INDUSTRIETECHNIK

SRI LANKA INSTITUTE of ADVANCED TECHNOLOGICAL EDUCATION

ELECTRICAL and ELECTRONIC

ENGINEERING
Instructor Manual

Training Unit

Fault Finding in Electrical

Control Systems
Theory

No: EE 082

Training Unit
Fault Finding in Electrical Control Systems
Theoretical Part
No.: EE 082

Edition:

2008
All Rights Reserved

Editor:

MCE Industrietechnik Linz GmbH & Co

Education and Training Systems, DM-1
Lunzerstrasse 64 P.O.Box 36, A 4031 Linz / Austria
Tel. (+ 43 / 732) 6987 3475
Fax (+ 43 / 732) 6980 4271
Website: www.mcelinz.com

FAULTFINDING IN ELECTRICAL CONTROL SYSTEMS

CONTENTS

Page

LEARNING OBJECTIVES ...................................................................................................4

INTRODUCTION ..........................................................................................................5
1.1

Safety rules ..........................................................................................................5

1.2

Accident prevention .............................................................................................6

1.2.1

Rescue procedure in the event of electrical accidents.....................................7

TYPES OF FAULT .....................................................................................................11

2.1

Short circuits to frame ........................................................................................11

2.2

Short-circuits ......................................................................................................11

2.3

Earth faults.........................................................................................................11

2.4

Winding short circuits .........................................................................................12

2.5

Turn-to-turn faults ..............................................................................................12

TEST AND MEASURING EQUIPMENT FOR FAULTFINDING .................................13

3.1

Basic equipment ................................................................................................13

FAULTHNDING METHODS .......................................................................................14

FAULTFINDING IN LIGHT CIRCUITS .......................................................................16

5.1

Faults on filament lamps ....................................................................................16

5.2

Faults on fluorescent lamps Lamp does not come on: ......................................19

FAULTFINDING ON ELECTRIC HAND TOOLS........................................................25

FAULTFINDING

ON

ELECTRICAL

CONTROL

SYSTEMS

USING

CIRCUIT

DIAGRAMS........................................................................................................................27

FAULTFINDING ON ELECTRICAL MACHINES........................................................30

8.1

Cage rotor machines..........................................................................................30

8.2

Slipring rotor machines ......................................................................................35

8.3

D.C. motors........................................................................................................40

8.4

Single-phase transformers .................................................................................45

FAULTFIND1NG ON EXCESS VOLTAGE PROTECTION EQUIPMENT .................49

9.1

Residual current devices....................................................................................49

9.1.1

Faults on residual current devices .................................................................50

9.1.2

Testing circuits ...............................................................................................53

9.2

Protective earthing conductors ..........................................................................54

9.3

Protective earth and neutral conductors (PEN) .................................................55

9.4

Protective multiple earth systems (IT systems)..................................................57

10

FAULTFINDING ON RECTIFIER CIRCUITS ........................................................60

10.1

Testing power semiconductors with an ohmmeter.............................................60

10.2

Testing power semiconductors with an oscilloscope .........................................61

10.2.1

Half-wave rectification ................................................................................62

10.2.2

Full-wave rectification (centre tapped transformer) ....................................63

10.2.3

Bridge circuit ..............................................................................................64

10.2.4

Threephase Bridge circuit ..........................................................................65

FAULTFINDING IN ELECTRICAL CONTROL SYSTEMS

LEARNING OBJECTIVES

The trainee should...

name the types of faults which occur in electrical circuits and equipment

name and use test and measuring equipment used for faultfinding in electrical
engineering

list methods of assisting fault-finding

detect and repair faults in lighting circuits and in lighting units

describe methods for faultfinding on electrical hand tools, such as hand drilling and
hand grinding machines

read electrical circuit diagrams

find and remove open-circuits and short-circuits in electrical control systems using
circuit diagrams

test cage motors for operation and condition

locate and repair faults in rotor and stator circuits

test windings of d.c. shunt wound machines

test single-phase transformers

locate and repair faults on excess earth voltage protection equipment (residual current
devices)

test the protective earthing circuits for perfect operational condition

locate and repair faults on protective earth and neutral circuits

locate and repair faults on protective conductor circuits

detect and repair faults in semiconductor rectifier circuits

FAULT FINDING IN ELECTRICAL CONTROL SYSTEMS

INTRODUCTION

When faultfinding it is assumed that the system was operating properly before the fault
occurred. However, it is advisable to check again the connections to the mains, load and,
if provided, any remote control system. If there is no fault until the load is connected, the
drive motors must first be examined for possible earth and turn-to-turn faults.
The measuring Instruments to be used must be double insulated, or at least connected
through an isolating transformer (without protective conductor), because there is a high
potential to earth for some measurements.

WARNING
Capacitors may remain charged long after the mains has been switched off. To avoid
damage to the measuring Instrument (e.g. when measuring with an ohmmeter), capacitors
must be discharged beforehand by short circuiting them for a short time.

1.1

Safety rules

For carrying out work on electrical installations:

-

Isolate all poles of the supply, on all sides of the installation.

Protect against reconnection.

Test for no voltage.

Earth and short-circuit (remembering correct sequence).

Cover adjacent live parts and enclose any danger points.

Connection is carried out in the reverse order.

1.2

Accident prevention

Causes of accidents:
-

tools in poor condition

carelessness and thoughtlessness

haste

inexperience

Electrical accident:
If an electrical circuit is completed through the human body, current flows through the
body and the person is at risk. The current flowing through the human body depends on
the voltage and resistance, according to Ohm's law.

The resistance of the human body depends on:

-

contact pressure: strong pressure - low resistance

contact surface: large surface area - low resistance

humidity: high humidity or wet conditions - low resistance

voltage: the higher the voltage the higher the current

location: only relevant when the circuit is closed above ground Level and depends on
the footwear to earth resistance and the resistance of the ground near the point of
contact

Body resistance at voltages of over 100 V is approx. 3000. The effect of the electrical
current on the human body is solely dependent on the current magnitude, the voltage
causing the flow through the body.

1 mA

Effect becomes perceptible

15 mA

The person may be unable to free himself

from 5041A

Highly dangerous!

Current over 50 mA and voltages from 50 V upwards can be fatal.

The 50 V mark provides a safety factor since body resistance and the current magnitude
dangerous to the human body are approximate values.

1.2.1

Rescue procedure in the event of electrical accidents

Switch off the circuit.

Release the victim from circuit.

Apply first aid.

Inform doctor, rescue service.

Report accident to police.

