NRE 8 Appliance Motors Package PDF

Three Phase / Single Phase Motors &Circuits
NRE 8
Student Resource Package No: NRE8.

Competence in this training program can be achieved
Delivery:
through either a formal education setting or in the

workplace environment.
Recognition of Prior Learning:
The student/candidate may be granted recognition of

prior learning if the evidence presented is authentic
and valid which covers the content as laid out in this
package.
This package provides the student with the
Package Purpose:
underpinning knowledge and skills to identify and test

three / single phase motors and their associated
power / control circuits. In addition the operation of
three phase motors, contactors, thermal overloads,
single phase motors and their starting devices.
Suggested Resources:
Australian Refrigeration and Air Conditioning Vol 1&2.

Electrical Principles for the Electrical Trades, J.R.
Jenneson
Assessment Strategy:
The assessment of this package is holistic in nature

and requires the demonstration of the knowledge and
skills identified in the student package content
summary. To be successful in this package the
student must show evidence of achievement in
accordance with the package.
NRE 8 Three Phase/Signal Phase Motors and Circuits

Compiled by Bruce Davison, Greg Riach & Robert Baker
Assessment:
Grade Code:
72
GRADE
CLASS MARK (%)
DISTINCTION
CREDIT
PASS
>=83
>=70
>=50
Assessment Events:
1.
2.
Practical Test
Theory Test
20/40
40/40
50%
50%
Practical Test:
Simulated practical exercises in regards to three phase motors, single

phase motors, DOL contactors and associated circuits..
Theory Test 1:
Short answer Questions, multiple choice questions.

This assessment covers the contents from sections 1 to 9 in the student
resource package.
Summary of Contents:
Page No
Delivery & Assessment Details:
Section No: 1
Three Phase Electrical Systems:
Section No: 2
Common Motor Information:
Section No: 3
Three Phase Induction Motors:
17
Section No: 4
Three Phase D.O. L. Motor Starter:
26
Section No: 5
Three Phase Motor Protection:
35
Section No: 6
Split Phase, motors Starters and Overloads:
41
Section No: 7
Capacitor, Shaded Pole & Synchronous Motors:
50
Section No: 8
Series Universal Motors:
57
Section No: 9
Servicing Motors and auxiliary equipment:
60
Answers to Review Questions:
64
End of Package Assessment:
70
This package is designed as a self paced package with all relevant information and
references contained. At the end of each section there are a number of review
questions which require responses. (Answers to Review Questions page 64).

Competence in this training program can be achieved through either a formal
Delivery:
education setting by completing the attached student resource package or in

the workplace environment.
Prerequisite:
The following resource packages or equivalent is a prerequisite:
Occupational Health & Safety (7793T)

Refrigeration Electrical 1 & 2.(NRE 1 & 2)
Refrigeration Electrical Wiring (NREW)
Recognition of Prior Learning:

The student/ candidate may be granted recognition of prior learning if the
evidence presented is authentic, sufficient and valid which covers the content
as laid out in this package.
Competency:
Upon successful completion of the Occupational Health & Safety (7793T),
Refrigeration the: Electrical 1& 2 (NRE 1&2), Refrigeration Electrical Wiring
(NREW) and Three Phase / Single Phase Motors & Circuits training programs
you will be assessed against the following competencies:
UTE NES208EA:
Disconnect & Reconnect fixed wired electrical
equipment (up to 1000Volts).
UTE NES 209EA:

Attach flexible cords and plugs to electrical equipment
connected to 240 volt supply
UTE NES 210EA:

Attach flexible cords and plugs to electrical equipment
connected to a supply up 1000 volts AC ( Three phase 415)
UTE NES106EA:
Install electrical/electronic apparatus and associated
circuits, refrigeration and air conditioning.
UTE NES 206EA

Maintain and repair electrical/electronic apparatus
and associated circuits, refrigeration and air conditioning.
UTE NES505EA
Locate and rectify faults in electrical equipment
intended to operate off fixed wired supply up to 415 volts A.C.
Suggested Resources:
Jenneson, JR., 1995, Electrical Principles for Electrical Trades, McGraw Hill, Sydney.
Australian Refrigeration and Air Conditioning Volume 1 & 2.

Section No: 1
Three Phase Electrical Systems:

Purpose: The purpose of this section is to provide you with the underpinning knowledge and
skills to identify and test three phase voltages, currents and three phase electrical connections.
Reason for Study. In the HVAC&R industry three phase is mainly used to power electric
motors because:
Three phase motors have greater outputs for their physical size.
Three phase motors have more uniformed starting torque.
Three phase motors are self-starting. (See later notes).
Three Phase systems require less copper in conductors to transmit the power, i.e. P=VI and
if the voltage is 415 less current is needed to make the same power as 240V. Less current
means smaller conductors.
At this stage you should be familiar with:
Production alternating current.
Ohms Law.
Impedance.
Resistive, Inductive and Capacitive Circuits.
Power in Single & Three Phase Alternating Circuits.
Note:
Reference to Refrigeration Electrical 1 & 2 may be necessary to revise single

and three phase alternating circuits and their characteristics, before the
commencement of this student resource package.
Three Phase Electrical Production:

Revision
Three phase voltage is produced with a device called an alternator.
The alternator has three sets of windings, mechanically fixed 120 electrical degrees to each
other which when passed (rotated) through a fixed magnetic field will produce an
Electromotive Force that is proportional to the strength of the magnetic field and the speed that
the windings pass through the field.
The current available from the alternator is limited by the cross sectional area (size) of the
conductor in the alternators windings. Because there are separate voltages, each one can be
used as a single phase power source provided a neutral connection is available.

Types of three phase connections:

References:
*
ARAC page 14.7.
*
J.R. Jenneson chapter: 11, Page 218 221. Electrical Principles For The Electrical
Trades
There are two ways three phase can be connected to form a working system;
Star (Y)
Delta ( )
Star connection (Y) Sometimes referred to as the WYE system for electric motors.
The star connection is formed, by connecting three similar ends of the windings together as
shown in Fig.1. Either the start or the finish ends of the windings can be used but not
dissimilar ends.
Note: the common
connecting point is
called the star
point.
Fig 1
Star Systems; This is the way three phase is delivered to the consumer. The delivery system
is referred to as a four wire system because there are the three phase cables and the neutral.
The three actives (lines) usually referred to as phase A. B. or C. they have a colour
code of Red, White and Blue and the neutral is Black.
The voltage between these three actives is called the Line Voltage and the current
flowing through the lines is referred to as the Line Current.
The Line Voltage is not equal to the Phase Voltage because two windings are connected in
series with two Line Voltages.
Line Voltage (V line) = 415volts
Formula:
Vline 415V
Phase Voltage (Vp) = 240volts
Vp
Vline
3
Note: for calculation purposes
Vp
415
1.732
Vp 240volts
The line current equals the phase current.
Where:
I line = line current
I p = phase current
Formula:
Iline Ip

Delta connection ()
The windings of a three phase alternator can also be connected in delta as shown below. The
delta connection forms a closed loop with dissimilar ends joined together with the line cables
joined at these junctions. (fig 2)
Fig 2
In a Delta connection, each phase winding is connected across two line voltages and therefore
the line voltage equals the phase voltage.
Vline Vp
The line current in a delta connection is a combination of the phase currents. If the phase
currents are all equal, then the line current is equal to;
3 x phase current or simply put: I line = 3 x I phase
Consumer Electrical Supply in Australia.

In Australia the three-phase power is delivered to the consumer via a four wire Star connected
system. The Delta does not have a neutral and is not used much as a commercial system, but
is used to transmit high voltage around Australia to consumers transformers. The
transformers high voltage side is internally connected in Delta and the low voltage side is
internally connected in star, so that the consumer can have the four wire system.

Electrical Power:
The amount of power consumed by a three phase load is determine by using the following
formula:
P = 3 x V x I x pf
Where:
P = power in watts or kilowatts (w or kW)

3 = 1.732
V = voltage in volts
I = current in amperes
pf = power factor (0 to 1)
Example:
A 415 volt three phase motor draws 6.5 amperes with a power factor of 0.84.
Determine the total power consumed.
P = 3 x V x I x pf
P 1.732 415 6.5 0.84

P 3924.5watts or 3.925kW
Note: the power consumed is measured and charged as a kilowatt hour kWHr
Example:
If the above motor operates for 24 hours and the cost per kWHr is 12 cents
determine the total cost of operation over 24 hours.
Total cos t kW cos t / kWHr time

3.925 12 24
1130.4cents
100
$11.30
Service Points.
Remember to check the voltage on all three phases, 415 volts between phases, and 240
volts to earth.
When testing the supply always check at a non-load point. i.e. at the input terminals of
the contactor.
The supply voltage should not be below 5% of the rated voltage. Check for continuity
of supply at the terminals of the device it is powering. i.e. the motor terminal block. It
must be the same at no load and full load, and within 5% of the rate voltage on the
nameplate of the device it is supplying.
Symptoms of low voltage supply.

Motor overheating.
Extra noisy motor.
Motor fails to start.
Overload tripping when motor not loaded.
Causes of low voltage

Dirty contacts, or loose terminals.
Supply from the electrical authority.
Overload building wiring.
Always tong amp test at least two of the three phases although it is best to tong all
three. They should be the same value and no greater than the Full Load Amps on the
nameplate of the device it is supplying.
Set the meg-ohmmeter to 1000V when testing three phase motors.
1. A reading less than 2Mohms indicates a burnt out motor.
2. A reading less than 25Mohms indicates moisture in the motor.
3. A reading greater than 25Mohms generally indicates no short to earth, but
remember a motor starts with infinity resistance so anything less means it is
wearing out.

