iM | li | | | | | | | | THESIS ze8 Il LOSSES AND EFFICIENCIES VURS mca mi SRG mela HA. WARNER = §.F. DELVIN Pee Riedl QA Wowwy pore 972, THESIS A STUDY OF THE LOSSES AND EFPICIENCIES OF A ZOTOR GENERATOR Sct. BY H, Ae WarlRe s Fe DELVIN. MICHIGAN ST4Tc COLLEGE BAST LacING, MICHIGAN SPRING 191s This thesis was contributed by Mir. Re A. Warner under the date indicated by the department stamp, to renvlace the original which was destroyed in the fire of Warch 5, 1916. THESIS OUTLINE OBJECT. The object of this thesis will be the determination ani study of the losses, together vith the efficiencies, existing in the motor- generator set in tho Large Engineering Labaratory at the yichigan State College. Furth rrore to gotermine a rating of the motor ané its capacity for driving the altenator. Bearing in mind that in order to obtain valusble data frou any test it is necessary to foliow standard methods of procedure, we hive decide: to detormnine experimentally all the individual lcsses ani com- bined efficiencies of the set throughout an operative range of speed, load ani field excitation, fo lowing the standardisation rules (See Etandard Hand Sook Section 19) as far as possible. NOTE 1. To avoid confusion and for th» sake of brevity, hereafter ve will call the gensrator of the get ‘he altenator, the motor of the set the motor and the outside driving motor the auxiliary. The losses are:~ le. Bearing Friction and Windage. Measured by driving the machine unexcited from tho auxiliary, the output of hich 4a vuitabdly determined. ée. Cormutator Bruch friction. Mexeure’ by the increase in input to tho auxiliary required for driving motor wien brushes on and brushes off (The (2 field being unexcited) 3. Collector Ring Brush Friction. Measured ina sicilar manner to tho Commutator Brush Priction. 4. Core Losses. Measured by driving ci.chine with fic. excite!, either as a motor or by an independent motor an: determined by subtracting @il othor losses from the imput to ~otor. 5» Armature Resistance Loss. Resistance measured by ths Drop of Potential Method. 6, Field Resistance Loss. Resistance measured by the Queene Acme Testing Set. The Deter:c:ination of Efficiencies. 1. Motor- Input-losses Input &. Altenator- Output Cut put+ lesses 3. Combined The efficiency of Motor x tho Efficiency of Altenator. Description of the Machines. To meet the growing nesd of the Electrical Departzcnt at the eollege for a source of altvrnating current for testing purzoses, a motor-genorator set was built up by diroctly connecting a remodeled D. C. motor to an A, C. generator. The history anit deserintion of eich michine, ac far as was obtainadle, is herein given, The Jeseription of the altenator is taken from the thesia of A. F. Pulling and ©. H. Ponits of the elass of 191° " The Machine (#69985) wus purchused by the Michigan State College October 24th., 1897 from the Wectinghouse Electric ani Miz, Co. .t a cost of $2490.° (2) It is a 75 &. We » 2200 volt, = phase, lo pole machine to be run at 720 Re Pe. Mo | During the first five years of its operation the alternator suyplied the colleg» with elestrical snercy. After that time up to October, 1909, it served varicus purposas. In the fall «of 1909 the alternator was ncovet from the Powsr Wcouse at Pluttts iam, Lanaing, Miche, to the Mechanical Laboratory of the colls.o where it has since been used for testinz: purposes." The motor, orizinally 2 5u5 velt, shunt vound machine of the General Blectrieal Compuny's make, wac purehazed Necembor 1910 fron the Capitol Electric Co., of Linsinj:, Mich. for S2C'Oe Oe Previcus to this time it was ths prcopert; of the Huzh Lyons Purriture Oo. of Laneinge During Ohristaas vacation of 1911 Mr. Clarence Be Cable, then a special student at the colloe, was employei by ths Electrical Department to make over the machino #0 as to be used on a 220 volt oirouit. This was dono by soldering each two consecutive armature segrents together and connectin.; the fur field ecils in rurallel. Bo aligned up ani direct connected the motor and alternator ag shown in Fize le The auxiliary consistoi of 2 [20 volt rotary converter run delt connectsd for all to:ts (foo Fizes. 