1.2.1.1 Rescue from the circuit

Up to 1000 V:
-

switch off safety switch and remove all fuses.

in the case of portable equipment, remove plug from socket.

in the case of fixed equipment, disconnect electrical apparatus and cables (N.B. there may perhaps be two power supplies).

pull away victim and insulate (intermediate layer of rubber, plastic,...).

Over 1000 V:
The circuit must first be switched off because it is very dangerous to approach the victim.

1.2.1.2 First aid

First aid cannot replace the doctor, but it may preserve the life of the injured person.
Burns - cover wound with sterile material, do not apply any ointments or cotton wool.
Unconsciousness, breathing discernible - loosen tight clothing, lay the injured person
down correctly.

Unconsciousness, no breathing - commence mouth-to-mouth resuscitation or use a

respirator.

Unconsciousness, no breathing, no pulse (ventricular fibrillation) - apply artificial

respiration immediately, also heart massage! A human being can only live for three
minutes without oxygen!

Artificial respiration:
Bend the head right back. This ensures that the victim's tongue does not drop back into
his/her throat. (Risk of choking).

Hold nose and blow air in slowly; if this proves too difficult, bend the head back further.
Helper breathes in again, and observes the victim's chest for signs of breathing activity.
About 15 to 20 breaths/minute.
If a respirator is available, use it.

Heart massage and artificial respiration:

Heart massage should only be done by helpers who are well acquainted with this therapy
and it always has to be combined with artificial respiration (mouth to mouth, if a respirator
is available, use it.)

Application
If there is
-

no breathing

a dilation of the pupil and no reaction at incidence of fight

no pulse to feel at the carotid artery

Performance
-

Place victim on a solid surface (lying on the Back)

Press the lower half of the breastbone with the eminence of the hands (put the second
hand exactly on the first - the fingers don't touch the chest) about 3 to 4 cm downward.

Keep your arms stretched!

As soon as the heart massage is starting also artificial respiration is necessary

because the lungs need oxygen.

The heart massage ensues 60 to 80 times/min.

The procedure always has to start with artificial respiration (5 times).

Heart massage and artificial respiration have to ensue in an equable rhythm.

1 : 5 (1 time artificial respiration 5 times heart massage etc.)
if there are two helpers

2 : 15 (2 time artificial respiration 15 times heart massage etc.)

if there is only one helper

10

TYPES OF FAULT

An insulation fault occurs when the insulation of electrical conductors, in equipment with a
metal housing or in cables, is damaged. These insulation faults may lead to short circuits
to frame or earth.

2.1

Short circuits to frame

These are electrical connections between active and inactive conductive parts.

Inactive conductive parts:

These are conducting parts which do not belong to the operating circuit (e.g. housings).
They are separated from active conductors by insulation.

Active conductors:
These are conductive parts which are live during normal operation and form the operating
circuit (e.g. cable conductors, plug pins, terminals, neutral conductors, but not PE or PEN
conductors).

2.2

Short-circuits

These are conducting connections between operationally live parts brought about by an
insulation fault.

2.3

Earth faults

These are conducting connections between conductors insulated from earth and earth or
earthed parts, brought about by insulation faults or by bridging of the insulation.

11

2.4

Winding short circuits

These are conducting connections between two conductors in the winding of an electric
motor brought about by insulation faults.

2.5

Turn-to-turn faults

These are conducting connections between two or more turns on the same coil or winding
of an electric motor brought about by insulation faults.

1 = Fault to frame
2 = Short circuit
3 = Earth fault
4 = Phase to phase short circuit
5 = Turn-to-turn fault

12

3.1

TEST AND MEASURING EQUIPMENT FOR FAULTFINDING

Basic equipment

Continuity tester:
-

with lamp or buzzer.

Test lamp:
-

for voltages ranging from 100 to 500 V

Multimeter:
-

this is a multiple range measuring Instrument suitable for voltages up to 1000 V,

currents up to approx. 30 A and for resistance measurement

Insulation tester:
-

for determining the insulation resistance of installations, cables and equipment.

Measuring voltages: 100, 250, 500, 1000 V

Single knob Wheatstone bridge:

-

for accurate measurement of ohmic resistances within a measurement range of 40

m to 50 ka

Phase sequence indicator:

-

for establishing the phase sequence in three-phase networks

Oscilloscope:
-

for measurements in rectifier circuits

Special measuring instruments are required for testing protective equipment.

They include instruments and equipment for testing contact voltage, earth resistance, loop
resistance, local insulation resistance, total current and residual current devices.

13

FAULTHNDING METHODS

The consuming component is tested for mechanical and electrical faults. There are two
types of mechanical fault or damage - internal and external. Intern & faults include bearing
faults, and external faults include damage to the housing.
The electrical faults are mainly insulation faults (short circuits to frame, short-circuits, earth
faults).
Safety devices which have been connected in the circuit are switched off or disconnected
in order to locate these faults (e.g. motor safety switch, automatic cut-out). Where the
protective conductor is separate, the neutral conductor is also disconnected.
The fault is then located by means of testing and measuring equipment (e.g. insulation
meter). The winding is tested for short circuits to frame or phase-to-frame contact and
cables are tested for insulation from earth and from each other. Each winding is
individually measured, which means that they must be disconnected.
If the fault is not at the consuming component, but in the supply cable, a test is carried out
with the voltmeter or a test lamp to determine whether the circuit is live (switch,
consuming component). This will indicate if the supply cable is open circuited, if neither
the fuse, automatic cut-out, residual current device nor other protective devices have
tripped. The switches are switched on. An open circuit may be at a switch or at the
terminals, and it is located accurately with the voltmeter or test lamp.
If one of the protective devices trips, an insulation fault has occurred. Measurement is
again carried out to earth or to conductors with an insulation tester, remembering that the
high voltage generated by the insulation tester may damage the equipment.

In the case of contactor circuits it must be remembered that there is a main circuit and a
control circuit. Both must be tested. In the control circuit one terminal after the other is
tested as far as the contactor coil to determine whether voltage is present. Depending on
the circuit, there are voltages of 24 V to 220 V.

14

A rectifier circuit may also be present and this must also be tested. The diodes or
thyristors are measured with the ohmmeter in the forward and reverse direction. In the
case of the thyristor it must be remembered that it can be triggered in both directions!
When selecting test equipment ensure that the equipment is also operating correctly and
accurately. Always set measuring Instruments to highest range, then reduce to the correct
range later (the Pointer should be located in the upper third of the scale).

