5 Carbon Brush Technical Guide Mersen - 07
5 Carbon Brush Technical Guide Mersen - 07
5 Carbon Brush Technical Guide Mersen - 07
T R A N S P O R TAT I O N / E N E R G Y
CARBON BRUSHES
F O R M OTO R S
A N D G E N E R ATO R S
Contents
1 Wh at is a carbon brus h? p. 3
8 APPENDICES p. 3 2
The specifications or data contained in present catalogue are only given for information and do
not create any undertakings whatsoever. Any copy, reproduction or translation, either partially
or fully, of these information is subject to the Mersens prior written consent.
In addition, due to the continuing improvement of techniques and change of applicable
standards, Mersen is entitled to modify at any time the characteristics and specifications of its
products as described in present catalogue.
What is a carbon brush ?
( a l so ca l led motor brush )
A carbon brush is a sliding contact used to transmit electrical current from a static
to a rotating part in a motor or generator, and, as regards DC machines, ensuring
a spark-free commutation.
Five brush grade families are used for brush manufacturing. Each of them
corresponds to a specific requirement and has its own production process (see
pages 9 to 17 of this guide). 3
Operating parameters
The carbon brush plays an essential part in the operation of electrical machines.
To enable it to fulfill its function, we need to consider three types of parameters:
l Mechanical
l Electrical
l Physical and chemical (environment)
Sommaire
joint effort between your company and Mersen will contribute to the performance
and longevity of your equipment.
For more information please refer to Technical Data Sheet TDS-01*, Functions of
a good carbon brush, what you should know.
Mechanical parameters
A proper slip ring or commutator roughness will give the carbon brush an adequate
seating base and will ensure a good current transmission (See Technical Data Sheet
TDS-02*). Slip ring and commutator surfaces must be neither too smooth (glossy),
nor too rough to enable optimal carbon brush performance. High mica often creates
serious problems for brushes. Commutators therefore have to be carefully checked
(correct mica undercutting, absence of burrs along the bar edges) and the bar
edges have to be properly chamfered (See Technical Data Sheet TDS-03*).
It is also necessary to check that the commutator or slip ring run out does not
exceed acceptable limits.
*More information can be obtained from our Technical data sheets, sent upon request, and also available from our
web site www.mersen.com
FRICTION COEFFICIENT (CALLED )
Carbon brush friction coefficient has to be low and stable over time to allow the
carbon brush to work without overheating.
has no fixed value. It is the result of many factors depending upon the carbon
brush grade, speed, load, commutator (or slip ring) condition and environment.
4 For a given carbon brush grade, it is not possible to indicate a precise value,
only a magnitude. This is sufficient for most machine calculations or projects.
VIBRATION
At any given machine speed, the spring pressure must be sufficient such that proper
contact between the carbon brush and the slip ring / commutator is maintained.
(See Technical Data Sheet TDS-11*).
Mersen recommends:
l For stationary electrical machines: 180 - 250 g/cm2 (2.56 - 3.56 psi)
l For electrical machines under heavy vibration (e.g. traction motors): 350 - 500
g/cm2 (5.00 - 7.11 psi)
Equal spring pressure must be maintained for all carbon brushes to ensure a good
current distribution. We therefore advise periodic pressure measurement with a
scale or a load cell.
BRUSH-HOLDERS
The carbon brush has to be guided by a brush-holder of sufficient height and with
an adequate clearance to avoid either the brush getting stuck or the brush rattling
in the holder. Tolerances and clearances are set by the International Electrotechnical
Commission (I.E.C.).
(See Technical Data Sheet TDS-04*).
*More information can be obtained from our Technical data sheets, sent upon request, and also available from our web site www.mersen.com
Electrical parameters
The voltage drop has to be moderate to avoid overheating and abnormal electrical
loss which can damage the sliding contact. It also influences commutation and Points of
current distribution in between the carbon brushes. contact 5
Interface
This is an important characteristic which depends on the carbon brush grade,
layer
electrical contact and film (which is a complex mix of metal oxides, carbon, and Brush
water, deposited on the slip ring or commutator).