When working with electrical circuits you should always analyse and assess
any possible risks that may affect you or any other person within your
working environment.
Therefore the total cost over a period of 24 hours equals: $11.30
Review Questions Section No: 1

Q.1
List the two methods of connecting a three phase systems?
Q.2
Can a single phase motor be connected into a three phase electrical supply system
and are there any additional requirements:
Q.3
What is the line and phase voltage of a three phase delta system?
Q.4
A three phase delta supply draws a phase current of 5 amperes from a 415, volt 50 HZ
power supply. Determine following in the space provided:
line voltage
phase voltage
line current
phase current:
A star connected 415 volt three phase motor draws a phase current of 3.6 amperes.
Determine the following: in the space provided:
line voltage
phase voltage
line current
phase current:
Q.5

Section No: 2
Electric Motors, Common Information
skills to identify, disconnect, diagnose and service various types of single and three phase
motors which are commonly used in the refrigeration / air conditioning industry.
Reason for Study: The A.C. electric induction motor is rugged and has a high degree of
reliability, and because of these quantities they are the most common type of motive force
used in refrigeration.
Introduction
The induction motor gets its name from the fact that the current that causes the magnetism in
the rotor is induced it is not drawn directly from the supply
Construction.
Stator
The stator is the magnetic field producing stationary part
of the motor and is made up of laminated steel
punchings with slots cut to accept the windings. The
slots are insulated with thick paper type insulation
(leatheroid), which acts to prevent the windings
conductors from rubbing against the steel laminations as
the magnetic flux cause everything to vibrate. Each
lamination has a build up of oxidized metal on one side
so that when they are placed together the oxidized
surface will create an area of high reluctance for the
Stator is for an Hermetic compressor.
magnetism produced by the stator windings, this then

gives each lamination its own magnetic field, as opposed
to a solid steel block having one magnetic field.
Windings; The windings are made from varnish

insulated copper wire, which is wound as coil sets,
the number of coils in each set is determined by
the number of magnetic poles in the motor. Single
and three phase motors have different numbers of
coils for the same number of poles.

Rotor / Shaft
The rotor is also made from laminated steel
punchings for the same reasons as that of the
stator. The rotor is designed to fit neatly in the
stator so that the air gap between it and the
stator is kept to a minimum. The closer they are
together, the greater is the magnetic attraction,
because air gap has a higher magnetic
reluctance.
Squirrel Cage Rotor

It will be a rare occurrence to
find any other type of motor
being used in refrigeration
other than the Squirrel Cage
Induction Motor.
The holes that accommodate the conductors are

often skewed across the curved surface of the
rotor to help with the inductive process during
starting. It also helps reduce the magnetic
humming noise.
The shaft and rotor are supported by ballrace
bearings mounted in the endplates.
Types of Rotors
Squirrel Cage; gets its name from the shape that
the rotor conductors form without the laminations.
The rotor conductors are mainly made from solid
aluminium which is cast into the laminations when it
is manufactured although there are some made from
solid copper.
The only insulation between the rotor conductors
and the laminations is the oxide on the aluminium
that comes from the casting.
Insulation is not necessary because the induced
voltage on the rotor is very low, but the current is
very high to produce the required magnetism.
The rotor bars are short circuited together so that
the induced EMF has a circuit in which the current
can flow. The rotor has low resistance that allows high starting current, to create the starting
torque.
They are available in a number of designs that provide different starting torque characteristics
by having different widths for diameter and closeness of the rotor to the stator.
Advantages of a squirrel cage motor include:
simplicity and rugged construction
No sparking contacts in the motor so they can be used in explosive atmosphere

(provided; the appropriate enclosure is used).
Wide range of shaft speeds (when used with electronic frequency controllers).
Disadvantages of squirrel cage motor include:
Relatively poor starting torque
Fixed characteristics.

10
Wire Wound (slip rings); (normally three phase), has a rotor winding the same
as the stator, except that one end of the coil windings are connected in star,
and the other ends are brought out through slip rings and brushes to an
external circuit, where equal but variable resistance is connected to the rotor
windings. The resistance is decreases as the speed increases. This limits the
starting current, increasing the starting torque.
They are not used much in refrigeration industry because of their cost and
their complex control.
Synchronous Motor; is not an induction motor and it is not the power tool
motor. It has a stator the same as the induction motor but the rotor is wire
wound with each individual coil leads attached to a segment of a commutator.
Now the rotor is now referred to as an armature. Both the stator and the rotor
are supplied with A.C., and because of the way the windings are connected to
the commutator on the rotor the A.C. is converted to D.C. for the rotor
windings which will create a constant position magnetic field on the rotor. The
constant position magnetic field reacts directly against the rotating magnetic
field. This combination causes the shaft to rotate at synchronous speed, and
has its strongest torque at synchronous speed.
Sometimes used to correct power factor as it causes the current to lead the
voltage, other than that not used in HVAC&R industry.
Small Synchronous Motors, however small synchronous are used
extensively in the industry for timer motors because they keep accurate time,
and small modulating motor systems. They use permanent magnets in the
rotor instead of the DC supplied magnetic field.
Synchronous motor used on a domestic defrost timer

11
Frames
The frame (motor housing), carries the stator and is also the mounting for the end shields (end
plates), that house the bearings.
It is also the means of sercuring the motor to what it
is driving.
There are several different types of frames;

Open, which means you can see the rotor and stator
windings from outside.
Drip proof that has a closed upper half, while
allowing ventilation through the lower half.
Drip proof
Weather proof is designed to be out in the rain.
Weatherproof motor frame
Hose proof types they are designed to prevent the entry of forced
water.
Flame proof, meaning any burnout will be contained within the frame enclosure.
Whenever you are servicing an electric motor, check that all the mounting bolts are secure
and that there are no cracks in the frame or its mountings. Electric motors must be held
down firmly, for they develop large amounts of torque which strains the mounting points,
and will twist the frame if it is not secure.

12
Basic Operation of an Induction motor.

At the instant of start up an induction motor is
a transformer, because as the electricity is
applied to the stator winding its magnetic field
will spread out cutting through the rotor
winding inducing a large current but low
voltage (step down transformer). The
magnetic field produced in the rotor is
opposite to the stator field, so the rotor will not
turn (unlike poles attracted fig 1).
To make the rotor turn, a force is needed to
make the rotors magnetic poles to be out of
alignment with the stator. (fig 2).
The following text describes the different types
of induction motors and how they cause the
stator and rotor magnetic poles to misalign
and start rotation.
Types of Motors and equipment covered in the
following text.
1. Basic Motor Information.
2. Three Phase Motors.
Contactors.
Overloads
Motor Starters
3. Single Phase Motors
Shaded Pole.
Split Phase.
Capacitor Start Induction Run.
Capacitor Start Capacitor Run.
Permanently Split Capacitor.
Synchronous.
4. Single Phase Motor Starting Relays

5. Single Phase Motor Overloads
6. Servicing of all the equipment.

13
Nameplate Information
Power
This is the rated shaft power, not the electrical input. The electrical input should be more and
the difference between the two is regarded as losses for electric motors. The losses can be
either electrical or mechanical and cause heat.
One horse power = 0.746 kW
Supply Voltage
Single phase motors have a supply of 240V.
Three phase motors will be supplied with 415V, make sure that
the motor has its internal connection arranged to accept the
voltage (star or delta), it will be on the nameplate.
Always check motor voltage

before energizing it.
Supply Frequency
Should be 50 hertz (cycles/sec). (60Hz USA motors)
Motor Current
Full Load Amps (FLA), is the maximum current that the motor is designed to draw at
full load while maintaining its rated speed.
Starting Current.(not on nameplate), this can be from 3 to 9 times the FLA, and is
something that should be kept to a minimum. eg. If a motor has a FLA rating of 10
amps, and is started fully loaded it can draw 90 amps to start. If this motor was to start
at your house the lights would dim until the motor reached running status.
Locked Rotor Current (LRC on hermetic compressors nameplates) is the current

that the motor draws if the rotor is locked by a too heavy load. eg. a compressor seize.

14
Motor Speed
Rev/min. (Shaft rotation on nameplate) is the speed that the shaft should turn at, even when
fully loaded.
Rotational speed of the electric motor is controlled by the number of poles built into the stator
and the percentage of slip needed to maintain rotoation.
Terms Related to Motor Speed

Synchronous Speed (not on nameplate) of an electric motor is the speed at which the
magnetic field rotates around the stator windings.
The synchronous speed is not the speed of the rotor shaft, it is the speed that the magnetic
flux appears to rotate around the stator. It travels faster than the rotor so its magnetic field will
continuously sweep through the rotor causing the reaction within the rotor windings maintaining
rotation and torque.
This can be calculated by knowing the frequency of the supply, the number of magnetic poles
(norths and souths always an even number), wound into the stator, and a constant of 120.
120 x frequency
nsyn =
number of Poles
Where nsyn = synchronous speed
Frequency = Hertz (cycles/sec)
Poles = magnetic poles
The voltage intensity has

nothing to do with the rotational
speed of the motor, but it does
have a lot to do with the ability
of the motor to turn the load.
120 = a constant.
The synchronous speed remains constant regardless of the
load placed on the motor.
120 x 50
nsyn = = 1500 rev/min.
4
Both three phase and single phase 4

pole motors have the synchronous
speed of 1500 rev/min,
Shaft Speed
The speed the shaft travels at is the rated speed on the nameplate of the motor.
The difference in speed between synchronous and shaft (actual) speed is referred to as slip
and is expressed as a percentage in calculations, usually around 4%.
( syn - actual speed) 100

slip =
x
Syn
1

15
e.g. A 4 pole motor (syn 1500 revs/min), has a rated shaft speed of 1440 revs/min, calculate
the percentage of slip?
( 1500 - 1440)
100
slip = x =
1500
1
60
100
x
1500
= 4%
1
Another calculation that can be used when referring to motors is how to calculate the actual
motor speed when the % of slip is given.
If the motor was running 4% slow it means it is running at 96% of synchronous the 96% can be
converted to a decimal (0.96) to make the calculation easier.
Actual speed is synchronous multipled by the slip
120 x Hertz
n = X % of Slip
Number of poles
Service information.
An electric motor must turn at its rated speed. If the speed isnt maintained the motor will have
less inductive reactance meaning, less impedance which will allow more current to flow
causing the motor to overheat, tripping the overload or burning out the motors stator windings.
Terminal Block
All electrical connections made to a motor must be completed in the motors terminal block.
Flexible conduit and multi-strand conductor must be used (preferably flexible conductor).
The conduit must be secured by an approved fitting or in the case of flexible cable to a small
fan motor an approved gripping type grommet.
The earthing connection must only be made at the terminal marked as the earth.
All electric
motors
must be
earthed at
the earth
terminal in
the terminal
block.