15

FAULTFINDING IN LIGHT CIRCUITS

If faults occur, the following points must be observed:

a) In the event of a fault, either the line fuse or the automatic cut-out or residual current
device trips. If the residual current device has tripped, the search for the defective line
may give problems (see section 9.1 - Faultfinding on current-operated earth leakage
circuit breakers).

b) If point a) does not apply, test the lamp.

c) If points a) and b) do not apply, test the defective line for open circuits (switch does not
operate, terminals open or poor contacts in the lamp socket)

d) If point a) applies - i.e. the line fuse, automatic cut-off or residual current device has
tripped, a fault to frame may have occurred. Locate the fault by means of an insulation
tester. Fault to frame can occur in the socket of the lamp!

5.1

Faults on filament lamps

Lamp does not come on:

Possible causes:
-

Filament burnt out

No contact or poor contact, open circuit (switches, terminals)

Fault in the Installation of the circuit (e.g. confused L-PE with N-PE, line-earth with
neutral-earth) - Short circuit to frame in the socket

Remedy:
-

Bend up the contacts in the lamp socket.

Replace lamp.

16

System type: Single-phase 220 V a.c.

17

E.g. Two-way lamp circuit:

a) Test power supply and lamp.

Even if the fuses or the lamp have no visible defects they should also be checked with
a continuity tester.

b) With the test lamp (or voltmeter) on the socket contacts, determine if voltage is
present. Actuate a switch and measure again.

c) If voltage is present, switch off circuit and bend up contacts slightly.

If no voltage is present, there must be an open circuit or one of the switches is
defective (e.g. contacts broken off or burnt off). In order to test a switch, switch off the
circuit, disconnect the wires, then check with a continuity tester.

18

5.2

Faults on fluorescent lamps Lamp does not come on:

Mains voltage too low

Lamp defective

Poor contact, open circuit, choke, capacitor

Starter damaged.

Remedy:

Mains voltage must be greater than 190 V;

Replace lamp

Test connections, contacts and ballast

Replace starter

Lamp does not come on properly:

-

Mains voltage too low

Temperature too low or too high

Poor contacts Remedy:

At mains voltage below 190V = ignition uncertain

Use incandescent starter if possible

Reverse polarity of the starter in the case of series connection

Test connections and contacts

Lamp flickering:
-

Lamp voltage too high; end of lamp life

Remedy:
-

Replace lamp

19

Faultfinding on fluorescent lamps:

E.g. fluorescent lamps switched with current impulse switch.

First establish whether it is only a single tube, a lamp with two tubes, or a group of lamps
which is not working.
If several lamps are not working, test power supply, press buttons, and observe impulse
switch to see whether it is also switching. Measure voltage at the impulse switch terminals
and at the terminals. If voltage is not present there is an open circuit in the wiring.

If a tube does not come on, test the starter and tube, replace if necessary, check wiring.
Possibly poor contacts at terminals; choke or capacitor may have an open circuit.

20

Fluorescent lamp circuits:

In industrial lighting systems, lamps are divided between the three phases (in duo circuit).
Hence load division and reduction in stroboscopic effect.

Lamp does not come on; starter switch operates continuously

-

Starter is located in supply cable between lamp and ballast

Lamp burning voltage too high; end of lamp life

Remedy:
-

Change starter

Replace lamp

Lamp does not come on, starter does not switch, lamp electrodes glow:
-

Starter is jammed, short-circuit in starter capacitor

Remedy:
-

Replace starter

21

Uneven illumination in lamp

-

Occurs in new lamps due to contamination

Remedy:
-

Allow the lamp to burn in properly

Camp comes on brightly then fails to come on again:

-

Turn-to-turn fault on ballast

Incorrectly chosen ballast

Connection to D. C. voltage - choke ineffective

Voltage too high (e.g. connection to two line conductors)

Remedy:
-

Replace ballast

Fit correct ballast for lamp

For d.c. voltage, fit a resistor instead of the choke

Change circuit

Blackening near electrodes:

-

End of lamp life

Current intensity too high

Considerable voltage variations or supply voltage too low

Remedy:
-

Replace lamp

Test ballast

Test mains voltage

22

Dark spots on lamp:

-

Mercury precipitation due to cooling

Regular precipitations on louvered lamps

Remedy:
-

Make the lamp temperature distribution even

Increase distance between louvre and lamp

Ballast giving disturbing buzzing sound:

-

Components loose

Not properly fitted

Lamp parts or cases too small (vibration phenomena due to magnetic stray field)

Remedy:
-

Tighten screws

Use elastic supports

Use correct cover for ballast

Radio interference:
-

Suppressor condenser not connected or defective

Interference due to radiation

Remedy:
-

Fit or replace suppressor condenser

Place radio further away; use screened antenna feeder cable if possible.

23

Lamp flickers:
-

Ignition without adequate preheating of the electrodes

New lamp not properly burnt in

Remedy:
-

Replace starter

Flickering may stop after a short burning time.

Lamp flickers, even though switched off:

Switch in neutral conductor, lamp remains live.

24

FAULTFINDING ON ELECTRIC HAND TOOLS

Electrical hand tools should belong to protection class II, (double insulated) and have
contour or flat plugs. The plugs are permanently connected to the supply cables.
Drilling machines, which have plastic reduction gears, are fully insulated; there can be no
short-circuit to frame.

The following must be tested:

-

Connecting cables and plugs for open circuit.

Switches and speed controls for open circuit and serviceability.

Brushes and brush holders; if the commutator is pitted, this is due to the brush
sparking. Brush sparking occurs, for example, when a commutator segment is
disconnected, when the commutator is not completely circular, when the armature
winding is open circuited, if the brushes are in the wrong position. When the motor
stops at the disconnected segment, it no longer starts up again. If it is rotated a little
further, it will run again and skips this disconnected segment.

Check motor windings for turn-to-turn fault and open circuits.

Worn brushes, connector, plugs, switches and speed controls can be replaced. When
replacing brushes make sure that they are of the same type as the ones being replaced.
The pitted commutator must be skimmed and the insulation between segments cleaned
(e.g. scraped out).
If a winding is open circuit (burnt), it must be replaced, even if there is only a turn-to-turn
fault.
A mechanical fault may also have occurred, e.g. on the reduction gearing, chuck, etc.

25

E.g. hand drilling machine:

1. First carry out a visual test (cables), turn the armature by hand; in most cases carbon
brushes can easily be tested from the outside (length free movement, sufficient
contact pressure?)

2. Test cables and plugs for open circuits; connecting cables are very often broken close
to the plug or the machine connection. When checking windings, make sure that only
the winding concerned is being checked, open the switch connections if necessary.