2 & 3)thrceuchcut thesis. (3) Pic> le PREPARATION FOR Tooke All meteors ani tachtometors used were carefully calibrated so that all readings might represent the actual conditions of the teste. Suitable pulleys were necess:ry for the auxiliary and moter to give the correct range of speed for the testse Those were found and put in place. The slip ring brushes wore thon removed from the Ae O. side of the auxiliary ani all the tests rum from the De Ce sitee That field current was then found which wuld give the correct speed (3a) with 220 volts across the Armature. Tris fieli current was kept constant at 1.3 amperes threuphcut all tests, thus keeping the core .oss of the auxiliary constant. The speed wis varied by the dc-ster method® and the following data obtained from which tho str.y puaur Jusees were cvleulated as shown below and plotted on curve sheet #1. I:r ediately aiter this test th= resistance of the armature was mecsured using the Queene Acme Testing set ani found to be .c7 ohms. The I“R loss curve of the armature is al.own on curve shuet Ho. c. From these :wo curves the total losses of the Auxiliary for any speed and «ny armature current may be obtained. Data and Caleculsviorns, R. P.M. E. I. EY I°R 8, 1899 222.7 6086 1420 13 1497 1770 218.9 5435 1170 9 1161 1750s 215.8 ~— 6,021 1295 12 1283 1610 250 5.35 1070 ¢ 1041 1600 197 5.35 1053 9 1044 1530 189 4.94 Q14 7 907 8 equals STRAY POWER LOSS IN YATTS RESTITU . ION We were iniebtad to Mr. G. A. Kelsall for the salibration of the meters and his tine spent in cur behalf and to Nr. Le. Fe Newell of the Power house for his coonvsration in the running of tre loal test. * fhe Boost.r method of changing the speed was used on all tests wherever the spesod was varied. (4) TEST ON MOTOR The motor was uncoupled from the alternator. Fig. 2 shows the auxiliary belt connected to the motor with its starting box, field rheostat and tachtometers in place. The fields of tho auxiliary and motor for ail tests were separately excited and provided with rheostats to vary the excitation when deisred. There were am-eters in the field and arrature circuits of the auxiliary and the field of the motor. A voltmeter was place: across the armature for all tests. Fig, 26 Mechanical Losses of wotor. The mechanical losses of the motor are? 1. Bearing Priction and Windage, 2. Comrmutator Brush Friction. The Bearing Frietion ani Windags losses wers obtaine? for different epesia of the motor by removing its brushes and measuring the input (5) to the auxiliarye Pris imput incluloz also all the losses f the auxiliary ait belt as ahewn on Curvo shoot 236 Data anil Caleoulsticns for Boaring Friotion ari Winiaze. A M B I BX B C D 1812 900 2310. 39 Ge? 1°57 Mle -- oo 1742 S70 P2303 = Go BE 14°75 1305 mi GL 1695 9841 P1505 8 8=— 6 SG 1377 1229 oo, BE 1610 803 2U%0e% Geed L550 100% Gn 154 1535 765 L9e 5 0&7 L105 Sus qT: Lee 1511 750 495 5 087 1144 CG3 Ti 125 1:40 T9 1: ¢ ven 104.5 195 SG 107 2400 699 133 Cet. GO rae) So 1:37 . . 7 6; __. ao fe , ~ . Lean . .$ 9. Ae cor Je RwPelie G? hmalissy e201 M. aude Bedelie of Mistere , : 7 ° ” ae ‘ “#6 , *- nn Ne re. * Seat caw hasty Tower fae Guosva vhost ol and ate . wv - we -_ “6 .e .