16
Section 3
Three Phase Induction Motor:
Reference: J.R. Jenneson pages, 253 260.
Three phase induction motors are said to be self starting
because as the electricity is applied to the motor it will
develop a rotating magnetic field, It doesnt require any
external equipment to cause the rotor to start to move.
Three Phase motors are used in the HVAC industry to drive
large loads like commercial compressors and large fans.
Construction
They have three separate sets of coil windings placed
o
120 E apart in the stator. Each winding is connected to two sequential phases, (see diagram
below). They have squirrel cage rotors.
Operation
Because of the winding configuration, and
the nature of three phase supply, as power is
supplied to the motor having two magnetic
poles (3000 rev/min synchronous), only one
set of coils will have maximum magnetic
strength, another set of coils will have a
rising magnetic field, and the other a falling.
As this is happening the rotor is being
affected by all three magnetic fluxes which
are moving at different angles through the
rotor conductors inducing three currents and
three magnetic fields which react with the
stator fields producing a very strong starting
torque.
The magnetic fields of the stator appear to
rotate around the stator, but actually they
only grow stronger and weaker in sequential
order around the stator windings.

17
Three phase motors made here in Australia are designed to

operate from our 415 volts 50 Hz four wire system.
Some motors are imported from
The neutral is needed for single phase motors and control
overseas and may not be suitable for
circuits.
our supply, so check the nameplate

information before you make the
Connection
connections. They may need a
There are two ways to connect the coil windings of three phase
transformer to be supplied
motor so that 415 volts can be applied to them.
separately, or have a transformer as
They are; Star or Delta.
part of package. Some imported
Some three phase motors can be connected in either Star or
motor have lower voltage and 60Hz
Delta. These motors will have six terminals in their terminal
frequencies and must be connected
block and their nameplate will indicate that they can be wired to
in star.
415V. They will have terminal bridging links to connect the

ends of the coil windings together so that they can be configured to either star or delta. When
the motor is connected in Delta will draw more current from the supply then when it is
connected in Star.
The lines are then connected to each set of windings at the motor terminals.

18
If the motor has only three terminals it is internally connected in either Star or Delta and should
just have the lines connected to the terminals. (Check the nameplate for voltage rating).
Most motors used in refrigeration and A/C will be connected internally in Star and there will be
three terminals for the connections.
Reversal of three phase induction motors:

Since the rotor follows the rotational magnetic force (RMF), to reverse the direction of a three
phase induction motor you must reverse the direction of the RMF. The directional change can
be achieved by changing the phase sequence (swapping two supply lead connections).
Reguardless if the motor has six terminals or three the reversal procedure is the same.

19
Hermetic Three Phase Motors.

An hermetic motor is basically an open framed motor directly coupled to the compressor it is
driving. They are both suspended on springs inside a fully sealed metal housing.
The suction vapour of the refrigerant used in the system is used to cool the motor windings.
Electrical testing of three phase induction motors:

The stator windings represent a balanced load that is each phase winding should have a
similar resistance
An ohmmeter is used to measure the resistance of each winding against the

manufacturers, requirements. Winding resistance readings can be between 10 to 100
ohms depending on the motor output capacity in kW, (more kW less resistance).
The windings that are in good condition will have similar resistance of several ohms or
more.
Damaged windings will have open circuit resulting in an infinite reading of resistance
and a short circuit will result a much lower resistance.
The motor windings are normally internally connected, therefore you can not do a
between winding insulation test with the megger.
The motor windings to earth insulation test should be well above 25Mohms. (see
earlier notes for resistance values).
Do not megger an hermetic motor when under a vacuum.
When connected to the supply the frame of the motor must be solidly earthed at the
marked earth terminal.
Check the motor line currents with a clamp on ammeter for correct operation.
There should be three similar line currents that do not exceed rated current on the
nameplate.
Cable protection such as flexible conduit must be secured at the motor.

20
Practical Exercise
Three Phase Motor Connections
Aim:
To test the supply of a three phase system and to draw a sketch of the component
layout needed to supply power to a three motor.
Equipment:
Electrical training boards in workshop.

415 volt power supply
Isolation switch
Fuses or circuit breaker
D.O.L. motor contactor
240 volt control circuit
ON/OFF control switch
Overload
Three phase motor
Note: drawing to be done on attached page.
Procedure:
Complete a risk assessment of the task.

On completion of circuit diagram check with you teacher/mentor and proceed
test a power circuit and a motor wired in Star and there Delta:
Electrical meters:
Megohm-meter
Multi-meter
Tong ammeter
Record Results:
Delta:
Resistances across each winding: 1
Star:
Supply Voltage
Line voltage:
Phase voltage:
Current:
Star. L1
L2
L3
Delta. L1
L2
L3

21
Three Phase Electrical Wiring Diagram

22

Q.1
When testing a three phase motor the tong tester is placed:

(a)
(b)
(c)
(d)
Q.2
The stator core is laminated to:

(a)
(b)
(c)
(d)
Q.3
improve starting torque

provide silent running
reduce eddy current loss
reduce hysteresis loss.
Rotor bars are usually made from:

(a)
(b)
(c)
(d)
Q.4
across the active or neutral cables

between any phase and earth cables
around any two phase cables
around any one phase cables.
steel or copper
copper or aluminium
carbon or copper.
steel or aluminium.
Slip speed is the difference between:

(a)
(b)
(c)
(d)
standstill and rotor speed

rotor and stalling speed
Synchronous speed and rotor speed
Synchronous speed and standstill speed.
Q.5
A typical three phase stator winding would be expected to have a resistance of:
(a)
10 to 100 ohms
(b)
100 to 1000 ohms
(c)
greater than 1 megohm
(d)
almost zero ohms.
Q.6
On completion of an insulation test between each of the phase windings and earth a
three phase induction motor would pass if all test results were:
(a)
(b)
(c)
(d)
Q.7
The rotor windings of a wound rotor induction motor is usually connected in:
(a)
(b)
(c)
(d)
Q.8
delta
series
parallel
star.
To reverse the direction of rotation of a three phase squirrel cage motor you
would:
(a)
(b)
(c)
(d)
Q.9
less than 2 ohms

between 10 kilohms and 1 megohm
The greater the better.
between 2 ohms and 100 ohms.
interchange any two supply lead connections

replace the squirrel cage rotor with a wound rotor
change the delta connected stator winding to star
remove the rotor and reverse end for end.
At what speed is the RMF produced by the stator winding rotate at?
23
Q.10
How would you change the direction of a three phase motor?
Q.11
Briefly explain why the rotor speed of an induction motor is always less that
the speed of the stator RMF:
Q.12
A three phase 415 volt, 50 HZ, 4 pole induction motor operates with a 4% slip.
Determine the synchronous speed and the actual rotor speed:
Q.13
From the details below determine the voltages for a three phase power supply
between:
Any two lines: =
Any line and earth: =
Any line and neutral: =
Earth and neutral: =

24
Q.14
The diagrams below (fig 1 & 2) represent a schematic layout of the motor windings for
a six terminal three phase motor. Complete the diagram from the three phase supply
(L1, L2, and L3) to include the phase windings for both a star and delta connections.
Star Y
L1
L2
L2
L3
A1
B1
C1
B2
C2
A2
Fig. 1
Delta
L1
L2
L2
L3
A1
B1
C1
B2
C2
A2
Fig. 2
Q.15
Indicate on the diagram below the main components of the squirrel cage induction
motor:

25
Section No: 3
Three Phase Motors Starters
skills required to identify a number of three phase motor starters and in particular the
construction and function of Direct On Line (D.O.L.) motor starters utilising the latch and
interlocking control methods for three phase motor circuits.
Reason for Study: Three phase motors are used extensively in the HVAC industry you need
to have a thorough understanding of how they are energized and de-energized.
A.C. Motor Starters (Contactors)
Motor starters (contactors) are devices that are connected between the supply lines and motor
in a functional system, for example:
The operating characteristics of an induction motor are that current and torque conditions are
considerably different during the starting sequence and then running conditions.
In the refrigeration industry, the compressor motor is the largest single load that has to be
switched by the control circuit. The control circuit can not directly handle the large starting
currents or switch the 3 phase for the motors, so it operates a contactor or intiates a starter
sequence that is in the power circuit.
Contactors
A Contactor is multi-poled device for repeated establishing and interrupting an electrical circuit
with a large current draw, and a Starter is an electric controller for accelerating a motor from
rest to normal speed. (Starters control is covered in greater detail in Systems Control).
The contactor has an electromagnetic coil that moves an armature which closes the
contact points.
The magnetic coil can have a different voltage ratings to the motors, some typical voltages are
24V, 240V, and 415V. (24V is common on Air conditioning systems because untrained
operators tend to fiddle with the controller adjustment).
The physical size of the coil will not relate to the voltage rating.
The control circuit is connected to terminals A1 and A2 on the contactor

26
Contactor Rating
The contact points are rated for different types of load. ie. The
e.g. 40amps resistive
same contactor will be rated for resistive load (heater bank), and
inductive load (motor).
15 amps inductive
The rating is done this way because the heater will have a
constant current draw whereas the motor has a very high starting
current.
Contactors normally have three main sets of poles so that the three phase supply can be
switched on/off to a three phase motor. The pole connections are marked by numbers, 1
through to 6. Odd numbers on top evens on the bottom.
There can be other contact points on the contactor these are referred to as the auxiliaries,
which can be used as part of an interlock system, or used to energized some other auxiliary
piece of equipment, (eg. A contactor for fan motor or water pumps).
Auxillary contacts have very low current ratings and should not be used to switch inductive
loads.
They are numbered 13 - 14 for normally open contacts and 21 - 22 for normally closed
contacts.
Contactor Selection Guide.