26

FAULTFINDING ON ELECTRICAL CONTROL SYSTEMS USING CIRCUIT

DIAGRAMS

Distinguish between faults in the main circuit and faults in the control circuit. Tripping of
the thermal overload switch indicates a fault in the main circuit!

Thermal relay or main circuit fuse trips: Fault on machine (motor), power supply (phase
failure), major voltage fluctuations, mechanical overloading: Observe the motor starting
current, relay contacts defective (burnt off or welded together).

Control circuit does not work:

-

Thermal overload trip also opens control circuit.

Check control circuit fuse and control voltage, if control circuit fuse is defective, test
coils for short-circuits.

Measure voltage on coils with voltmeter, note any voltage drop. (particularly at low
control voltages, voltage must be 85 % of the rated voltage).

If possible carry out an operational test on the circuit (remove main circuit fuses).

Contactor remains actuated, although no voltage on coil:

Clean magnet body.

Voltage present on coil, contactor is not actuated.

Coil interrupted, seized voltage too low.

27

E.g. Reversing contactor circuit

Fault - contactors are actuated, motor is not running.

a)

Main circuit diagram:

Testing the voltage.

Testing on the main circuit:

1. Test power supply (L1 - L2; L1 - L3; L2 - L3)
2. Test operation of relay contacts
3. Measure motor terminals, test thermal overload trip and cable as far as motor
terminals for wire breakage, poor terminal connection.

28

Control circuit of a reversing contactor circuit:

E.g. fault - K2 not actuated.

Measure control voltage with voltmeter on N conductor and phase L, then check for open
circuit, step by step (a, b, c, d, e, f). Remember that the measurements at points e and f
can only be carried out with push button S 3 pressed (contact 3-4 closed). If there is
voltage at a-b on the coil, the coil is defective or the contactor has seized (also note
voltage level).

29

FAULTFINDING ON ELECTRICAL MACHINES

Electrical and mechanical faults may arise.

The machine is tested for mechanical damage:

-

turn the rotor shaft by hand to check whether the rotor is jammed or is otherwise
seized (bearing).

broken feet, defective terminal boxes, burst end housings, external damage

test supply: supply cables, transformers, fuses, motor safety switch, rectifier

test electrical machine components

8.1

Cage rotor machines

Jerky running:
-

Bearing damage, bearing support or balls damaged

Out of balance or loose pulley or coupling

Failure of one phase

Remedy:
-

Replace bearing

Balance rotor

Test phases with test lamp

Motor does not start:

-

Open circuit in supply cable, fuse or motor safety switch has tripped

Open circuit in stator circuit

Open circuit in rotor circuit

Bearing seized.

30

Remedy:
Test power supply, fuses, thermal overload trips, measure voltage at motor terminals.
Cage motors have a very low starting torque, and must not therefore start under heavy
load1 lf there is voltage at the motor terminals, check the motor. Switch off the voltage,
disconnect at the terminal board and check windings.

Motor terminal board for star and delta connections:

1. Measure winding resistance with measuring bridge and compare:

U1 - U2
V1 - V2
W1 - W2

2. Insulation resistance of windings relative to each other:

U-V
U-W
V-W

3. Insulation resistance of windings to earth:

At least 1000 ohms per volt of operating voltage

31

The resistance of the individual windings should not differ substantially (5 % max.).
The insulation resistance between the windings, and between the windings and earth is
measured with an insulation tester or insulation resistance bridge.

A cage motor does not start in the star position of the star-delta switch, only on the delta
stage:
-

Contact broken in the star-delta switch

Motor torque in star connection is so low that it cannot operate the driven machine; too
high a load

Remedy:
-

Test star-delta switch and remedy open circuit, if necessary

Reduce starting lad, use a starting V-belt or use a motor of higher rating - slipring
motor.

Motor starts in the operating position of the star-delta switch, speed greatly reduced under
load:
-

Rotor bars have become unsoldered

Overloading

Remedy:
-

Replace rotor bars

Measure input with an ammeter; reduce load or use motor with higher rating.

Motor has difficulty starting; excessive speed reduction on load:

-

Mains voltage too low

Voltage drop in the supply cables too high

Stator wrongly connected in star-delta

Phase and neutral conductor interchanged

32

Remedy:
-

Measure mains voltage; replace transformer

Check the cable current ratings

Test circuit Test connections

Motor has difficulty in starting, loud humming noise when switched on, motor heats up
quickly:
-

Worn bearing bushes or fracture in the ball bearing

Rotor rubbing against stator

Remedy:
-

Check bushes, ball bearings and shaft clearance

Replace bearing bushes or ball bearings if necessary

Three-phase motor runs sluggishly in star connection, or not at all:

-

Load too high

Mains voltage too low

Star-delta switch contact seized

Remedy:
-

Reduce load, or install larger motor

Test mains and cables

Overhaul switch

Motor humming very loudly on load; overheating:

-

Winding of stator winding has turn-to-turn or phase-to-phase fault

Remedy:
-

Measure phase currents; if they differ seriously from specification, the motor must be
rewound.

33

Motor becomes very hot; motor safety switch does not trip:
-

Overloading

Too frequent starting up.

Voltage too high or too row; one phase disconnected on terminal board

Incorrect corrections

Turn-to-turn or phase-to-phase fault

Fan not working

Incorrect mode of operating Remedy:

-

Reduce load or use larger motor

Use motor with slipring rotor

Measure voltages with voltmeter

Compare circuit with wiring diagram

Replace winding

Test fan

Use motor according to operating mode (according to rating plate)

When motor is switched an, fuses blow or the motor safety switch trips:
-

Fuse or motor safety switch too small

Short circuit in cable from star-delta switch to stator

Short circuit between two lines or phases of the stator winding or to frame.

Remedy:
-

Replace with correct fuses; adjust motor safety switch correctly

Disconnect cables from terminal board, and test insulation; remedy insulation faults

Disconnect cables from terminal board, and remove links from terminal board.
Measure insulation between phases and to case; replace winding.

34

8.2

Slipring rotor machines

Jerky running:
-

Bearing damage, bearing arrangement or balls damaged

Out of balance or Loose flange or pulley

Phase failure

Remedy:
-

Replace bearing

Balance rotor and pulley

Test phases with test lamp

Motor does not start:

-

Interruption in the supply cable; fuse or motor circuit breaker has tripped

1. Open circuit in stator

2. Open circuit in rotor
3. Brushes do not bed on slipring
4. Bearing seized

1. Test stator circuit:

Test supply, fuses, switches, measure voltage at the stator terminals, check the
windings as for the cage motor.