* sys * _ 4 v Ce f Belt accsa: in Vaures cao frum Curcvo shouts <4 un2 7 ‘ wees -- . . 8 we? - ie > - 2 os oo, Ye OW Ry ea tes wy 3 - at . ve, ry “1°! uf wy .4 7 108003 wala Wot, ve e ‘ ~ . - Ly ae !~C«*S Jolbzs oarnad acspre of wzllianry z - ee :™ 4 _ won . ate aye tT. " Curcois Paput to smelt lire Ja amr orese The belt los: -rs3 leturuined by messuring the incressed ixrut or power required ts run the mctor by the auxiliary thin was re vulred wier run electrica.ly ac a :otor witn tha sass fisll excitation fcr the motor in both ouiese Whor. run clectricali, iv cust bo romorbess d to subtract the IR loys of tne motor armaturve aA cO* dian. eplit wooten pulley was uged on ths shaft ef the wotor a.l ay 5,8" diame on the auxildurye The wiith of tho velt was 5". Data and Calculations for th: Belt Loss A. M, g, I, SI 3, yr. 1750 882 862300 «-114,51 «33400230 «1388 = 2052 1690 850 228.2 14.51 3230 1284 1946 1655 833 0ss26.8 Sis 3150 1026 1924 1595 €03 298.4 14.01 2920 1113 1807 152576920 " en2o— 993827 1480 745 195 8 2734 $le 1616 1435 7272 189 13.72 75.55 813 1752 1400 705 §=184 " £5.10 783 1727 FP eyusals rower in watts deliver i to belt by auxiliary . 399 Curve A curves eneei 25. :, For data and calculations when motor is run electric.lly see Core loss test page for 3.88 Amz -can Field excitation, also see curve B. on Curvy» sheet No. 4, The Cos:utator Brush Friction losses Were to hive boan de- tercined by the inereussd input to auxiliary required to drive motor with the brushes on tian vith tho brushes off ( the field being un- excited) but owing te 81 error tiscoversi in ths armeter reading too late .o be corrsetet, another method wi: weed as follows: The motor has the com:utator orushes arranged in sets of three each, The motor will run idle equally well -vith one, two or all the brushes of vach set in contrct with the coreutator. A finely reuling ammeter in tha arrature cireuilt +1ll chow ths diffcrence in the current necesnary to drive the rachine under these different eonditicns. The average data for the thres brushes together with ths compute: power necessary to overcome tno brush friction is shown below ani the brush {riction loss plotted to sreed as abscissae® on Curve she-t No. 3. (7) Cosmutator Brush Friction Msnta, a. Ee I. set 810 C5503 1.4 987 130 210.6 1.4 985 645 186.9 1.866 771 I equals Ay. Current in Amp. reguirei to over come 1/8 {friction due to brushes. E. eyuals Voltage across Armature of Hotor. Curves of core icsses a functions of speed and exciting current are shown on Curve sheut Noe 4. or wach value of field current th= core 40053 Was Obtained al different speeds by measuring the inzut to the motor, run eleotricilly, and subtr.cting the I°R and mechanical losses. Core Loss Data an:! Calculations Field Current 6.78 Aw>o res. Me he I. i I°R We H. Tia e34.c 8.98 2195 i 1011 = 1965 710 231.1 9.9 980 " 966 1965 6S 224.4 8.98 «015 ® 974 15le 672 216.9 £&.9& 1969 " 941 979 G. equals Nach «nienl losses of motor in watts. EK. * Core loss in watts , x, * Voltage across armature of motor. Field Current 3.79 Amp. ue E. I. EI. IR. G. H. 747 £34,1 8.98 2950-29 1031 1029 730 228.9" ~— 285 . 