In refrigeration contactors are used for two different purposes;
1. Switching on Heaters.
2. Motor Starting.
1. To switch on Heaters. a contactor from the AC1 category is sufficient, as the loads have a
power factor of greater than 0.95.
2. Motor starting, you need contactors of the AC3 category, as the contactors contact points
are designed to handle the high starting current of the motors (8 times F.L.A. for three phase
motors).
If you have a motor that has to be reversed while it is still rotating in the other direction you
need to use a contactor of the AC4 or AC2 category.
Rated Voltage.
The voltage rated on the contactor is stated as the voltage between phases. (Line voltage)
Rated Current.
Current rating take into account the operational voltage, rated frequency, the category of
operation and the environmental conditions.

27
Motor Starters
There are a number of three phase motor starters used within the refrigeration, air conditioning
and electrical industries and they are as follows:
Note: further reference:
ARAC, page 14.11 14.19
D.O.L. (Direct on Line)
Reduce Voltage
star- delta starter
primary resistance starter
secondary resistance starter
auto-transformer starter
part winding starters.
Electronic (soft- start) starter.
Note:
reduced voltage and

electronic soft starters
will be covered in more
detail in another student
resource package.
All reduced voltage starters
require the motor to be
unloaded to start.
Direct on Line Starter (D.O.L.)

The basic D.O.L. motor starter, consist of a contactor with a thermal overload relay that will trip
in the event of an overload condition. The D.O.L. starter has the added feature in that it can be
operated by manual or automatic control devices.
A simple ON/OFF control switch is all that is needed to energize the contactor coil via the
overload. This will create the electromagnetism that causes the contactors armature to pull in
and close the three Line contacts and switch any auxiliaries on the contactor.
D.O.L. motor starter uses its three line contacts to simultaneously energize the motor winding.
The windings receive full line voltage so they will draw up to eight times their running current.
Control Circuit Cycling Devices:

A number of control devices can be used to stop and start a three phase motor control circuit
utilising a D.O.L. starter. These devices can be stand alone or used as part of the other
circuits:
Switches like, Thermostats, Pressure Controls.
Relays with Latching circuit
Other contactors with Interlocking circuit.
Advantages of D.O.L. motor starters:
Fail safe operation of the control circuit
Simple operation
Low initial cost
Remote stop and start features of control.
Disadvantages of D.O.L. motor starters:
No current limiting ability, therefore maximum current occurs at start.

28
Components in Starter Circuits

Latching circuits:
Latching uses the auxiliary contacts on contactors to hold (latch) circuits for as long as the
contactor is energized. A typical example of this is a three phase pedestal drill with a stop start
switching arrangement.
Interlocking circuits:
Interlocking uses the auxiliary contacts on contactors to automatically bring in other
components, or stop them if a fault appears in another circuit.
The interlocking circuit represents the control circuit for a refrigerated coolroom operating with
a three phase evaporator, condenser fan motor and compressor drive motor.
Note:
The diagram interlocking compressor drive motor in a refrigerated coolroom. The

compressor drive motor contactor will be energised when the evaporator fan motor
contactor is energised via EF/1. The normally closed auxiliary (EF/2), will indicate fan
failure.

29
Practical Exercise
Three Phase D.O.L. Motor Starter
Aim:
To construct an electrical wiring circuit diagram for a three phase exhaust fan motor in
accordance with the following details:
Note:
415 volt power circuit

Isolation switch / fuses etc
D.O.L. contactor
Star connection.
Control circuit consists of: STOP/START switching and overload protection for
the fan motor.
Complete circuit diagram on the page provided below.
Procedure:
Read the procedure completely.
Complete a risk assessment for the task.
On completion of your circuit diagram proceed to electrical workshop and hard

wire on three phase training boards, using the correct meters tools and safety
procedures.
Test run on completion of connection and check current and voltages under
supervision of your teacher or mentor.

30
Three Phase D.O.L. Motor Starter Circuit Diagram

31
Practical Exercise
Three Phase Motor Connections
Aim:
To draw a complete wiring diagram for a three phase motor for star and then delta in
accordance with the following details:
Procedure:
Electrical training boards in workshop.

415 volt power supply
Isolation switch
Fuses or circuit breaker
D.O.L. motor contactor
240 volt control circuit
ON/OFF control switch
Overload
Three phase motor.
Condenser fan to be energized via contactors N/O auxiliary.
Note: drawing to be done on attached page.
On completion of circuit diagram check with you teacher/mentor and proceed
to:
Isolate the power supply and proceed to connect the motor circuit
(STAR).
Test the motor windings resistances and record.
Switch the power supply on and measure the operating voltages,

current and record results.
Reverse the direction of the motor.
Electrical meters:
Megohm-meter
Multi-meter
Tong-ammeter
Record Results:
Star:
Line voltage:
Phase voltage:
Current:
Delta:
Line voltage:
Phase voltage:
Current:

32
Three Phase Electrical Wiring Diagram

33

Q.1
Describe the operation of a DOL motor starter:
Q.2
What are the three main components of a three phase contactor?
Q.3
What is the major advantage of a D.O.L. contactor over an isolation control switch?
Q.4
List three types of motor starters used to operate three phase induction motors:
Q.5
Draw an electrical control circuit for D.O.L. contactor controlled by a start / stop switch.
(space provided on the next page).
Q.6
With the aid of the above circuit diagram, explain how the control circuit operates:

34
Section No: 5
Three Phase Motor Protection

skills to identify various motor protection devices and how they operate within three phase
motor circuits.
Reason for Study: In the refrigeration industry motor overloads must be selected and applied
with considerable care to reduce any nuisance tripping but protect the motor from faults that
cause having to replace the motor.
Motor Protection:
Motor protection is required to prevent motor windings being damaged or burnt out.
Three phase motor breakdown is typically due to electrical or mechanical damage.
Excessive rise in motor phase current is due to one or more of the following:
Mechanical load is greater than the electrical rating (kW).
Rotor shaft becomes locked.
Partial loss of supply voltage.
Reduction in supply phase voltages.
Winding insulation breakdown.
Irrespective of the cause of motor breakdown the effect is often a rise in motor temperature
due to an increase in motor current.
Motor Protection Devices:

Inverse time characteristics of Protective Devices:
Protection devices installed in the electrical circuit must be capable of discriminating between
normal operating conditions and conditions which may cause damage. To meet this need
protective have a design feature called inverse time characteristic which reduces their
operating time when there is an increase in overload conditions and prevents nuisance tripping
under normal starting currents.
Protection devices are designed to either monitor short duration high current overload
conditions, short circuits or long duration medium to low current overload conditions.
Types of Protection Devices:
.
1. Fuses and circuit breakers:
C/Bs and fuses are there to protect the wiring to the motor from damage due to short
circuit, and to degree they provide protection for motors against excessive current
overloads.
The most common type of fuse used on three phase motors is the (HRC) this of fuse
operates with a high rupturing capacity, A combination of the HRC fuse and circuit
breaker are used in most cases. On some older installations you may come across rewire-able fuses (outlawed under AS3000). C/Bs should have at least a 3kV rating when
used to protect motors.
2. Overloads.
Overloads are designed to protect a specific piece of equipment that is connected to the
electrical supply. They are not designed to protect the circuit wiring mainly because the
circuit wiring should be capable of carrying a far greater current than the O/L setting.
Overloads are designed to absorb start up current without tripping; but will heat up during
an overload condition.
Always have the current rating of the overload matching the

FLA of the motor it is protecting.

35
Overloads for three phase motors will either be;

1. Current sensing
2. Heat detecting.
Current Sensing
Thermal Overload Relay.
These are current sensing devices that have all three phases flowing through individual branches
so that any phase can cause the device to trip. They are fitted directly to a contactor so that the
current flowing to the motor flows through it first.
If a current greater than its rating flows through the overloads heaters, the heat produced will affect
a bi-metal strip that moves a lever to trip open a normally closed switch (relay). The normally closed
switch is connected to the control circuit via terminals numbered 95 96 on the O/L. The overload
relay is connected in series with the control circuit for the contactor coil. (A1 A2).
The Thermal Overload Relay has a limited adjustable current range, that allows the tradesperson to
fine tune the setting for the motors protection.
They can be manually or auto reset.
Magnetic Overload
The magnetic overload is current sensing, and will only operate if the current flow through it
exceeds its rating.
They are normally only wired in series to two of the phases and operate a set of contacts in series
with the control circuit.
They have fixed ratings and are found on imported package air conditioning systems.
Heat sensing
These devices are usually embeded in the motor
windings when it is manufactured.
They are connected in series with the control
circuit supplying the contactor coil and open circuit
if the motor windings temperature exceeds their
rating.
The new types are made from semi-conductor
material,(thermistor), while the older types used bimetal strips that were manufactured as a set of
contacts.
Both embeded types are non-adjustable, and the
motor has to cool down before they will reset
automatically.
36
Setting and re-setting overloads:

Only thermal overload relays can be adjusted and the correct setting must be
made to the motor specifications. Set at motor full load amperes.
If the setting is to low nuisance tripping may occur.
A motor may burn out due to a high setting. This is particularly relevant for
modern motors because their design efficiency has increased along with
operating temperatures.
Under Voltage and Over Voltage Relays:

The under voltage relay will respond to low voltage on the control and motor circuit
and the effects of under voltage are as follows:
Relays and contactors will not operate correctly.
Sensing devices do not respond as required.
Increase in temperature of motor windings dur to the lack of inductance with will
allow more current to flow.
The over voltage relay responds to over voltage on the control and motor circuit and
the effects of over voltage are as follows:
Increase power consumption in the control circuit.
Sensing and controlling devices operating incorrectly.
Increase in motor temperature because more current will be push by the

higher voltage..
Electronic motor protection relays:

The electronic motor protection relays offer the ultimate protection functions by
incorporating thermal, magnetic and voltage protection.
37
Isolation Switch:
The AS/NZS 3000 requires that every circuit and apparatus has a point of isolation. In the event of
electrical or mechanical hazard, the circuit between the motor supply and its associated control circuit
must be capable of being isolated through the installation of an approved isolation switch. A licensed
refrigeration mechanic is allowed to repair and replace up to the isolation switch, but not the switch itself.
Motor Timer Protection: (lock out timers)

Timers can be used to protect three phase motors against the problems associated from short
cycling. These problems include:
Increased heating of protective devices.
Increase in temperature of the motor
Extra stress placed on the motor.
Control contacts, both power and control, have increased operation which will
result in lowering the life span
Coupling between motor and load is subjected to increased stress.
Fault finding in three phase motor installations:

An electric motor may not operate due to a fault within the motor or in the circuit supplying the
motor. A fault in the load the motor is intended to drive, can also affect the motors
performance. Remember a motor is a component that converts electrical energy to mechanical
energy and therefore a mechanical fault will be reflected in the electrical circuit.
The general areas where faults in motors and their associated circuits occur are:
The electrical supply and controls to the motor
Within the motor itself
In the load being driven by the motor.
Note: To become competent in motor fault finding it is essential that you have on the
job training guided by a licensed mentor in the workplace.