Film
It is therefore to be expected that the contact drop is influenced by all the factors
which may modify the film:
The contact drop data indicated for each of the Mersen carbon brush grades are
typical values obtained in specific operating conditions. They are grouped into
five categories ranging from extremely low to high (see pages 13 to 15 of this
guide).
What is Commutation?
Commutation is the process of reversing the direction of the flow of current
in the armature coils under the brush of a DC/AC commutator motor or
generator. The time of commutation is the time taken for complete reversal.
Incorrect adjustment of the brush position relative to the neutral zone, or asymme-
trical brush arm adjustment, can generate commutation sparking, which should not
be confused with other types of sparking due to:
l Mechanical causes (vibration)
l Winding faults (open or short-circuit)
l Poor commutator construction
MULTI WAFER BRUSH
l Quality of the DC supply (ripple or spikes) from the electronic static converters
l Multi
wafer carbon brushes
l Dual
grade composite carbon brushes (with wafers made of different grades)
lS andwich brushes (with two layers of the same grade), which limit cross currents, and
SPLIT BRUSH
have a positive influence on film control. The wafers are glued. (See Technical Data
Sheet TDS-07*)
l Staggering
carbon brushes, adapted for large slow machines (See Technical Data
Sheet TDS-09*)
STAGGERING
BRUSHES
*More information can be obtained from our Technical data sheets, sent upon request, and also available from our web site www.mersen.com
DISTRIBUTION OF CURRENT IN THE BRUSH CONTACT SURFACE
Current does not flow uniformly across the whole brush contact surface. It flows
through a varying number of very small areas called contact spots. Ideally these
contact spots are evenly distributed.
This balance may be disrupted when the contact spots concentrate and decrease
in number. The film will then show signs of grooving, bar marking, streaking, and
6 electrical erosion, deteriorating over time.
CURRENT DENSITY
Current density has a major influence on all aspects of brush performance: wear,
friction, and temperature.
The maximum current densities for each grade are those at rated speed. They
can vary, however, depending on the machines characteristics and the ventilation
method.
Please note that a low current density can be more harmful to the carbon brush
and commutator / slip ring than a high current density (please contact us for more
information).
RESISTIVITY
NOTE
What is resistivity?
Resistivity values for The resistivity of a material, usually symbolized by the Greek letter
brush grades indicated
rho (), represents its resistance to the flow of electrical current.
in this guide are mea-
sured along the radial
direction (please refer
to page 18 of this guide Higher resistivity materials increase the overall resistance in the commutation
for the definition of the circuit, thereby improving commutation. It is a key parameter in the choice of the
radial dimension).
suitable carbon brush grade (please contact us for more information).
Multi wafer brushes, especially sandwich brushes, enable an artificial increase of
transverse resistivity and can improve commutation.
Physical and chemical parameters (environment)
HUMIDITY
Mersen proposes carbon brushes with special treatments for these particular
applications. Do not hesitate to consult us.
Mersens treated brushes can help mitigate these problems by creating a protec-
tive film on the contact surface
Commutators, slip rings and carbon brushes can get contaminated by oils and fats
from various origins:
l Leaks from a bearing which is not properly sealed
l Tiny drops or mist carried by ventilating air
l Vapor condensation (developed at hot points)
*More information can be obtained from our Technical data sheets, sent upon request, and also available from our web site www.mersen.com
DUST
The more abrasive the dust, the more harmful it is. Dust causes:
l Grooving of commutators and slip rings
8 l High brush wear
l arbon brush side gulling (see picture opposite), with brushes sticking in their
C
holders
l Pollution of machines
Dust grooves partly avoid these problems, but the best remedy is prevention,
providing clean filtered air to the machines.
In totally enclosed machines, where carbon dust is continuously recirculated, the
same problems are likely to arise, with the possibility of polluting the machine and
decreasing its insulation resistance. These machines should be cleaned regularly.
