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  Troubleshooting Chart of DC Machines

Troubleshooting Chart - D.C. Machines:

A) Symptom:  Failure to build up of voltage (dc generator)

Possible Cause of Trouble:

  • Faulty Voltmeter, test output voltage with separate voltmeter. Open field resistor.
  • Open field circuit. Test coils for open circuit or loose connections.
  • Nonexistence of residual magnetism in self excited generator.
  • Dirty commutator, high mica, brushes not comprising good contact with commutator.
  • New brushes seated but not contacting enough area.
  • Armature shorted internally to ground.

Remedy:

  • Change voltmeter. Replace or repair resistor
  • Change defective coils, tighten or solder loose connections.
  • Flash the field. Connect battery to field with correct polarity permit current momentarily and cut off. Field will resume residual magnetism.
  • Within cut mica, clean or dress commutator.
  • Change or reseat brushes, free if binding in holders.
  • Brush bedding and reseat brushes. Eliminate, test and repair or replace.

B) Symptom: Output voltage too low (dc generator)

Possible Cause of Trouble:

  • Grounded or shorted field coil. Shorted filtering capacitor; open filter choke, open ammeter shunt, broken brush shunts.
  • Prime mover speed low (test speed)
  • Brushes not seated properly. Commutator dirty, or film very heavy

Remedy:

  • Test, repair or replace. Adjust governor on prime Mover. Reseat brushes.
  • Clean commutator with fine sand paper. Change brushes with appropriate grade set or Use complete new set of brushes
  • Adjust correctly. Connect properly

C) Symptom: Output voltage too high (dc generator)

Possible causes of trouble:

  • Field resistor not appropriately adjusted
  • Reversed  field  coil  or armature coil connections
  • Prime mover speed too high.
  • Faulty voltage regulator
  • Overloaded.

Remedy:

  • Adjust governing device.
  • Adjust or change faulty voltage regulator.
  • Test speed.

D) Symptom: Armature too hot

Possible causes of trouble:

  • Test meter readings against name plate rating.
  • Excessive brush pressure.
  • Belt very tight or coupling not aligned.
  • End plate out of position. Bent shaft.
  • Armature coil shorted Armature striking poles. Test bearing for play and air gap for correct spacing, shaft for bent condition.
  • Poor ventilation. Clogged air passages.
  • Repeated changes in load In bulk. Examine meter readings.

Remedy:

  • Decrease load.
  • Adjust pressure or replace tension springs.
  • Adjust belt. Align units properly.
  • Assemble accurately.
  • Straighten on lathe or replace.
  • Repair or replace armature. Replace bearings.
  • Straighten shaft or replace Armature.
  • Clean clogged air passages. Give clearance. For circulation of air around equipment. Clean equipment.
  • Faulty design. Generator should be employed in steady load application.

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