration as illustrated in the following two pictures:
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Most problems with AC Motors are related to Single Phase AC Motors dealing with the
Centrifugal Switch, Thermal Switch, or Capacitors. These motors are usually serviced and
repaired if the problem is related to the centrifugal switch, thermal switch, or capacitors. If a
motor is less than 1/8 HP it is usually replaced as the cost to repair can exceed the replacement
cost. As for Three Phase AC Motors, they usually operate for many years without any
problems as they have fewer components that may malfunction than Single Phase AC or DC
Motors.
AC Motor Maintenance is extremely important and if maintained properly, many motor
failures can be minimized or in some cases prevented. In general, electrical motors are very
dependable and will provide good service under the conditions in which the motor was designed
to operate within. To provide the safest service possible, a technician should check a motor name
plate prior to putting it in service to ensure that the proper voltage and current are being used.
The below picture depicts the type of information found on a motors name plate:
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Troubleshooting Shaded-Pole Single Phase AC Motors when they fail are usually replaced.
The reason for the motor failure needs to be investigated to ensure the replacement motor not
subject due to an overload situation or environmental conditions that may have caused its
failure. To Troubleshoot a Shaded-Pole Motor the following picture illustrates a two step
process:
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a.
b.
c.
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STEP TWO
AC Generators, Transformers, and AC Motors
Skill/Performance Objectives
Inspect an AC Motor or Generator for proper operation and identify any defects on
operation
Evaluate the performance of a transformer to determine transformation efficiencies
Disassemble and inspect an motor, transformer or generator and identify service needs
Assemble a motor, transformer or generator replacing normal seals and wearing parts
as specified in the technical manual
Test a service motor to ensure safe and correct operation
Perform a meggaohm test of a motor, generator or transformer and identify any faults
indicated by the test results
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