E-Carbon Asia Sdn. Bhd.

Co. No: (649735H)

71-71A, Jalan Sesama, Taman Perusahaan Batu Caves
68100 Selangor Darul Ehsan, Malaysia.
Tel: 603-61888390 Fax: 603-61888391
E-mail: sales@ecarbonasia.com Web site www.ecarbonasia.com

TECHNICAL REPORT
By:
Inspection date: 18 October 12

Customer : Date:
Area/Section: Coal Mill

Machine Details: EMZ DC Motor Motor No:

KW: 400KW Voltage: 6.6KV
Rated Rotor Current (amps): 360A RPM: 1500
Running Rotor Current (amps): 85 - 90%
No. of Rings : 3
No. of Brushes/Ring: 3 (9 per set)
Brush Size: 25 x 32 = 8.0 cm²
Schunk B25 - 90% metal
Brush Grade in Use: Rating 25 – 30 A/cm²
Current Density: 360÷8÷3 =15.0 A/cm²
Brush Grade Pantrac Gmbh Grade RC67
Recommendation: Rating 15 - 18 A/cm²
Spring Pressure: 1400 Gram - Good
Ring Condition: Threaded/Grooving on 2 rings

General:

1. Inspected motor at xxx on xxx along with Mr. xxx of xxx.

2. Inner & outer ring threaded – No film or Patina formation on all rings with high friction.
3. Excessive brush wear & carbon/copper dust.
4. Checked Spring pressure – Good at 1400 G (Recommended 180 g/cm²) x 8 = 1440G
5. Holder setting good (air gap between holder & ring at 3.0 mm & to spec)
6. Motor was de brushed to 2 brushes per ring to improve the problem, but still no signs of
improvement due to poor ring condition & brush instability.
7. Brush Grade B25 in use is not suited to the motor output as it is very unbalanced. The
current density of 25–30 A/cm² & 90% copper/metal content of Grade B25 is creating
high friction as the brush is unable to work at it max capability in order to lay down a
protective film or patina to enable a low coefficient of friction & hence provide good
brush wear with no ring wear.

.
Contd/Pg. 2……………
 E-Carbon Asia Sdn. Bhd.
Co. No: (649735H)
71-71A, Jalan Sesama, Taman Perusahaan Batu Caves
68100 Selangor Darul Ehsan, Malaysia.
Tel: 603-61888390 Fax: 603-61888391
E-mail: sales@ecarbonasia.com Web site www.ecarbonasia.com

Page 2

Photos of Carbon Brush & Slip Rings.

Brush Face Badly Threaded/Grooved Middle Ring No Film & Threaded

No Film on all Rings Center & R.Outer grooved Spring coils sitting on in grove on brush
(Recommend insulating pad on brush top
to prevent current passing throgh the coil springs)

Contd/Pg.3………………
 E-Carbon Asia Sdn. Bhd.
Co. No: (649735H)
71-71A, Jalan Sesama, Taman Perusahaan Batu Caves
68100 Selangor Darul Ehsan, Malaysia.
Tel: 603-61888390 Fax: 603-61888391
E-mail: sales@ecarbonasia.com Web site www.ecarbonasia.com

Page 3

Recommendations:

The present problems with excessive brush wear & carbon dust is mainly due to the unsuitable brush
grade & can be remedied for good performance.

a) Skimming of rings & undercutting/chamfering of spiral grooves as rings are very threaded &
contributing to brush instability & poor brush contact with ring, resulting in high brush wear.

b) Recommend Grade RC 67 rated at 18 A/cm² which will be better suited to the machine output &
operating conditions. This will ensure good film formation & prevent ring wear & deterioration.
Please refer attached data sheet.

c) Recommend an insulated pad be fitted to the new brush grade to prevent current passing through
the constant force coils which may deteriorate through heat. The insulated pad will prevent this
from occurring & preserve the spring coils & loss of tension which is critical for good brush
performance.

d) E-Carbon Asia xxx will manufacture & supply the new brush grade & design to xxxx. We will
also liaise with xxx to discuss with xxx on a suitable time to carry out the machining of the Slip
Rings before fitting the new carbon brushes.

e) It is also not advisable to de-brush the motor to using 2 brushes per ring even though it is a
suitable way to increase brush current density even though de-brushing is an acceptable practice &
is carried out on other machines. I do not recommend it on HV machines.

f) From my experience with HV motors it is advisable to fit a minimum of 3 brushes per ring just in
case at some stage a carbon brush losses it contact with the ring due to loss of tension or brush
jamming in the holder which is possible on Slip Ring machines. Using a minimum of 3 brushes as
per your original design is a good factor as this assists with the other 2 brushes being able to
handle the current in an emergency situation & the machine will still operate & prevent any major
failure. This has always been my theory with HV machines with my long term experience. It is a
good safety factor.

g) It is also advisable to perhaps thoroughly clean out the motor due to the excessive dust generated
by the brush wear which could possibly get into the motor windings. The filters have been cleaned
by Pahang Cement on regular basis, but this may still not prevent some dust from entering other
areas of the motor.

h) E-Carbon Asia will also undertake to carry out a regular inspection & monitor the performance of
the new brushes every 4 – 6 weeks to ensure the performance is good.
 Page 4

Conclusion: E-Carbon Asia will liaise with xxxx to carry out the necessary measures to ensure this
machine performs well & will keep you advised as we progress.

If you require any further details or assistance, I would be only too pleased to further discuss with you.

General Manager & Technical Director SE Asia

E-Carbon Asia
H/P No:

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