DUSTCOLLECTOR,
A NEW INNOVATION
PATENTED BY MERSEN
As stated in this guides introduction, there are five main brush grade families, each with a distinct set of
properties. Some of these groups are complemented by a subgroup of impregnated brush materials (please
consult us to find out more about the specific properties of those special materials).
The choice of the most suited brush grade depends on a large number of parameters linked to the machine
itself as well as its environment. Choosing the brush grade that performs best for a specific application requires
an in-depth knowledge of its working environment. Mersen therefore recommends contacting our experts for
assistance with your specific needs.
Mersen has developed a wide range of brush grades able to meet even the most demanding requirements.
Hereafter, you will find a description of the manufacturing process of our main grade families, as well as a table
with their material properties (see table pages 14 and 15). You will find on pages 16 and 17 a summary of the
major applications together with the operating limitations of most of the grade families (based on our usual
conventions reminded page 13).
Grade families
MAIN CHARACTERISTICS
Electrographitic brushes have a medium contact drop and a low to medium friction
coefficient, and therefore have low electrical loss, particularly suited to high peri-
pheral speeds( 50 m/s). The graphitization process yields a high strength, low
resistance material, particularly resistant to high temperatures.
MAIN APPLICATIONS
lA
ll
DC stationary or traction industrial machines, operating with low, medium or
high voltage and constant or variable loads. They are also found on AC synchro-
nous and asynchronous slip ring applications.
OPERATING LIMITATIONS
lC
urrent density in the brushes:
8 to 12 A/cm2 (50 to 75 A/in) under steady conditions
20 to 25 A/cm2 (130 to 160 A/in) for peak loads
lM
aximum peripheral speed: 50 m/s (154 ft/s).
A. Carbographitic brushes
MAIN CHARACTERISTICS
Carbographitic brushes commutate well due to their high resistance and provide
good polishing action, while maintaining moderate contact drop. As a result of
their high temperature treatment, carbographitic brushes can withstand both high
temperatures and variable loads.
MAIN APPLICATIONS
lM
achines with an older design, mostly characterized by a slow speed, lack of
interpoles, generally operating at low voltage
lM
odern small machines, operating with permanent magnets, servomotors, and
universal motors
lL
ow voltage battery powered motors
OPERATING LIMITATIONS
lC
urrentdensity in the brushes: 8 to 12 A/cm2 (50 to 75 A/in2 ) depending on the
application
lM
aximum peripheral speed: 25 m/s (82 ft/s)
MAIN CHARACTERISTICS
LFC brushes have a low Shore hardness with excellent shock absorbing properties.
This allows them to work in applications where other materials would fail. They
excel at high peripheral speeds which amplify the mechanical stresses associated
with friction, vibration, air flow, run out, and heat.
MAIN APPLICATIONS
lS
teel and stainless steel slip rings for synchronous machines
OPERATING LIMITATIONS
lC
urrent density in the carbon brushes: 10 to 13 A/cm2 (71 to 84 A/in2)
lM
aximum peripheral speed: up to 100 m/s (328 ft/s)
OVERVIEW OF THE MANUFACTURE OF ELECTROGRAPHITE
11
MAIN CHARACTERISTICS
Carbon brushes with high to very high electrical resistance, contact drop, electrical
loss, and mechanical strength, which have very good commutating and cleaning
properties. They can also work at very low current densities.
MAIN APPLICATIONS
OPERATING LIMITATIONS
These metal-graphite materials also include EG and A carbon brushes that are
metal-impregnated (see metal-impregnated brush grades on page 15).
MAIN CHARACTERISTICS
Dense to very dense carbon brushes with low friction and very low contact drop,
therefore operating with very low losses and high currents.