2. Test rotor circuit:

Disconnect rotor terminals and measure rotor stalled voltage with the stator switched
on. Compare measured voltage with the voltage specified on the rating plate.
If no voltage is measurable - open circuit in the rotor.
If rotor voltage corresponds to value specified - switch off stator and test sliprings,
carbon brushes and resistances for open circuit.

35

Starting circuit of a slipring rotor with contactor control:

Motor terminal board of a slipring motor:

E.g.:

Stator

Rotor

When inspecting the rotor winding, two windings are measured (in series).
K

in m or

36

Insulation measurement: test windings to earth.

Jerky starting:
-

Starter too small

Starter has burnt contacts or contacts do not make

Starter incorrectly connected

Remedy:
-

Replace starter

Overhaul starter; locate the open circuit with test lamp and bridge or replace starter

Compare starter connections with wiring diagram

Motor has difficulty in starting, speed drops under load

-

Motor is connected in star instead of delta

Mains voltage too low

Voltage drop in cables excessive

Phase and neutral conductors cross connected.

Remedy:
-

After checking rated data on rating plate: reconnect the motor in delta at the terminal
board.

Measure mains voltage, replace transformer if necessary

Check cable cross-sections

Check connections

37

Motor has difficulty starting, loud humming when switched on, motor warms up quickly:
-

Worn plain bearings or fracture in ball bearing; rotor rubs against stator

Remedy:
-

Test plain bearings, ball bearings, shaft clearance; if necessary replace bearing
bushes or ball bearings

When motor is switched on, fuses blow or motor circuit breaker trips
-

Short circuit in cables between switch and stator

Short circuit in cables between starter and motor

Short circuit between turns or phases or short circuit to frame

Short circuit between slip rings

Remedy:
-

Disconnect cables from the terminal board and test insulation, remove any faults found

Disconnect supply cables from the starter, insulate brushes from slip rings with piece
of paper or wood, and test starter cable insulation; remove faults

Detach supply cables from terminal board, and remove links on terminal board; test
insulation between phases and to earth; replace winding

Lift brushes from the sliprings; remove belt from pulley, motor will then idle; repair as
required.

Motor humming loudly at high input; overheating:

-

Stator winding has short circuit between turns or phases

Open circuit in rotor

Remedy:
-

Establish, by touching, whether the winding is heating irregularly, considerable heating

at location of fault indicates rewinding

38

Spasmodic humming and stator current fluctuations

-

Open circuit in rotor

Remedy:
-

Test brushes (brush holders and brush springs)

Measure with voltmeter or test lamp to check that full voltage is present

Test cables between motor and starter

Motor is becoming very hat, motor overhead switch cuts out

-

Overload

Voltage too high or too low

One phase open circuit at terminal board

Circuit incorrect

Short circuit between turns or phases

Fan not working

Incorrect motor rating

Remedy:
-

Reduce load (test with ammeter) or change motor

Test phase with test lamp

Compare circuit with wiring diagram

New winding

Test fan

Use motor according to rating plate

39

8.3

D.C. motors

Jerky running:
-

Bearing damage - Bearing ring or ball bearings

Unbalanced or loose coupling or pulley

Remedy:
-

Replace bearing

Balance armature or replace bush

Motor does not start:

-

Open circuit in the supply cable

Brushes do not bed on commutator

Field winding open circuit

Terminal voltage too low

Bearing seized

Fault in starter

Armature open circuit

Remedy:
-

Test terminals and cables

Remove terminals in brush holder, replace worn brushes

Test field winding

Measure terminal voltage

Replace bearing

Test contacts and connections in starter Check connections on commutator

Test voltage supply, inspect starter and windings (open or short-circuit or earth fault).
Check type of motor, because different types have different characteristics.

40

The different motor types:

Shunt wound motor

Series motor

Compound motor

Faultfinding on separately excited D.C. motor:

(Most commonly used)

First establish whether armature and field voltage are present. Many motor control
systems are provided with field monitoring devices to prevent the armature from taking too
high a current or becoming damaged in the event of field failure. This point must also be
given attention when faultfinding.

41

a)

Testing the field circuit:

Voltmeter at L2+ and L2-, then at F1 and F2, if no voltage is present at F1 and F2, test the
field circuit step by step.
Voltmeter at L2 and terminal t of field control element, then at terminal s, noting the
position of the field control element.
If voltage is present at F1 - F2, test armature circuit and winding FT - F2 for open circuit,
turn-to-turn fault or earth fault.

b)

Testing the armature circuit:

Voltmeter at L1+ and L1-, then at A1 and A2, if no voltage at A1 - A2, inspect armature
circuit step by step.
Voltmeter at L1- and contact L of starter, then L1 - contact R (note position of the starter),
then at L1- and A1, A1 - B2, A1 - B1, A1 - A2.
If voltage is present at F1 - F2 and A1 - A2, and if motor is still not running, check load
and armature.

42

Jerky starting:
-

Starter too small

Starter contacts burnt or not making correctly

Starter incorrectly connected

Short-circuit between laminations

Turn-to-turn fault in armature

Remedy:
-

Replace starter

Overhaul starter

Compare starter connection with wiring diagram

Overhaul laminations

Rewind armature

D.C. motor has excessive sparking at brushes:

-

Motor overloaded

Brushes displaced

Projecting mica an commutator

Out-of-round commutator, dirty

Jerky running, bearing damage

Turn-to-turn fault in the field or inter-pole winding

Remedy:
-

Measure current, reduce load

Test marking of brush position

Mica must be scraped to approx. 0.8 mm below segments with special saw

Rotate commutator, clean and remove oil and dirt

Replace bearing

Replace winding

43

D.c. series motor running too quickly

-

Load too low

Brush gear incorrectly set

Terminal voltage too high

Turn-to-turn fault in field winding

Remedy:
-

Test and increase load

Set brush gear to marked setting

Measure terminal voltage; test mains voltage

Replace winding

Blackening of commutator in places:

-

Lamination short-circuiting

Remedy:
-

Overhaul laminations

Burning out of lamination insulation at one point:

-

Armature coil has become unsoldered

Remedy:
-

Overhaul armature coil.

