INTRODUCTION OF OPERATIONS, MAINTENANCE & TROUBLESHOOTING OF ELECTRICAL – AC AND DC MOTORS

The key to minimizing motor problems is scheduled routine inspection and service. The frequency of routine service varies widely between applications.

Including the motors in the maintenance schedule for the driven machine or general plant equipment is usually sufficient. A motor may require additional or more frequent attention if a breakdown would cause health or safety problems, severe loss of production, damage to expensive equipment or other serious losses.

Written records indicating date, items inspected, service performed and motor condition are important to an effective routine maintenance program. From such records, specific problems in each application can be identified and solved routinely to avoid breakdowns and production losses.

The routine inspection and servicing can generally be done without disconnecting or disassembling the motor.

COURSE OVERVIEW

This course is industry designed, to provide a broad understanding of the improvement methodology, concepts, and process. The methodology is presented with case studies and examples drawn from service, business process and manufacturing applications. With a heavy practice orientation, as much as a third of your time will be spent working through interactive practical exercises and assessments. This course is designed as an introduction to concepts and methodology.

• What types of AC and DC motors commonly used.
• Identification and construction of motors.
• How to connect a multiple speed motor or a dual voltage motor for operation.
• Motor nameplate information and how it is used.
• The duties and training needed by motor maintenance personnel.
• A simplified explanation of a complex subject.
• How to operate a motor for forward or reverse operation.
• Motor braking methods.
• Requirements for motor installation.
• How to use test equipment to check motor operation.
• Troubleshooting and maintenance procedures for motors.

COURSE OBJECTIVES

This training program is designed to provide an understanding of engineering related problems related to industry globally and a clear sense of what is required to effectively  structure, establish measurements and solve problems. Participants will learn the goals and deliverables behind the solutions. Methodology as well as the most commonly used tools within each phase will be discussed. Participants will also learn how to support a problem solving initiative within their organization.

LEARNING OUTCOMES

On successful completion of this course, the participant should be able to:-

• Understand the benefits and implications of motor problem solving programs, and relate the concepts to the overall business mission and objectives.
• Think about his/her organization as a collection of processes, with inputs that determine the output.
• Use the concept of motor systems engineering problem solving to evaluate the capability of a process or organization.
• Recognize the engineering problem solving model used to improve processes.
• Recognize the organizational factors that are necessary groundwork for a successful engineering problem solving program.
• Integrate the motor systems engineering problem solving program effort with other process improvement initiatives.
• Understand how to improve the efficiency of electric motors to reduce downtime.
• Cross-train nonelectrical maintenance personnel for increased versatility.
• Eliminate the need for outsourcing repair.

TRAINING METHODOLOGY

• The latest educational methods and strategies will be utilized.
• The course is designed to maximize delegate participation.
• Questions and answers are encouraged throughout and at the daily wrap-up sessions. This gives participants the opportunity to discuss with others and the presenter their specific problems and appropriate solutions.
• The course shall be conducted through lectures, case studies, group discussions and exercises to reinforce participant’s learning.
• Learn everything from basic operational theory to the actual operation of various types of AC and DC motors.

TARGET AUDIENCE

Manufacturing, process, executives, managers, maintenance personnel, operational managers etc.

COURSE FORMAT

The course consists of formal content presentation interspersed with content quiz sessions. The presenter’s style involves intensive participant participation.

COURSE CONTENT

Day-1

Basic Motor Theory

• Magnetism, construction, induction, rotation

Nameplate Data

• Voltage, phase, FLA, frequency
• RPM, horsepower, duty, design, code letters
• Service factor, insulation, temperature
• Frame, connections, efficiency

Three-Phase Motors

• Wyes, deltas and leads
• Dual voltage connections
• Squirrel cage, synchronous, wound rotor

Single-Phase Motors

• Capacitor-start, permanent-split, shaded-pole, split-phase, repulsion and universal
• Dual voltage and multiple speed connections

Introduction to Servo Motors

• Servo Motor Control
• RC Servos
• Servo vs. Stepper motor
• Controller Settings

Introduction to Stepper Motors

• Cross Section of a Stepper Motor
• Full Step Operation
• Half Step Operation
• Six pole rotor, two electro magnets
• Practical Stepper motor operation
• Stepper motor applications

Day-2

Fundamentals of Troubleshooting and Replacing Motors

• Overview of operation and types of electric motors
• Test equipment for rotating electrical equipment
• Troubleshooting checks for rotating electrical equipment
• Selecting replacement motors
• Understanding Motor Nameplate Data

Safety Issues for Troubleshooting and Replacing

• Hazards of Rotating Electrical Equipment
• OSHA Lockout/Tagout Requirements for Electrical Equipment
• Determining motor power supplies and voltages
• Using the multimeter to verify circuits de-energized (including PPE requirements)
• Visual Inspections of Motor Disconnects
• Control Circuit Operation to further verify safe working condition

Motor Replacement Procedure

• Verification of safe working condition
• Properly terminating motors including marking of leads
• Coupling removal
• Motor removal
• Setting replacement motor
• Overview of shaft coupling/alignment procedure options
• Electrical checks on replacement motors before termination
• Verification of proper size line conductors
• Determining proper connection scheme using nameplate data
• Selecting the best method of motor termination
• Lugs and insulation tapes for termination
• Termination kits
• Methods of verifying proper phase rotation
• Lubrication requirements
• Sizing fuses and overloads
• Final checks prior to re-energizing motor
• Electrical, visual and mechanical checks during motor operation

Industrial Applications:- Case Study 2

• Checking for open motor windings
• Insulation Resistance testing of motors
• Visual and mechanical examination of motors
• Use of phase rotation meter
• Visual Inspection of Motor Disconnects and Motor Control Centers (MCC’s)
• Locating and verifying power supplies
• Using the multimeter to verify circuits de-energized
• Termination procedure practice

Question &Answer Session

End of Workshop

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