38

Q.1
List four problems that are associated with excessive current flow in a three phase
induction motor:
Q.2
List three types of circuit protection devices:
Q.3
List and describe two types of thermal overloads:
Q.4
List two main considerations that need to be taken into account when setting
overloads:
Q.5
Describe the operation and advantage of a thermal overload:
Q.6
List two problems associated with under voltage in a three phase motor circuit:
Q.7
List two problems associated with over voltage in a three phase motor circuit:

39
Q.8
Electronic motor protection relays offer three protective functions. What are they?
Q.9
What is the function of an isolation switch?
Q.10
Timers can be used to protect three phase motors against the problems associated
from short cycling. List three of these problems:

40
Section No: 6
Single Phase Motors, Starting Relays & Overloads
Purpose: The purpose of this section is to provide the underpinning knowledge and skills
required in the construction, operation, directional change applications and to identify the
motor terminals for various types of single phase motors and starting relays.
Split Phase Motors: (ARAC, 14.1)
Symbol
Development of starting torque in split phase induction motors:

Split phase motors like all A.C. induction motors requires a rotating
magnetic field to be produced in the windings so that it can act on the
rotor and cause it to rotate. A split phase motor is designed to produce
a directional, non-rotating magnetic field. The field is developed by
placing two separate windings on the stator core at 90 electrical
degrees to each other.
At start up both windings are energized. The start windings magnetic
flux is slightly ahead of the run winding (see lagging and inductance),
the runs stronger magnetic flux pushes the start's flux to the side which gives the moving
magnetic field through the rotor windings allowing it to react with the runs field, resulting in the
rotor turning.
After the motor reaches approximately 75% of its rated speed, the start winding should be
isolated from the supply by the start relay, to prevent the winding from burning out.
Run & Start Windings:
The run and start windings are electrically dissimilar in that they are wound using different
gauge wire, with a different number of turns and are physically positioned at different depths in
the stator slots which affects their inductance
Characteristics.
Run and start winding.
Run winding thicker wire, lower resistance high
inductance deeper in the stator laminations
Start winding thinner wire, higher resistance low
inductance positioned on top of the run winding in the
stator
Start relay needed either a, current coil, solid state or
centrifugal switch.
Medium starting torque.
Picture of an open frame washing

machine motor.
Applications: anything that doesn't require the motor to start

loaded;
Domestic compressor (equalize or the off cycle)
Fans, Load comes with speed increase.
Pumps, the same as above
If a split phase motor is designed for two speeds it will have three
windings;
One will be the start winding so it will have the highest resistance.
The second highest resistance will be the slower of the two speeds,
because the there needs to be more poles for the slower the motor,
therefore more copper windings, more resistance.
The third winding should have the lowest resistance. This means less
copper windings for fewer poles.

41
Reverse Rotation
Reverse connection of either (but not both) starting or running windings connections are
swapped around.
Winding connections behind terminals
Even though both terminal links are moved it only changes the point that the A.C. is first
applied to one winding.
Characteristics of a split phase motor:

The run winding by itself does not develop starting torque.
The start winding, working with the run winding, is needed to develop starting torque.
Starting currents are around five to seven times the rated motor current.
The starting current is not damaging because it decreases as soon as the motor
accelerates.
Because of the high starting current the starting torque developed is around 1.5 to 2
times the rated full load torque.

42
Split Phase Motors in Sealed compressor:

The signal phase hermetic motor/compressor unit is used in both refrigeration and air
conditioning systems consists of a compressor with a drive shaft connected to the rotor of the
motor which is hung on springs that are attached to an internal frame. The whole unit is fitted
into a two piece pressed metal housing, called the dome and hermetically sealed by welding
the two parts together
Note: the electrical motor terminal connections are as follows:
start winding connects between S and C
run winding between R and C
C is common to both windings.
Correct electrical terminal identification:

There are three terminal connections on a hermetically sealed motor compressor and are as
follows: Common (C), Start (S) and Run (R). To identify the correct terminal connection the
following procedure applies.
The highest resistance reading is between the start and run terminals
The middle resistance reading is between the start and common terminals.
The lowest resistance reading is between the run and common terminals.
Testing and fault finding:
The insulation resistance between the motor frame and all windings and active conductors
must be greater than 30 meg-ohm. Remember when it was new its resistance started out so
high it could not be measured (infinite).
Damage to start windings could be due to one of the following:
Starting device not opening because of a sticking centrifugal

switch or a malfunction of the current sensing device (current
coil / solid state relay).
Frequent stop / start
Excessive load on the motor
Incorrect winding connections
Low supply voltage.
Possible causes of non-starting are as follows:
Loss of supply voltage

Overload reset button needs to be reset
Open circuit in either winding
Locked rotor
Faulty relay
Excessive load on compressor motor (Trips out on overload)
Advantage:
Disadvantage:
Rating:
operates on a single phase supply.

low starting torque and high slip on heavy load.
output ratings are: 250 watts 1.5kW.
Hermetic Compressor
43
Practical Exercise
Split Phase Motor
Aim:
With the aid of the ohms scale of a multi-meter and meg-ohm meter determine the
motor winding resistances and check for earth leakage on a split phase sealed motor
compressor.
Procedure:
After obtaining the results place the appropriate resistance readings across
each winding connection and indicate the Common (C), Start (S) and Run (R)
terminals on the diagram below.
Hermetically sealed motor compressor motor windings
Recorded results:

44
Single Phase Motor Starting Relays

Centrifugal switch. (Fitted to open type motors only)
Construction
The centrifugal switch is a mechanical device that relies on the centrifugal action of the motors
spinning shaft for its operation. It is made up of two parts. One, the Centrifugal Flyweight and
rotating element which is attached to the shaft of the motor, and the other part is a normally
closed switch plate attached to the motors end shield. The switch plate also acts as the motor
terminal block.
Operation
When the motor is at rest the springs hold the flyweight in, which keeps the rotating element
pushing against the switch closing the contacts. As the motor accelerates from rest centrifugal
force starts to be exerted by the flyweights against the springs, when the rotor speed reaches
about 75% of its rated speed the centrifugal action will overcome the spring tension allowing
the rotating element to release the N/C switch opening its contacts disconnecting the start
winding from the power supply.
Different speed motors have different tension spring.
e.g. A 2880 rev / min motor will have springs with a greater tension than a motor which
operate at a speed of 960 rev/min.
Advantages
If the speed of the motor decreases (because of increased load etc.), the centrifugal action will
also decrease allowing the switch to reset energizing the start winding. This gives the motor
extra torque to try to get back up to speed again.
Disadvantages
Cannot be used on hermetic
compressors because the flash
from the arcing contacts will
burn the refrigerant. (The
refrigerant vapour is used to
cool the windings of the sealed
unit compressors).
Applications
Motors that drive open
compressors, pumps, fans or
any application where the motor
is air cooled.

45
Sealed Unit Starting Relays.

The purpose of the starting relay is exactly the same as the centrifugal switch i.e. it disconnects the
start winding circuit from the supply as the motor speed reaches approximately 75% of its rated
speed. There are several different types, and each use a different force for their operation.
Current Coil Relay. (CCR)
Construction
The current coil type relay is a low resistance (a few turns of thick wire)
magnetic solenoid coil that is wired in series with the run (main),
winding. The solenoids armature operates a set of normally open
contacts which are wired in series with the start winding circuit.
Operation.
When the motor is energized it initially draws Locked Rotor Current, which is sufficient to
energize the relay coil lifting the armature closing the N/O contacts connecting the start
winding circuit to the supply, which starts the motors rotation. As the motor builds up to its
rated speed the increasing inductive reactance within the motor reduces the current flow
through the run windings and the relay coil.
At about 75% of the motors rated speed the current flow should be insufficient to hold the relay
closed, opening the start winding circuit.
Disadvantages
Current coil relays are designed to suit individual motors because the LRC and running
currents are critical to the operation of the relay.
Current coil relays need to be mounted the correct way up, as they rely on gravity to complete
the disconnecting process.
Advantage
As with the centrifugal switch, if the motor slows for load reasons, the current draw will
increase and some current coil relays will pull their start winding back into the circuit.

46
Potential Coil Relay.

A potential coil (voltage coil) is used for the magnetic force needed
to move the armature of the relay. The contacts in this relay are
normally closed (N/C), and open only when sufficient back EMF is
generated in the auxiliary winding.
The high voltage produced in

the auxiliary winding is a result
of the transformer action
between adjacent coils.

Operation.
At the instant of start up both the main and auxiliary windings are
connected to the supply, as the rotational speed builds up so does the induced EMF in the
auxiliary winding. The potential relays coil is connected in parallel across the auxiliary winding,
and responds to the voltage flowing in that winding. At about 75% of the motors rated speed
the induced EMF in the auxiliary winding is around 350 to 400 volts, which is the voltage
needed to energizes the coil opening the N/C contacts that are in series with the auxiliary
winding.
The motor continues to induce the high voltage in the auxiliary winding holding the coil
energized. Current flow in the potential coil is restricted by the high resistance of the small
CSA conductor of the potential coil.
Potential coil relays are used with high torque, capacitor start motors, because the contacts
are closed at start up and only opening as the motor reaches its running speed therefore the
current will be low which will reduce arcing at the contact points.
If Potential Coil Relays needs to be replaced, one of the same coil characteristics should be
selected so that the pick up voltage (the voltage that is needed to make the relay work), will
be available from the start winding, as the motor reaches 75% of its rated speed.
Wiring Diagram with a potential coil relay.