MAIN APPLICATIONS
lL
ow-speed, low voltage DC machines
lM
edium-speed, highly-loaded AC asynchronous machines (wind turbine generators)
lM
edium-speed AC synchronous motors slip rings
lH
igh current collection systems (electrolytic treatment lines, wire annealers, galvanizing lines)
lL
ow-voltage current collection (military, medical, paramedical, signal)
lS
pecial machines
lS
lip ring assemblies in rotary joints
OPERATING LIMITATIONS
lC
urrent density:
10 to 30 A/cm2 (75 to 200 A/in2) under steady conditions
Up to 100 A/cm2 (660 A/in2) for peak loads, depending on metal content
lP
eripheral speed: up to 40 m/s (131 ft/s), depending on metal content
MAIN APPLICATIONS
lS
ignal current transmission (thermocouples, thermometric sensors, regulation)
l Pulse transmission to rotating devices (radar, prospection)
l Tachometer generators
l Aerospace and space applications
l Shaft grounding in a dual-grade construction
OPERATING LIMITATIONS
lC
urrent density up to 50 A/cm2 (440 A/in2).
lP
eripheral speed: up to 30 m/s (98 ft/s)
Consolidation of carbon brush grades
Our Customer Technical Assistance Service is at your disposal for any question
Mersen is present in over 40 countries around the world; our branches are also at
your disposal for local technical assistance.
You can reach our worldwide network through our website at www.mersen.com
The contact drop and friction values are given in the following table:
Contact drop
Symbol Signification (Sum of both Friction
polarities)
E High >3V > 0.20
M Medium 2.3 V - 3 V 0.12 < < 0.20
B Low 1.4 V - 2.3 V < 0.12
TB Very low 0.5 V - 1.4 V
EB Extremely low < 0.5 V
The contact drop and friction values were measured on a copper commutator in the
following laboratory conditions:
The current density and peripheral speed operating conditions were derived from
observations on actual machines in good working order and operating in normal
conditions.
Brush grade groups main characteristics
(according to IEC norm 60413)
Recom-
14 optimum mended
Flexural
BRUSH Resistivity Shore current upper Metal
Apparent strength* Contact Fric-
GRADE Grades .cm hard- density speed content
density* MPa drop tion
GROUPS (.in) ness A/cm m/s %
(PSI)
(A/in) (ft/s)
The specifications or data contained in present catalogue are only given for information and do not create any undertakings whatsoever.
14
Brush grade groups main characteristics
(according to IEC norm 60413)
Recom-
optimum mended
Flexural 15
BRUSH Resistivity Shore current upper Metal
Apparent strength* Contact Fric-
GRADE Grades .cm hard- density speed content
density* MPa drop tion
GROUPS (.in) ness A/cm m/s %
(PSI)
(A/in) (ft/s)
The specifications or data contained in present catalogue are only given for information and do not create any undertakings whatsoever.
15
Grade selection based on application
Mersen has developed a wide range of carbon grades to meet even the most
!
demanding applications. We recommend that our customers contact the Customer
16 Technical Assistance to correctly select the most suitable grade for each specific
application.
Never mix different The tables below detail brush grades most suited for different applications and
brush grades on a slip operating conditions (current density, peripheral speed and applied brush pressure).
ring or commutator.
For each machine group, the most common brush grades are listed.
The order of the brush grades in the table does not imply a ranking of their performance.
ALTERNATING CURRENT
Single phase and repulsion
8 (51) 5 - 15 (16 - 49) 18 (2.6) A252 - EG367
motors
Schrage-type three-phase motors 8 - 12 (51 - 77) 5 - 35 (16 - 115) 18 (2.6) BG412 - BG469 - BG348 - EG367
Schorch-type three-phase motors 10 - 14 (65 - 90) 5 - 35 (16 - 115) 18 (2.6) BG28 - BG469 - EG367 - BG348
Scherbius machines 7 - 9 (45 - 58) 30 (98) 18 (2.6) EG389P - EG313 - LFC554 - EG362
Traction commutator machines
Current
Speed Pressure
Type of current density
m/s kPa Brush grades
/ Application A/cm
(ft/s) (PSI)
(A/in)
DIRECT CURRENT
Light traction
8 - 12 8 - 12 40 - 50 30 - 40
All motors EG34D - EG7099 - EG387 - EG9599 - EG8067 17
(51 - 77) (131 - 164) (4.4 - 5.8)
Heavy traction
Old motors 10 - 12 (65 - 77) < 45 (< 148) < 35 (< 5) EG34D
EG300H - EG9117 - EG387 - EG8067
Modern motors > 12 (> 77) > 45 (> 148) 35 (5)
EG7097 - EG6754 - EG8220
RECTIFIED CURRENT
Heavy traction
Modern motors 12 - 15 (77 - 100) 50 (164) 35 (5) EG367 - EG300H - EG8067 - EG7097 - EG6754
ALTERNATING CURRENT
1623 and 50 Hz heavy traction
Motors 12 - 16 (77 - 104) 45 (148) 25 (3.6) EG367 - E8067 - EG7097
t, a and r dimensions
When contacting us regarding your brush requirement, please provide the following:
lD
imensions in t x a x r (IEC norm 60136).