1014-1012 710.0 22,2 (1983 " 986 968 699 el7.9 * 1954 °84 942 (8) M. 786 760 740 732 46 § 7 ‘@ . B20 ae 733 720 Field Current 4.84 A. E. I. £353.46 8.98 226.5 " aobed " 218.9 3.98 me 83,75 221 8.47 Field Currant E I 234.2 8,47 244.4 « oot 4 " 201 " 197 " 186 . Fiald Currant 5 I #d4ee 7.92 aaLe8 " 2 a 197 " i191 " 185 ® The resistance of the fisid was found to toe 29.45 oheas, taken ET. E995 2935 1986 é “~ 7°%C) 9 ote L6u% 4756 1596 1655 1$21 1468 tn 03 27 S AmlLeres 1'R ti COPTER LOSSES with Queene Acme Testing set. (9 ) 927 92: 773 ovl 839 657 530 $83 The resistance of the arcature wax obtained by taking the avarage resistance from three trials by the drop of potential method, and it was found to ba .0°2 onzs. The droy of potential in this case vas moaaured from the terminals of ths machine. Both were taken efter michine had been running under load. The drop due to brush cortact resigstar.ce was afterward taken cord foun’ to ba 2312 ohms for all brushes Shen the machines was standing stili. This rscistance wiil probubly change whon she echine 4s running ani de a comll error that can not ve remedied, For 1°R loss of urmature see Curve sheet No. 4. » 8 » faeld ts f n * 9, ON ALTERYATOR ewig > ah _ = , y & teh ‘ Seen A similar tast to chat ron on motor waz run on th: alternator. MECHANICAL LO3558 The Beariag Priciion und Plrdiics loasen were detarsined by the Sar) methe’ ant with the gare auxiliary as were these of the motor. fhe auxiliary 13 shown beltoi zw the alternator in Pig. 3. This picture was taken after the test was run and shove the auxiliary field rheostat and anmetor, tho armature combined volt-aameter, ani the tachtometers. Bearing rriction and Wincags Data A Ni E t v2 Y £ C dD 1680 830 218.5 9.61 2102 1295 230 682 1612 39 219.5 9.40 1978 1194 = =a40 634 41538 = 7690 201 925 1355 967 230 641 - 18ND 742 135 - 8.98 1762 919 253 330 1463-720 199 B46 L665 £26 259 530 1408 698 184.5 8,26 1575 747 250 S24 C equals Belt les: di: watts texun from curve she t New Oe D =«° Besring friction ar? wirdese icases in watts see curve sheet Ho. 8, | (10) Fig « 4e (10a) The Slip Ring Friction losses were deter::ined by weasuring the difference impute with tho brushes up ani with tho brushes down. Becring Prictictn, Winiace ani Slip Ring Frictione A M E I EI B C G 1675 830 21904 10055 «83400 sanko 2 20 390 1612 798 21905 10.34 2189 1llo 240 330 1832 760 POL 10.02 s0l.oOF 250 7189 2605 745 19605 W002 1969 925 254 790 1458 720 197 GeTl LEGB = OAS 230 168 L4C5 695 1&5 G50 17.5 755 258 748 C is tha belt losacs ¢ukon from Curvs she: t loe 9 and transferred to surve ahaat Noe Se % dis tha total Mochinfe.u lLoeces of Alternator See Ourve sheet To. de Pro Belt loss 423 iatsrninyd by masiring the increased imput required te run ths alternitor by tho auxiliary than was required wion run J rect sonnestod to rotor under sume oconditionsbe Date and Ocleviaticns. le Altersatey ren ty Auxiliary. A & E I EY B y ar 220 28086 6650 1538 5212 1650 808 222.2 287633 6670 1415 4659 1610 790 216.5 26.82 5315 1336 4679 1537 730 9s 207e4 0 2566053053 418 1450 720 19705 24.8 4990 1037 3863 1406 692 19105 92402 «4666. 930 3730 1365 672 186 $368 4430 a0 2620 AL equale R.Pele of Altornators vid) Curve A. Curve sheet No. 9) F equals Power in watts delivurod to belt by auxiliary. (See ce Alternator run by Notor M E I EI J K 820 264.4 29.86 66% 1847 4753 820 we 28.86 6350 1762 4588 778 212.6 328.86 6130 1690 4440 732 202.1 25.8 $2820 1544 3676 721 198 " $110 1512 3598 703 194 * 5994 1479 3525 679 158 25.29 4760 1438 3322 J equals total losses of Notor in watts. Field current of motor 3.88 Ampores. K equals Powsr in watts to run alternator by direct connection to motor. See curve B- Curve sheet Ho. 9. Note! Wield current of alternator was kept constant at 8.9 Auperes for both of the above tests. CORE LOSS The core loss data for the alternator was obtained with the set connected as in Fig. 1. The core loss of the alternator is equal to the imput to the motor minus all motor losses minus all of the me~ chanical losses of the alternator. This data togeth-r with the cale- culations are shown below. The results are plotted to speed as absciesae Curve sheet $10 The core loss-field current eurve is shown on Curve sheet 411. (x ) 810 798 780 T71 731 720 702 673 820 780 736 720 702 A7a Core Loss Data and Caloulations,. Field Current of Alternator equals 11.67 E 22908 216.8 213.6 211.8 201 197 193 186 Field E 224.4 218.9 . 