47
Solid State Relay. (SSR)

The solid state relay has no moving parts. It is a positive temperature co-efficient (PTC)
thermistor that increases its resistance when heated by the start winding current passing
through it.
Operation
At start up the SSR is cold allowing sufficient current to flow to the start winding to energize it.
Within milliseconds the current flowing through the SSR causes it to heat up increasing the
resistance, reducing the current flowing to the start winding to milliamps.
Although there is still a 240 volts potential on the start winding, the current flow through it is so
small it produces very little magnetic effect in the windings, but produces enough heating effect
in the SSR to maintain the resistance.
Disadvantages
The Solid State relay can be affected by other sources of heat, such as radiated heat from a
discharge pipe and should be mounted away from any heat source.
Be careful when handling Solid State relays, as they can get hot.
This type of relay requires a cool down time between starts, and is not designed for operation
on compressors that have a high number of starts per hour, such as commercial systems.
Advantage
Unlike the Current Coil and Potential Coil Relay, the SSR does not have to be exactly sized
to suit the electrical characteristics of the motor.
One relay can be used to control the start winding circuit for motors ranging in size from 0.25
kW to 0.37 kW.
Wiring Diagram for a

domestic refrigerator.

48
Single Phase Motor Overloads

Signal phase motor overloads are either heat or heat/current sensing.
Heat Sensing
External Bi-metal thermostat overload.
This type of overload is often referred to as a Klixon (brand
name), because it clicks off when it reaches a predetermined temperature, and clicks on when the reset is
pushed.
This type of overload is fitted on the outside case of the
motor, and it normally is accessible for resetting manually.
# not used on hermetic motors.
Current and Temperature Sensing.

These are referred to as the inherent protector, as they have
a bi-metal strip (deforming disk), that senses the motor
housing temperature, as well as a heater that has the motor
running current flowing through it, that when heated will also
affect the bi-metal. The bi-metal is part of a single pole single
throw switch that is in series with the motor supply, and will trip
it if heated to a set point.
The active conductor should be connected to the screw
terminal on the overload.
# Used on hermetic compressors.
These overloads
automatic reset after they
have cooled.
They are fitted to the
outside of Hermetic
compressors in the
terminal box next to the
motor terminals. They
must have good thermal
contact with the body of
the compressor. The
adjustment screw should
not be fiddled with.

49

Q.1
Which of the windings is open circuited by the current sensing switch?
Q.2
Explain how you would reverse the direction of rotation of a split phase motor:
Q.3
Explain the operation of the following switching mechanisms on a split phase motor:
Current coil relay:
Solid state relay:
Q.4
When energised, a split phase induction motor fails to start. List in point form the
steps you would take to locate the fault:
Q.5
Describe the operation of a centrifugal switch when used on a split phase motor:
Q.6
When energised a split phase induction motor continually trips out on its thermal
overload. List a least four possible faults that would cause this condition:

50
Q.7
A 50 HZ two pole split phase induction motor operates on full speed with a 4% slip.
Calculate the full load rotor speed:
Q.8
In the space below draw an electrical wiring diagram for a split phase compressor
motor controlled by a thermostat, current coil relay and overload protection. Include on
your drawing the motor windings and terminal connections.
Q.9
You are to replace the current coil relay with a solid state relay within the circuit above.
Draw an appropriate electrical circuit diagram to meet the requirements for a solid
state relay.
Q10.
After checking a hermetically sealed motor compressor the following resistances were
measured between the terminals. Indicate the common (C), start (S) and run (R)
terminals on the diagram below:
47 ohms
22 ohms
25 ohms

51
Section 7
Capacitor, Shaded Pole and Synchronous Motors
Capacitor Start Induction Run Motor.
Symbol/Schematic
Characteristics:
Requires a starting relay.
Centrifugal switch or current coil.
Run winding resistance less than start

winding.
High starting frequency. (starts per

hour)
Winding connection are now referred

to as;
Run = main
Start = auxiliary.
This is because the auxiliary will have a
current flow through it as the capacitor
charges and discharges from the A.C.
Operation.
Much the same as split phase motors, except the capacitor is in series with the auxiliary
(starting) winding which will bring the current in the auxiliary to be nearly in phase with the
supply voltage. (See A.C. impedance Z). In doing this the "phase angle" difference between
the main windings current and the auxiliarys is increased.
Having the main windings magnetic field at a greater angle to the auxiliarys will result in a
stronger starting winding torque.
Capacitors must be matched to the motor to obtain optimum starting torque.

Manufacturers will specify the capacitor value required for a particular motor.
Start capacitors can range from 40f to 180f.
Start capacitors remain in the circuit for approximately three seconds and are limited
on the number of starts per hour. This depends on the motor design.
Increasing the starting torque with this type of motor is accompanied by an increase in
starting current.
Application
Small commercial compressors that will cycle loaded, i.e., high discharge pressure.
Reverse rotation same as split phase motor.

52
Capacitor Start Capacitor Run Motor
Symbol/Schematic
Characteristics:
Starting relay required;
Centrifugal switch or potential

coil are normally used.
Main and auxiliary windings.
Running capacitor
Starting capacitor.
High starting torque.
Capacitors must be
matched to motor
Operation.
Similar to C.S.I.R. motor with the exception that two capacitors are connected
in parallel and then in series to the auxiliary terminal (winding). Once the motor reaches 75%
of its rated speed the starting capacitor is switched out of the circuit leaving the running
capacitor connected in series with the auxiliary winding. This arrangement gives a high starting
torque (reduced phase angle) and good running torque.
Application.
Large single-phase compressors that starts loaded. e.g. low temps.
Reverse rotation same as Split Phase motor.

53
Permanently Split Capacitor Motor

Symbol/Schematic
Characteristics:
No starting relay required.
On small fan motors both main and auxiliary

windings can have the same
resistance, but with compressors there
is a difference in resistance.
Picture of a Fan Deck motor assembly
Capacitor 3 to 80MF
Quiet electrical characteristics, i.e. won't

upset T. V. at start up.
Torque
Low starting so, motor starts unloaded.
Good running torque.
Operation
At start up both windings are energized but having the
capacitor in series with the auxiliary will cause its
magnetic field to be less "out of phase" with the supply
voltage. This will result in the rotor's magnetic field to
misalign with the main windings magnetic field given the
rotor its rotation.
The capacitor and auxiliary winding remain energized
during operation, giving the motor its good running
torque. They are used on fans and pumps because with
these devices the load increases with speed.
They can all be used with compressors that unload on
the off cycle. i.e. capillary systems
Applications.
Evaporator fans, condense pumps and compressors in
residential. A/C.
Reverse rotation - Connect active to other side of capacitor.
Compressor motors should not be reversed.

54
Capacitors Used for Single Phase Induction Motors:

Start capacitor features:
AC electrolytic
Connected during starting only
Limited number of starts per hour (20/hour)
Capacitance ratings between 30f and 250f.
Voltage rating of 240 volts.
Run Capacitors features:
Oil bath
Permanently connected
Capacitance ratings between 4 and 35f.
Voltage rating over 400 volts.
Capacitors are used on single phase motors to correct the lagging current in the windings,
which will improved starting torque in Capacitor Start Induction Run motors over Split Phase
motors, and even better starting torque and running efficiency of Capacitor Start Capacitor run
Motors. They are also used to create the phase angle in the Permanently Split Capacitor
motor.
Capacitors are very common in refrigeration because there are many motors that are started
loaded, and even more fans being driven by PSC motors.
How to test a capacitor is covered in section 9 of this package.
Service Points.
Capacitors have a limited life so always test the capacitor on a
single phase motor before you replace the motor.

55
Shaded pole
Symbol
Characteristics
Picture
Low torque
Can be stalled without
damage therefore they do not
have an overload.
Has a single winding.
No starting relay required.
Operation: The shading ring causes

the defection in the magnetic flux,
starting the rotor to turn.
Uses/ Applications:
-Small evaporator fans.
-Non critical timers
-Two position value/damper motors with spring return.
Reverse rotation:
Must be dismantled and rotor and shaft must be reversed in
stator.
Synchronous Motors.
Characteristics:
Symbol:
Single winding of
high resistance.
No starting winding
or relay.
Permanent magnets
in rotor.
No overload.
Synchronous motor
used as a defrost timer
Operation.
A.C. is applied to the stator winding creating a magnetic field across the rotor. Rotation
happens because the rotor's permanent magnets will react to the stators electromagnetism.
Synchronous motors are so named because they spin at synchronous speed, (e.g. 2 pole
motor will have a shaft rotation of 3000 revs per minute).
Application
Timers (because they rotate at an exact speed).
Small modulating motors.
Reversing Rotation, is the same as the

Shaded Pole motor in as much as the motor
must be dismantled and the rotor reversed in
the stator.

56
Section 8
Series Universal Motors (commutator motors)
Purpose: The purpose of this section is to provide the underpinning knowledge and skills to identify
the construction and applications for the series universal motor.
Reason for Study; The Series motor is not used much in the refrigeration industry as it is expensive
to manufacture and requires a lot of maintenance compared to induction motors. They where used to
drive modulating valves but they have been replaced with permanently split capacitor motors.
Construction: Components parts of a series universal motor are as follows:
1.
Stator consists of:

Frame, rolled steel or cast iron shell
Field core, laminations pressed tightly together and contains the field windings.
Field coils, few turns of wire and are connected in series with the armature.
2.
Armature consists of:

Laminated core having straight slots
Windings housed in slots with the coil sides brought out to the commutator segments
Both armature core and commutator are pressed onto the armature shaft
3.
End plates and brush holders

End plates house the bearings in which the armature revolves.
One end plate has brush holders and can be removed.
Brush holders and brushes provide the sliding electrical contact between the field
and the armatures commutator.
Operation. The Series Universal Motor (Commutator Motor), is not an Induction motor, the current
flowing in the armature (rotor) is not induced it is fed directly from the supply via a set of brushes and
the commutator. The main magnetic field is set up by two field poles mounted on the stator. It
remains in a constant position.
The armature has overlapping coils wound on to it similar to an induction motors stator but each
coils leads are connected to individual segments on the commutator. The commutator converts the
AC to DC and because of the way the brushes are positioned, supplies the voltage only to the coil
that is being affected by the field coils magnetic flux. This will position the armature magnetic field to
give an alternating magnetic field reacting with a permanent magnetic field resulting in rotational.
The Commutator motor can be supplied with either AC or DC voltage of the same intensity.
e.g. 240V AC or 240V DC.
Applications:
Portable hand held tools
Drills (240 and Battery)
sanders
jig saws
routers
grinders
Domestic appliances:
vacuum cleaners
sewing machines
hair dryer.