Motor is becoming too hot:

-

Load too high

Voltage at the terminals too low

Incorrect circuit

Turn-to-turn fault

Fan not operating

Incorrect operating mode

44

Remedy:
-

Reduce load, use larger motor

Measure mains voltage; check cross-section of cables

Compare circuit with wiring diagram

New winding

Test fan Use motor according to rating plate

Motor has difficulty in starting, speed variation under load:

-

Voltage too low at terminals

Excessive voltage drop

-

Turn-to-turn fault

Field incorrectly connected

Earth fault

Remedy:
-

Measure mains voltage

Test supply cable cross-section

New winding in case of turn and earth fault

Test terminal board

8.4

Single-phase transformers

Transformer oil too hot

-

Overloading, note ambient temperature, cooling surface contaminated;

Primary voltage too high

Remedy:
-

Reduce load, install ventilation, clean surface;

Compare voltage with type plate and change transformer

45

High primary current:

-

Short circuit between turns or to earth

Remedy:
-

Switch off load, measure current and voltage on high and low voltage side

Replace winding

No output voltage:
-

Break in secondary or primary winding

No input voltage - open circuit of mains - disconnection at transformer terminals

Remedy:
-

Replace windings

Measure input voltage; replace supply cable

Reduced output voltage:

-

Short circuit between turns or to earth

Remedy:
-

Replace winding

Fuse trips:
-

Short-circuiting

Remedy:
-

Locate and remove fault

46

In parallel operation the following must be remembered:

-

Primary and secondary must have the same voltage

Short-circuit voltages must be the same

Phase angle between high and low voltages is either 0 or 180. If the phase angle is
not the same, only the low voltage connections need be replaced.
If measurement is carried out with a voltmeter, there must be no voltage between two
winding terminals which are to be connected to a conductor on the output side.

Checking the phase position with a voltmeter:

In the case of parallel connection of three-phase transformers, the following must be

remembered:
-

Primary and secondary power ratings must be the same.

Short-circuit voltages must be the same

They must belong to the same switching group, with the possibility of equalising
different characteristics by making suitable terminal connection.
A voltmeter is installed between terminals (phases) of the same name. If this voltmeter
does not indicate a voltage, the circuit is in order.

47

Checking the phase position with a voltmeter:

_ _ _ _ _ Make connections only when voltmeter reads zero

48

9.1

FAULTFIND1NG ON EXCESS VOLTAGE PROTECTION EQUIPMENT

Residual current devices

The supply cable for the equipment to be protected is monitored by a total current
converter for residual current. The equipment casings are earthed. If fault to frame occurs
in equipment thus protected, a fault current flows via earth; the sum of the currents in the
supply cables is no longer 0, and the residual current device operates. The connected
equipment is now protected against contact voltage (UB = 50 V). The switch also protects
against contact of live-conductors to earth (earth fault).

Example of a fault current protective circuit:

49

9.1.1

Faults on residual current devices

Safety switch does not trip

1. Testing the residual current device

When the test knob is pressed, only the switch is tested, not the protective circuit.

Fault - Connection between neutral (N) and protective conductor (PE) after the residual
current device

RB

Operating earth

RS

Auxiliary earth electrode

PE

Protective conductor

Neutral conductor

Outer conductor

If the residual current device falls to trip despite exceeding the rated fault current, this
leads to the conclusion that there is a fault between the neutral (N) and the protective
conductor (PE), after the residual current device. Most of the fault current flows back via
the neutral conductor.
In the event of fault to frame after rectifier circuits, the unidirectional fault current flow may
lead to magnetisation of the core of the residual current device, so preventing tripping.

50

Residual current devices (FI safety switches) bearing the symbol must cut out reliably
even in the event of fault to frame after rectifier circuits (pulsating direct fault currents).

2. Testing the residual current

Fault - Defective insulation before the residual current device

RB

Supply earth

RS

Auxiliary earth

PE

Protective conductor

Live conductor

Neutral conductor

An insulation fault between the outer and protective conductor occurs before the residual
current device. An earth leakage current flows via the earth electrode and an earth
electrode voltage is generated. The residual current device does not trip.
To avoid such faults in the area of the residual current device, the protective conductor
before the residual current device should not installed together with the supply cable in
one conduit.

Safety switch trips:

One reason for this might be a connection between neutral conductors in different residual
current circuits behind the safety switch. In this case possible fault currents are distributed
in any neutral conductors, and this may lead to undesirable tripping of a safety switch.

51

Safety switch trips too early:

This means that it trips before the permissible tripping range is reached. Either the
protective conductor is defective, or the system already has a certain basic fault,
producing a current below the release current. This occurs in measuring circuits where the
basic leakage current is added to the test current supplied by the measuring instrument
therefore the safety switch trips earlier.

If the residual current device has tripped, all poles of the supply are disconnected. This
means that the circuit in which the fault has occurred cannot be identified immediately. All
the circuit breakers are now switched off or all the fuses are unscrewed, and the residual
current device is reset. One of the circuit breakers is now switched in, or a fuse is screwed
in until the residual current device trips again. The defective circuit is now identified.
The main circuit breaker is now switched off or the fuse unscrewed, and the residual
current device as well as the remaining circuits which have no faults are connected.

In the defective circuit switch off all current using equipment, if plug-in pieces of
equipment are being used, unplug them and reconnect the circuit. If the residual current
device now holds, one of the pieces of equipment is defective. If the residual current
device fails again, the circuit must be examined with insulation testers and the circuits
sub-divided at the terminals to isolate the fault. The insulation of the N conductor must
also be tested.

Damp and wet areas are particular sources of faults. Sometimes faults occur where the
residual current device trips irregularly. In this case install a device with a lower tripping
current, these trips more easily and faultfinding is therefore simpler to carry out.
If the residual current device repeatedly cuts out and all the circuit breakers are switched
off; this indicates a fault between neutral and earth!

52

WARNING
The fault current release value of the residual current device may only be changed if
permitted by the earthing condition of the system, i.e. a higher fault current release value
requires a lower system earthing resistance.

9.1.2

Testing circuits

Testing the residual current device

-

on single-phase alternating current:

on three-wire three-phase current:

53

9.2

on four-wire three-phase current:

Protective earthing conductors

In protective earthing, the casings of the equipment to be protected are connected via a
protective conductor to a suitable earth electrode.

1. Fault current flows back through the ground

It must be remembered that the specific earth resistance varies due to seasonal climatic
fluctuations (dry weather, wet weather).

54

2. Fault current flows back via a metal water pipe network to the electricity generator or
transmitter (e.g. in shipbuilding).

If fault to frame takes place in protectively earthed equipment, a high current flows via the
fault location and the protective earth electrode to the supply earth of the network, and the
series-connected fuse cuts out. If several Current using units are protected by a single
fuse, the fault must be located by measuring the insulation resistance to deter- mine which
of the current using units is defective.

9.3

Protective earth and neutral conductors (PEN)

The cases of the equipment to be protected are connected to the PEN conductor. Short
circuits to frame on equipment employing PEN conductors causes the series-connected
fuse to trip, for a large current flows through the fault and the PEN conductor.