213.6 c1e.6 Ose 198 194 186 Field E 225.5 220 214.7 anc el 198, 194 LRA I 36.6 36.1 36.1 36.1 32.98 32.46 31.94 current I 31.94 31.94 31.94 81.42 28.35 28.35 27,84 07 933 currant I 26.82 26.82 23.8 90 979 EL J 8170 1862 7830 1841 7720 1820 7640 1802 6642 1724 6400 1759 6170 1672 $940 1622 equals 9.85 ET J 7170 1262 TOOO 1850 6825 1810 6680 18%) 5790 l7e2 5620 1790 54%) 1672 5080 1420 7.96 amperos ET J 6050 1867 5900 1637 §770 1807 4810 172e 4720 1691 4620 1652 ACTE 1K11 G 845 825 812 602 774 764 754 736 775 TE 75d 736 863 832 812 775 764 754 722 H 5463 5164 §088 503 6 4142 3936 3744 3582 4425 4315 4203 4073 3293 3156 2975 3320 3231 8151 2813 2265 2215 IRQA Field current equals 6.03 amperes M E I EI J G H 834 228.9 21.76 4980 1895 904 2181 810 Ba08@ 81.625 4725 1845 845 2025 788 £1528 ® 4560 1895 817 1958 731 ee 19.7 3969 Wool 778 1481 720 198. “ E950 1683 764 1553 692 191 " 37 62 1633 745 1384 675 186 19.18 3570 1602 740 11732 Field current 5.96 amperes M E I Et J G H 8:3 227.8 19.7 4480 1893 9090 1667 820 $22.2 a 4880 1863 863 1654 787 214.7 19.18 4120 1802 815 1503 7387 198 18.12 3590 1691 774 1125 720 196 " 3550 1681 7164 1105 12 193 * ~~ 8500 1651 754 1095 674 186 " 3370 1600 738 1032 Eand I rsfer to the motor Test of Alternator continued. COPPER LOSSES The resistance of the two phases of the armawmre were measured separately by the drop of potential method inmediately after the load test wae run and while the armature was warn. For sake of convenience the phase leading to the two alternate rings nearest the armature of the machine will be designated ay Phase 2. The drop of potential was measured across these rings. The average resistances thus obtained for several readings were for Phase $1, 1.84 ohms and for phase #2, 1.76 ohms. (14) The TER losses for doth phases are shown on curve shevt #12. The resistance of th: field taken warm by the Quesne Acme testing set was found to be 10.15 ohms cand the I“R losses plotted to field current on curve sheet 47. Load Pest on Set. In order to test the set under load conditions two large water boxes were fixed up and each phase loaded on one of the water boxes. The water box consisted of a large barrel insulated {rom the floor and fillsi with clean well water. One terminal led through the bottom of the barrel to a cast iron disk about 5” in diameter and 1° in thickness. The other terminal consisted of an old suw blade suspended in such a ranner that it could be raised out or lowered inta the water as desirsi from thse table directly back of the machines. Bee Fig. 4) Bator boxes fixed ur for 220° Volts ware neceasiry because the transformer equipment wis not large enough to transform the full load current of the machine. The water box described worked with ontire satisfaction at 2200 volts. Considerable heat was evident however. It wus also necessary to construct a temporary line from the main feeders, vhere they came into the Engineering Building under the Last stairs, to the machine, as thos: fecders leading to the motor we-e not heavy encugh to carry full load current. All fuses on the line were taken out and the line connected to run directly from the circuit breakers of a separate gonerator in the power house. . Owing to an inefficient anmeter in the armature circuit of the motor ite isput is not entirely