57
Review Questions Section No: 6, 7 and 8

Q.1
Name four methods used to switch the start/auxiliary winding of a split phase motor.
Q.2
Describe how would you change the direction of a shaded pole motor:
Q.3
Explain why a capacitor start motor can develop a greater starting torque than a split phase
motor.
Q.4
Explain how you would change the direction of a permanently split capacitor motor:
Q.5
Explain the operation of a potential coil relay:
Q.6
Which of the following motors is best suited for a single phase evaporator fan motor?
Q.7
(a)
Series universal motor
(b)
Permanently split capacitor motor
(c)
Split phase motor.
(d)
Capacitor start motor
The single phase motor which is most suitable for a domestic refrigerator evaporator fan
motor is the:
(a)
Capacitor start motor
(b)
Series universal motor
(c)
Shaded pole motor
(d)
Permanently split capacitor motor.

58
Q.8
Which of the following motors would be best suited for a domestic refrigerator compressor?
(a)
Shade pole motor
(b)
Permanently split capacitor
(c)
Capacitor start / capacitor run motor
(d)
Split phase motor
Q.9
List a least three desirable characteristics of a capacitor start / capacitor run motor
Q.10
Why would you use a capacitor start capacitor run motor in preference to a split phase motor
compressor on a refrigeration system that has a TX valve as a refrigerant metering device?

59
Section 9
Servicing Motors and Auxiliary Equipment
Safety. Never attempt to change electrical components while the power is still turned on.
TURN OFF, SAFETY TAG and LOCK THE ISOLATOR
Reason For Study
A refrigeration mechanic will be required to test an electric motor for electrical and mechanical faults.
To this end the mechanic will need to have a good working knowledge of the basic electrical test
instruments and have a feel for the small tolerances associated with the mechanical side of the
motor.
It is hoped that you as a student would have successfully passed Electrical Testing Equipment,
before attempting to use the meters.
The minimum testing equipment required is;
Megohm meter, (1000 volt), to check for the insulation quality for leakage to earth.
Resistance meter, (ohmmeter), to check the resistance of the windings, and continuity of the
circuits, and also to do a field test for a capacitor.
Tong Tester (clamp on ammeter), to check the current without interrupting the circuit.
Voltmeter, to check the supply voltage at the motor terminals.
Develop a procedure that follows a sequence so that you check the motor in a logical manner.
Here is an example testing procedure, with explanation.
Power Supply
Check the voltage at the switchboard, if a fuse is blown look at the way it has melted. Splatter fuse
element to the terminals, usually means a short circuit, (do not replace fuse, megger circuit to find
earth or short between windings), and if the fuse element has broken with small droplets of melted
wire at the tips, usually indicates an overload, replace fuse and tong test for excessive current flow.
Check the voltage at the terminals of the motor as it is starting where it is possible, or at a junction
box. The supply voltage should not fall below 10% of the rated voltage on the nameplate.
Remember to check the voltage on all three phases, 415 volts between phases, and 240 volts to
earth.
Symptoms of Low voltage supply.
Motor overheating.
Extra noisy motor.
Motor fails to start.
Overload tripping when motor not loaded.
Causes of low voltage
Dirty contacts, or loose terminals.
Supply from the electrical authority.
Overload building wiring.
If the voltage supply is OK, proceed to check the motor.
Disconnect the motor from the supply wiring, and remove any bridging connection so that the
windings can be tested without getting errors via parallel circuits.
Check the windings continuity and resistance of each winding. Relate the results to the type of
motor being tested, (single phase or three phase). Remember the motor resistance will be very low
as the opposition to current flow is inductance of the windings, and inductance only happens while
the motor is operating.
60
Megger the windings to earth, at least 1Mohm for open type motors and 30 Meg-ohms for hermetic.
Remember when the motor was new it had a resistance that was so great it could not measured,
(infinite).
Do not megger a hermetic motor while it is under a vacuum, the risk of insulation damage is
very high under vacuum conditions.*
Overloads.
Overloads are generally not serviceable, and if the fail they are replaced.
Testing is limited to continuity check and checking of the mechanical action of the three phase
overload relays, although you can purchase replacement bi-metal heaters for the larger three phase
thermal overload relays.
If the overload is tripping, and the motor current draw is within the FLA rating do not attempt to adjust
three phase overload relay current setting, as the overload tripping mechanism has failed through
age or other means, replace the overload completely.
Always replace an overload with one of the same rating and calibration.
Some overloads are buried in the windings, so if they fail it will be necessary to fit a replacement
externally.
Fitting an overload externally requires careful selection as the heat generated by the windings will
take a lot longer to conduct to the frame of the motor where the replacement overload will have to be
fitted. As a general rule if is better to replace the buried temperature sensing type with a current
sensing device that is set to the FLA of the motor
Testing Capacitors
Tests can be made for continuity which will indicate short circuits or open circuits.
* On run capacitors disconnect the Bleed resistor from one terminal.
Test 1. Set the ohmmeter to the Rx1 scale, and do a continuity check between the terminals, if there
is a circuit the capacitor has a short circuit between the plates
Test 2. Set the ohmmeter to the Rx10000 scale, do a continuity check. There should be an
immediate indication of a short circuit, leave the meter connected and wait for the capacitor to
charge up as the electrons (from the battery in the meter), flow onto the negative plate. The number
of electrons flowing will reduce as the plate fills with electrons, which will be indicated on the
ohmmeter as if the resistance of the capacitor is increasing. This is an indication that the capacitor is
serviceable, and could be put back into operation.
Test 3. Some capacitors have a metal case which can allow the outer wound plate to track to earth.
A megohm meter is used to test for shorts to earth. Use the lowest voltage output of the megger to do
this test.
Connect one lead of the megger to one terminal, and the other lead to the case, operate megger,
there should be a very high resistance to earth. Do the same of the other plates terminal.
Do not megger between terminals as the dielectric between the plates is not designed to withstand
the high DC voltage from a megger.
To accurately test a capacitor use a capacitor analyser.
Remember to reconnect the bleed resistor on run type capacitors.
Symptoms of Faults
Run Capacitors.
An open circuit on the run capacitor connected to a PSC motor will effectively disconnected the
auxiliary winding from the supply therefore the motor will not turn, it will just hum.
An open circuit in the capacitor on a CSCR motor will reduce the running performance to about the
value of a split phase motor. The starting relay may chatter, and the motor overload should begin to
heat because of the excessive current flowing in the windings
61
A short circuited capacitor on either a PSC or CSCR motor should cause excessive current flow.
Start Capacitor.
An open circuited capacitor on a CSIR motor will disconnect the start winding from the supply
leaving the motor to hum.
A short or open circuited capacitor on a CSCR motor will reduce the starting torque only.
A short circuited capacitor on a CSIR motor normally reduces the starting torque to a point where it
will not start to turn against a head pressure.
Mechanical Testing
Electric motors are used because they are reliable and rugged, they rarely suffer from mechanical
failure other than bearing replacement.
During routine servicing it is a good practise to check the mounting of a motor to ensure that it is held
down firmly, and that the coupling to the compressor or fan is secure as well.
Another check that can be made on site is to feel for bearing movement. there should be no vertical
play on the motor shaft, there can be horizontal slide of the shaft in and out of the end plates, but if
you push it in it should spring back out, as there is a spring fitted to the back end bearing of some
cheaper motors to ensure that the rotor lines up with the stator.
Be-careful of moving parts while you are doing this test.

Place a long screw driver against the end plate of the motor and then cover the handle of the
screwdriver with your ear you can hear if the bearings are making a grinding sound. If the bearing is
making this sound it means that they will need replacement soon.
This check generally can not be made on motors directly coupled to compressors, as the piston
movement sound is transferred to the shaft and bearings.