PEN System
In the event of fault to frame the fault current flows
through the PEN conductor. In cables having a cross
section of less than 10mm2, the PEN conductor must
be divided into an N and a PE conductor (on the right
in the diagram).

55

The risk of conductor breakage is avoided by division in the case of small conductor
cross-sections. The PE and N conductors must not be reconnected after the division.

Example of PEN conductors in a three-phase four-wire network (standard system):

Example of PEN conductors in a three-phase four-wire network. The neutral and

protective conductors are laid separately. (No current normally in the PEN conductor).

56

Like protective earthing, PEN systems require a low earth resistance

"PEN system" by connecting the system components to be protected to the neutral

conductor (normal system)

PEN

Protective earth and neutral conductor

Ra

supply earth

Li .. L3

Line conductors

HA

supply connection

During installation the fuse in the defective circuit blows. It must then be checked whether
the current using unit is short-circuiting or has an earth fault. If several current using units
are protected by a
single fuse, the fault must also be isolated between the units, i.e. disconnect the units,
check the insulation resistances of each unit with suitable measuring instruments until the
fault is found.

9.4

Protective multiple earth systems (IT systems)

A high degree of operational safety is achieved with the protective cable system (e.g. in
operating systems).

57

Layout example of a protective cable system in a three-phase three-wire network:

If fault to frame occurs, a fault current flows due to the insulation and capacitance
condition of the network. No contact voltage occurs due to the connections of the
protective conductor to the numerous earth electrodes. For immediate location of the fault
to frame the mains - earth insulation condition is monitored (signal is received in the
control room). The fault must then be removed as quickly as possible.
The rise in voltage in fault-free conductors increases the possibility of a second fault to
frame. This causes the equipment with the least protection to be disconnected.
The double fault to frame (earth short-circuiting) then becomes a single fault again.

Protective cable system with a 2-voltmeter circuit for insulation monitoring:

58

Fault

V1

V2

None

approx. half

approx. half

phase voltage

phase voltage

Phase voltage

Phase voltage

Phase voltage

Phase-to-phase

Earth fault
of N
Earth fault
of L1
Earth fault
of L2
or L3

voltage

The first fault is indicated by the monitoring system, but there is no indication of where the
fault is located.
The faultfinding is carried out by measuring the total current of the individual circuits from
the supply transformer. Since an earth fault gives rise to a fault current (albeit small), the
sum of the currents in the outer conductors and the neutral conductor is no longer zero
(1st law of Kirchhoff).

The individual circuits are measured until the damaged circuit is found.
A second possibility would be to switch off the individual circuits and observe the
monitoring device until it no longer indicates a fault, but this procedure is not often
possible because of operational breakdown.

59

10 FAULTFINDING ON RECTIFIER CIRCUITS

Testing of voltages U1, U2, U- with voltmeter and oscilloscope for open circuits.
Compare the measured voltages U1, U2 with the data on the type plate.

If the transformer voltages conform to the specifications, the fault lies in the diodes. Each
diode must then be checked individually (oscilloscope).
If a pulsating d.c. voltage is present, but no smoothing is visible, the capacitor is defective.
Diodes and capacitors can only be replaced.
In most cases the r.m.s. value is indicated on the transformer, and the value measured
with an oscilloscope is the peak to peak value Uss.

10.1 Testing power semiconductors with an ohmmeter

In most cases a defective power semiconductor can be checked with an ohmmeter (1.5 V
battery in ohmmeter).

Diodes:
Disconnect to measure values. Apply a threshold voltage of approx. 0.7 V in the forward
direction. If the measurement is carried out so that the positive pole of the ohmmeter is
located at the anode of the diode to be tested, the resistance value must be lower than
that in the reverse direction.

60

If the positive pole is located at the cathode, the instrument indicates a very high
resistance value. If the diode is destroyed, a low resistance value is indicated in both
directions.
If the diode has a high resistance in both directions, there is an open circuit and the diode
must be replaced.

Thyristors:
These can have a high resistance in both directions. If the thyristors are intact, the
Instrument does not show any deflection in either direction, but if the thyristors are
destroyed, 0 ohm can be indicated.

If a power semiconductor is defective, it can only be replaced by the same type.

The following data must be observed:

-

Type designation

Inverse voltage

Release time

Permissible voltage and current rise time

10.2 Testing power semiconductors with an oscilloscope

Among other things, the following is of vital importance to a rectifier circuit:

-

the output voltage supplied by the circuit

the voltage drop under load

the amplitude of the superimposed a.c. voltage (hum voltage)

the testing of diodes, if possible at rated voltage.

The following knowledge is required for designing a rectifier circuit:

-

Average forward current

Peak current

Max. inverse voltage at the diodes

Internal transformer resistance

61

In addition to the arithmetical mean value and r.m.s. value, the peak factor S, the form
factor F and the ripple W are also frequently used to determine the raw D.C. voltages and
direct currents.

10.2.1 Half-wave rectification

Distribution of A.C. voltage between load and rectifier:

Voltage and current waveforms for load:

This circuit is used for rectifying low currents.

62

10.2.2 Full-wave rectification (centre tapped transformer)

Transformer voltages

Voltage and current waveforms in the load:

This circuit is used for rectifying low currents.

63

10.2.3 Bridge circuit

Transformer voltage U2 (A.C):

Output voltage of the bridge circuit (voltage across load):

This circuit is most frequently used for powers of up to 2 kW.

1. with smoothing choke

64

a)

Waveform of the load voltage ua

b)

Inductance opposes all variations in the current, and so smoothes it.

The load current ia is continuous.

10.2.4 Three-phase Bridge circuit

This circuit is used most frequently for powers of over 2 kW.

65

EE082 - Fault Finding in Electrical Control

Systems

Theoretical Test

66

FAULTFINDING IN ELECTRICAL CONTROL SYSTEMS

TEST 1

1. What are the safety rules when carrying out work on electrical systems?

2. What is the rescue procedure in the event of electrical accidents particularly for
release from the circuit?

3. What types of faults are there?

4. In the sketch below, draw circuits to illustrate the following: earth fault, short-circuiting
and fault to frame.

5. With reference to insulation testing in an installation, name the individual insulation

resistances which should be measured.

6. State the order in which the faultfinding procedure is carried out.

7. Name two types of faults which can occur on electrical hand tools and machines.

67

8. Name three faults which could cause a motor overload to trip when a cage motor is
switched on?

9. State three possible causes and their remedies, if a slipring motor does not start.

10. State four reasons for a motor overheating.

11. What fault causes the residual current device to trip?

12. State

briefly,

how

faults

on

power

diodes

can

ohmmeter, giving the method of connection to the ohmmeter.