available. All other readings were | taken as shown below and the rerulation for one phase and for both phases together deternined. The motor carried the losi without show- ing any signs of being overloaded up to 3/4 load on the alternator. At full load of alternator the only sizns of distress was excessive brush sparking. (15) Bata and epleulations for Load Test Spsed constant ai 720 FR. PF. M. Oe5 9.04 4.92 4.72 425* * At “ower Hceuse Motor Readings z 243.7 250A 338.4 236.3 234.2 23301 | £: Qed 331.1 233.1 243.7 33362 3 ade ay ™ 6.3 9.2 15 “19,5 17.5 Q Tf eguals Fhel: current in ancsres A Ip | ae ') 2160 2160 2190 2160 2160 2159 Ear at -19) 2150 2119 2070 2059 2010 2090 £360 9.85 9.58 10.78 Armature current on phase 1 in amperes Regulation for one phase e200 (16) aguals ,O991 or .31] Regulation for both phases £360-2200 equals .9727 or 7.27% 8200 Efficiencies from Losses Efficiency of Motor equiles JMput-Logses Imput Ef{ficienoy of Alternator equile Output Output Losses Combined effielency equals Product of the efficiencies of motor and altornator when the output of mrtor in equal to the imput So ths Alternator. Ths separate efficiencies of sach machine and their combin.d effiecluicy are shown olotted to K. ¥. output of motor and K. YW. Amput to altornator on Curve she ¢ #13, The. Eff{iclercy-Imput curve of motor ani the combined Effi- cisncy -Izput curve of set are shown on Curve sheet #14, fhe Effictency-Output curve of Alternator and the combined Ef fdeiency - Ovtout curve of set are shown on Carve sheet 415. Prom the Efficiency curves 56 near an actual rating for tha motor an js ros«ible to get would be a 235 volt, 4 pole, 720 RMP. 94 H.P., motor as it row stands direct connected to tho alternator. Motor g£f{ficieney Data The constants are 720 R.N.?., 6.78 amperes field current, 1370 watts field resiatance loss, 80 watte bearing friction and windage loss and 1996 watts core lese, taken from curve sheets. (17) I IR Total poss Imput Output §. 4 KF. K.*. 0 0 1370 1.37 0 0 10 3.2 3409 3.57 16 4.5 eo 20 3426 6,57 3.44 39.5 59 gC 3486 12.37 8.8ée 71.8 75 79 3585 17.87 14.2 AC: 109 320 8726 23,27 19, 34 84.1 1590 20 4125 34.37 3.24 88 202 1280 4556 47.37 49.6 89.5 250 «20% 5606 90.37 +). 96 90.3 369 880 $266 67.37 5b OS 91,6 380 2900 7306 78.37 71,06 90.7 4090 $12C 8525 89.37 8,64 99.35 4590 6470 9276 109.37 99,49 99,21 900 8000 — 11496 111.37 99.96 £9,7 Alternator Effieloncy Data, Constants 760 RPM, 220) volts, 745 bearing friction and Windage and slip ring friction losses. I I¢ Totel Losses K.7.1.P. K.=.0.P. kr. % Q 9.58 4690 4.49 D 0 3 9.63 A721 13,50 8.8 65 4 $.69 {922 Pe AN 17.6 Toe 6 9.75 4934 31.33 £5.4 84.2 8 9.82 O07 S 40.28 35.2 57," 10 9.9 9299 49.29 44, 89.3 12 10.2 5529 58.33 56.8 99.6 14 10.35 S762 67.36 61.6 91.6 (18) 0.P.M IPA. 10 K? AO ert > 69 60 Aiternator Efftcisney Data Continued. Ty 10, 65 19.78 10,9 6335 6795 7002 Roa. Totes Losacs K. .I.F. 76.74 83,89 9°, 00 £04.25 L1e.Se Efficiency Calculations I .P Me 13.34 22.8 31.8 45.6 66.2 BFA 112.6 (19) K,W.0.F. Tio 04 77 OPA. 4.7 16.8 2%ell 35. 54.6 73.76 92.7 E. % 91.9 92.1 92.6 92.8 9260 oe i ms ae es a 1S) & Ny ) Ss wes | SiS | $ au Raa eae te Aun. Semen s Racensoe at Si x LS / ae | | | S A) | rs ESS SES Seas Mi Tei , yo yr | eae : » / Feat : | Ne | Bet BT Sata } / | } | / | | pete zeae : | | / | ; i | : | | | ge eee ! s t > coo | f | aaa a | A aetedcel WEEE DE) /O7 | wre are Sy a, oe ed ha vats] { TE O77 Scale | A aed A, eit sad Shes se CORRECTION oe ELECTRICAL LABORAT BEACON Onan “72-10 Ste Mi CURVE AIIMETER "23 ed eh LD ee) ae, sa hks sete WME E LL, AY; rey = Es ' J on 4. 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