62
Starting Relays
Centrifugal Switch.
Centrifugal switches suffer from mechanical wear because the switching arm actually rubs against
the rotating element. Over time the switching arm will break off, this requires switch replacement.
This problem is indicated by the motor not starting to rotate combined with excessive current draw.
Another mechanical problem that can occur is that the springs that hold the flyweight and determine
the speed at which the switch will open circuit break. Symptom of this is that the motor will not start
each time, and when it does it appears to be slow at getting away. ie. The starting torque is reduced
because the start winding is removed from the circuit too early.
What normally happens is that the motor will kick off but slow down immediately causing the
centrifugal switch to reset and give the motor another kick along. This will continue to be repeated
until the motor overload heats up and trips open. There is no electrical test for this you need to
dismantle the motor and look.
Remember replace the spring or the centrifugal switch with one of the same rating.
Current Coil Relay.
Because the conductor in the coil of the currents coil relay is so large in diameter not much can go
wrong with it, other than mechanical breaks at the connection points. There are a few things that go
wrong with the contacts. Burning is one which makes the contacts a high resistance point. This is
indicated by the motor starting some times but not others.
To check for this remove the relay from the motor, connect an ohmmeter between the pin connection
points on the relay turn the relay upside down and check the ohm reading it should be a perfect
circuit. Repeat this a few times, each time check the ohmmeter reading it should be the same. If there
is any reading that is not a perfect circuit keep the relay upside down but shake it side ways to see if
the reading will improve. Replace the relay if the readings are higher than 5 ohms.
Another problem can be the contact points welding together. This is indicated by the motor starting
but continuing to draw a high current and not getting up to full speed. This is checked the same way
as before, except that when the relay is returned to the upright position the ohmmeter will continue to
show a circuit. Replace the relay.
It is critical to make sure the ohmmeter is working correctly for both of these tests.
Potential Coil Relay.
The potential coil relay has one set of normal close contacts wired in series with the start winding.
The contacts are moved by the potential coil that is wired in parallel across the start winding.
The potential coil needs about 380 volts to work. This is obtained via the step up transformer action
between the run winding (primary) and the start winding (secondary).
Faults.
Start winding stays energized. Either the potential coil has burnt out or the switch contacts have
welded together, use an ohmmeter to test the coil, and a screw driver to feel for the welded contacts.
The coil should have a high resistance, you may have to adjust to a high range setting on the
ohmmeter.
Motor hums but will not start. Normally dirty contact points resulting in an open circuit to the start
winding. The contacts can be cleaned on a lot of potential coil relays so open it up and clean them
with a points file or fine wet and dry paper.
Solid State Relay.
The solid state relay is made from a Positive Temperature Co-efficient semi-conducting material
which needs time to cool between starts. This is the biggest problem.
If the relay hasnt cooled it will not allow a current to flow to the start winding therefore the motor will
not rotate but it will hum and drop out on its overload.
If short cycling of the motor is indicated turn off the machine for 15 minutes then re-start it checking
the operation of the relay with an ammeter to the start winding.
Other than short cycling of the device the motor is connect to not a lot can go wrong, as the are no
moving parts.
Some early relays developed an oxide between the semi-conductor and its holder causing an open
circuit.

63
Answers to Review Questions:

Section No: 1
Q.1
Star and Delta
Q.2
Yes a single phase motor can be connected to a three phase supply as long as a neutral is
present.
Q.3
Phase voltage = 415 volts
Q.4
Line Voltage:
Vline Vp
Phase Voltage:
Vp 415volts
Line Current:
Iline 3 Ip
Phase Current:
Q.5
Ip
Iline
3
Line voltage = 415 volts.
Vl 415volts
1.732 5
8.66
1.732
8.66amperes
5amperes
Line voltage 415volts

Phase voltage
Line current
Vline
415
3
1.732
Il Ip
Phase current
240volts
Il 3.6amperes
3.6amperes
Section No: 2
Q.1
Q.2
Q.3
Q.4
Q.5
Q.6
Q.7
Q.8
Q.9
Q.10
Q.11
Q.12
(d)
(c)
(b)
(c)
(a)
(c)
(d)
(a)
Synchronous.
Swap any two phase connections.
because of the slip speed.
Actual speed = 120 x 50 X 0.96 = 1440 rpm.
4
Q.13
any two lines = 415 volts.

any line and earth = 240 volts.
any line and neutral = 240 volts.
earth and neutral = zero volts.
Q.14

64
Star Y
Delta
L1
L2
L2
L3
A1
B1
C1
B2
C2
A2
L1
L2
L2
L3
A1
B1
C1
B2
C2
A2
Fig. 2
Q.15
Electrical terminals
Bearing
Rotor
Frame
Stator

65
Section No: 3
Q.1
The three contacts when closed supply the electrical power to three phase motor windings.
An ON/OFF control switch when closed energises the contactor coil KI through the overload
and thus creating an electromagnet causing the three contacts close.
Q.2
Coil, armature, electrical contacts.
Q.3
Can switch the three phase appliance on and off automatically and provides overload
protection.
Q.4
D.O.L.
Star Delta
Auto- transformer
Primary Resistance
Part Winding.
Electronic Soft Start.
Secondary resistance.
Q.5
N
Stop Switch
Start switch
K1
O/L
Auxiliary Latching
Contact (K1-4)
Q.6
Pushing the start button energises K1 and closes K1 contacts and thus when start button is
released K1 is latch in through K1 4.
Section No: 4
Q.1
Mechanical load is greater than the electrical rating (kW)

Rotor shaft locked
Partial loss of supply voltage
Reduction in supply phase voltages
Winding insulation breakdown.
Q.2
Fuses, circuit breakers, thermal overload, magnetic overload.
Q.3
Thermal overload (bi-metal strip)Thermistors.
Q.4
Not to be set to low to prevent nuisance tripping

Not to high causing motor burn out.
Q.5
A heater senses a rise in temperature on either one of the phases, this rise in temperature
causes the bi-metal strips to warp and through a lever mechanism the overload switch is
opened.
Q.6
Relays and contactors will not operate correctly.

Sensing devices do not respond as required.
Increase in temperature of motor windings.
66
Q.7
Increase power consumption in the control circuit.

Sensing and controlling devices operating incorrectly.
Increase in motor temperature.
Thermal
Magnetic
Voltage
Q.8
Q.9
To isolate electrical circuit between the motor supply and or its associated control circuit in
the event of electrical or mechanical hazards.
Q.10
Increased heating of protective devices

Increase in temperature of the motor
Extra stress placed on the motor
Control contacts, both power and control, have increased operation which will result in lower
life span.
Coupling between motor and load is subjected to increased stress.
Section No: 5
Q.1
Start
Q.2
Change either the start or run winding connections but not both.
Q.3a
Q.3b
Circuit energised causes a high rush or current through the relay coil.
Relay contacts close and energises both start and run.
As motor reaches full speed current falls and relay contacts to open.
The start winding drops out and leaves the run winding in circuit.
Voltage is applied to the motor.
As the current flows through the SSR it causes the semi conductor to heat up.
The semi conductor will reach a temperature where its resistance will change for very low to
very high.
This will reduce the current flow to a trickle maintaining the heat in the semi conductor.
Q.4
Ensure correct voltage is present.

Isolate power supply to motor.
Check relay and overload operation.
With the motor terminals disconnected check the winding resistance against the
manufacturers specifications using an ohm meter or megger.
When the motor is at standstill the centrifugal switch is closed.

Both start and run are energised.
Centrifugal switch will open at approximately 75% full motor speed dropping the start winding
out and leaving the run in.
Q.5
Q.6
Locked rotor
Open circuit in either winding
Faulty relay
Excessive load on motor trips out on overload.
Q.7
N = 120 x f
P
x slip
N = 120 x 50 X 0.96
2

N = 2880 rpm
67
Q.8
O/L
Split phase motor with a

current coil relay
Q.9
R
C
S
O/L
PTC
Split phase motor with a solid
state relay
Q10

68
47 ohms
22 ohms
25 ohms
Section No: 6
Q.1
Speed sensing, current sensing or voltage sensing devices. Which include: centrifugal
switch, current coil relay, solid state relay and potential coil relay.
Q.2
Dismantling and turning the stator end for end, relative to the rotor.
Q.3
The capacitor start motor has a start capacitor connected in series with the start winding.
Q.4
By switching the supply connection from one side of the capacitor to the other.
Q.5
The contacts are normally closed energising both windings (aux & main).
The contacts will open at approximately 75% full speed due the back EMF generated in the
auxiliary winding.
The auxiliary drops out and leaves the main in circuit.
Q.6
(b)
Q.7
(c)
Q.8
(d)
Q.9
Reduced noise and vibration.

Improved motor efficiency and power factor.
Current coil relay can be used on this type of motor.
Q.10
Because the refrigeration system would require a motor with high starting and running
torques to compensate for varying loads. Split phase motor has both low starting and running
torques.

69

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Three Phase / Single Phase Motors &Circuits

Student Resource Package No: NRE8.

through either a formal education setting or in the

Recognition of Prior Learning:

The student/candidate may be granted recognition of

underpinning knowledge and skills to identify and test

Australian Refrigeration and Air Conditioning Vol 1&2.

The assessment of this package is holistic in nature

NRE 8 Three Phase/Signal Phase Motors and Circuits

CLASS MARK (%)

Simulated practical exercises in regards to three phase motors, single

Short answer Questions, multiple choice questions.

Delivery & Assessment Details:

Three Phase Electrical Systems:

Common Motor Information:

Three Phase Induction Motors:

Three Phase D.O. L. Motor Starter:

Three Phase Motor Protection:

Split Phase, motors Starters and Overloads:

Capacitor, Shaded Pole & Synchronous Motors:

Series Universal Motors:

Servicing Motors and auxiliary equipment:

Answers to Review Questions:

End of Package Assessment:

NRE 8 Three Phase/Signal Phase Motors and Circuits

Competence in this training program can be achieved through either a formal

education setting by completing the attached student resource package or in

The following resource packages or equivalent is a prerequisite:

Occupational Health & Safety (7793T)

Recognition of Prior Learning:

UTE NES 209EA:

UTE NES 210EA:

UTE NES 206EA

Australian Refrigeration and Air Conditioning Volume 1 & 2.

NRE 8 Three Phase/Signal Phase Motors and Circuits

Three Phase Electrical Systems:

Reference to Refrigeration Electrical 1 & 2 may be necessary to revise single

Three Phase Electrical Production:

NRE 8 Three Phase/Signal Phase Motors and Circuits

Types of three phase connections:

Phase Voltage (Vp) = 240volts

Note: for calculation purposes

NRE 8 Three Phase/Signal Phase Motors and Circuits

3 x phase current or simply put: I line = 3 x I phase

Consumer Electrical Supply in Australia.

NRE 8 Three Phase/Signal Phase Motors and Circuits

P = power in watts or kilowatts (w or kW)

P 1.732 415 6.5 0.84

Total cos t kW cos t / kWHr time

Symptoms of low voltage supply.

Causes of low voltage

NRE 8 Three Phase/Signal Phase Motors and Circuits

Therefore the total cost over a period of 24 hours equals: $11.30

Review Questions Section No: 1

List the two methods of connecting a three phase systems?

NRE 8 Three Phase/Signal Phase Motors and Circuits

magnetism produced by the stator windings, this then

Windings; The windings are made from varnish

NRE 8 Three Phase/Signal Phase Motors and Circuits

Squirrel Cage Rotor

The holes that accommodate the conductors are

simplicity and rugged construction

No sparking contacts in the motor so they can be used in explosive atmosphere