68

be

checked

with

an

FAULTFINDING IN ELECTRICAL CONTROL SYSTEMS

TEST 2

1. State the range of voltages and currents which can be dangerous to man. In the
sketch below, draw in the current and voltage paths which would be highly dangerous.

2. Explain the difference between a fault to frame and short circuiting.

3. Name and describe three types of faults which may occur in windings.

4. Name five items of test and measuring equipment used for faultfinding, and state their
uses.

5. The following faults occur on fluorescent lamps:

1. Lamp does not come on
2. Lamp does not come on, starter switches continuously
3. Lamp lights brightly and fails to come on again

State the causes and their remedies.

69

6. State three causes of a cage motor failing to start.

7. State two possible faults if a cage motor with star-delta starting will only start in the
delta connection.

8. State the causes and their remedy when a slipring rotor starts jerkily.

9. State five causes and their remedies, when a D.C. motor fails to start.

10. Why does excessive brush sparking occur?

11. State three types of faults which occur on the transformer.

12. State two faults which can cause the fuse or the power circuit breaker to operate.

70

FAULTFINDING IN ELECTRICAL CONTROL SYSTEMS

TEST 1
(Solution)

1. Switch off at all poles and on all sides.

Protect against accidental switching on again.
Test for freedom from voltage.
Earth and short-circuit.
Cover adjacent live parts and protect danger point.

Connection is carried out in the reverse order.

2. Switch off the supply.

Remove the victim from the circuit.
Apply first aid immediately.
Inform doctor, rescue service and police.

up to 1000 V:
4. switch off supply
5. in the case of portable equipment, remove plug from socket.
6. in the case of fixed equipment, switch off consuming units and disconnect cable.
7. remove all fuses.
8. place victim on insulated surface out of the danger area.

over 1000 V:
9. the equipment must be switched off.

3. Open circuit, fault to frame, short-circuiting, earth fault, short circuit between turns,
phases.

71

4.

1 = Short circuit

2 = Fault to frame

3 = Earth fault

5. Conductors to earth, conductor to conductor and system to earth should be measured.

In the case of PEN systems the neutral to PEN conductor resistance is measured.

6. The following are tested: Connections to mains, load, remote Connection to mains,
load, remote control system or control system
Check whether the fault occurs when the current using units are disconnected

Either fault in current

Fault in supply cable or

using unitsvoltage supply

Either current using unit is

Switches, terminals, transformers

tested for mechanical and

etc, are- tested

electrical
Motors, Iamps,...

7. Mechanical faults (bearings, chuck in drilling machines, gears) Electrical faults

(conductor interrupted, etc...)

72

8. -

Rated release current set too low

Switching on and off too frequently

One phase missing

Short circuit between turns or phases

9. -

Break in supply cable (test fuses and motor safety switch)

Break in stator circuit (After switching off, loosen connections on terminal board,
and examine windings, replace stator winding if necessary).

Break in rotor circuit (inspect brushes and rotor resistances, test rotor winding,
replace if necessary).

10. -

Bearing seized (replace bearing).

Voltage too high or too low

Incorrect circuit

Incorrect operating mode

Ventilation obstructed

Motor circuit breaker set too high etc.

11. A fault to frame or earth fault

12. Diode:
Measurement in forward direction (positive pole of measuring instrument connected to
the anode) - relatively low resistance. Measurement in reverse direction (positive pole
of the measuring Instrument connected to the cathode), a high resistance is indicated.
If a low resistance is measured in both directions, the diode is destroyed.

73

FAULTFINDING IN ELECTRICAL CONTROL SYSTEMS

TEST 2
(Solution)

1. At voltages over 50 V and current over 50 mA conditions are highly dangerous

2. The fault to frame is caused by a conducting connection between a conducting part of

the operating circuit and a conducting part which does not belong to the operating
circuit.
In short-circuiting there is a conducting connection between live operating parts.

3. Conductor break - one strand is- broken

Earth fault - Contact between winding and laminations or casing
Turn-to-turn fault - Contact between two turns of a coil
Phase-to-phase fault - Contact between two winding lines

4. Ohmmeter - Cable open circuit, examine power semiconductor Resistance measuring

bridge (Wheatstone bridge) - measure winding resistance

74

"Prufrex" (Growfer) - Testing armatures, and for short circuited turns

Insulation meter - Earth, phase-to-phase contact
Voltmeter, test lamp, Duspol - Voltage testing
Rotary phase sequence indicator - testing the phase sequence for three-phase current
Oscilloscope - Voltage measurement in rectifiers

5. Lamp does not come on:

-

Mains voltage too low

should be greater than 190 V

Lamp defective

replace

Break in circuit

test contact unit, terminals

Starter damaged

replace

Lamp does not come on, starter switches continuously

-

Starter is in the supply cable

between lamp and
ballast

alter circuit

Lamp burning voltage too

high; end of lamp life

replace lamp

Lamp burns brightly then does not come on again

-

Turn-to-turn fault at
ballast

replace

Incorrectly chosen ballast

must conform to lamp

Connection to d.c. voltage;

is only possible with

choke ineffective

resistance

Voltage too high (e.g. 380 V);

alter circuit

connection to two outer

conductors

6. This fault occurs in the supply cable (motor safety switch has tripped), break in the
stator and rotor circuit, or due to seized bearing.

75

7. Either the star-delta contactor has a contact break, or the torque in the star connection
is so low that the working machine cannot be started.

8. Starter too small replace

Starter has poor contact locate open circuit with test lamp;
either bridge the contact or replace starter.
Starter incorrectly connected - compare with wiring diagram.

9. Break in the supply cable - test terminals and cables

Brushes do not bed an commutator
Replace brushes if necessary.
Field winding interrupted - test
Terminal voltage too low - measure
Fault in starter - test contacts and connections
Bearing seized

replace bearing

10. Brush sparking occurs where the commutator is out of round or if it is clogged with oil.
Also when the motor is overloaded, displaced brushes, turn-to-turn fault in the field or
inter-pole winding, and when the bearings are damaged.

11. Transformer oil overheating - due to overloading or too high connection voltage
high primary current - turn or earth fault
low voltage - partial turn-to-turn fault

12. The fuse or cable safety switch trips in the event of short-circuiting and overloading.

76

KEY TO EVALUATION

PER CENT

MARK

88 100

75 87

62 74

50 61

0 49

77