where t is the tangential dimension or thickness
a is the axial dimension or width
and r is the radial dimension or length.
The r dimension may be for information only.
lT
he same rule applies whether this is a commutator or slip ring brush.
lB
e careful in specifying the unit of measurement as imperial and metric units may be easily
confused (1 = 25.4 mm, is not the same as 25 mm).
a
r
18
Types of hardware
Standard brush configurations
GUIDING HOLE
GROOVED TOP R
R R
BOTTOM BEVEL RADIUS RADIUS + BEVEL
(See Technical Data Sheet TDS-16*)
bolt (mm) 3 4 5 6 8 10 16 - 20 - 25 - 32 - 40 - 50 - 56 - 63 - 71
d (mm) 3,4 4,3 5,2 6,5 8,5 10,5 80 - 90 - 100 - 112 - 125 - 140 - 160
19
*More information can be obtained from our Technical data sheets, sent upon request, and also available from our web site www.mersen.com
Mounting methods
20
SHOCK ABSORBER
AND HARD PLATE
(THE TWO PLATES
SHOCK ABSORBER ARE THREADED TOP PLATE
AND HARD MATERIAL ON TWO FLEXIBLES WEAR LIMITING FOR CANTILEVER BRUSH WITH
FIXED PLATE SILESS AND NOT GLUED) PLASTIC CLIPS PRESSURE DEVICE ALARM SHUNT
DUAL GRADE
GLUED BRUSH* COMPOSITE BRUSH
CONTACT FACE CROSS GROOVED SANDWICH BRUSH* 1 EG LAYER FOR SLIP RING*
WITH SAW CUT CONTACT FACE (2 EG LAYERS) 1 BG LAYER 1/3 EG LAYER
2/3 CG LAYER
*See Technical Data Sheet TDS-7, sent upon request, and also available from our web site www.mersen.com
20
Hardware for split brushes
Shunts
Diameter
(mm)
1.6 1.8 2 2.2 2.5 2.8 3.2 3.6 4 4.5 5 5.6 6.3
Nominal value
of current (A)
15 17 20 24 28 32 38 44 50 60 75 85 100
All shunts are available with tinned wires for corrosion protection.
Tamping: Riveting:
Conductive powder Process used for specific
tamped mechanically applications (e.g. aviation).
into the hole around the The shunt loop placed
shunt. into the carbon brush is
preformed with a tool
before the riveting opera-
tion.
21
R ecommendations
for insta l l ing carbon
brushes in machines
22
Carbon brushes
To precisely match the carbon brush contact surface to the slip ring or commutator
radius, use brush-seating stones (pumice stones) while running at low or no load.
Seating stone dust rapidly erodes the brush contact surface to the right curvature.
It is of course essential to use the M (Medium grain) grade of grinding stone again
after this operation.
When a lot of carbon brush material has to be removed, first rough-grind the
surface using 60 or 80-grit sandpaper. To do this, just insert it with the abrasive face
up between the contact surface and the commutator, and move it back and forth as
shown in Fig. 1. After brush seating thoroughly clean the contact surfaces, blowing
away any abrasive material and/or carbon brush dust.
FIG. 1
CORRECT INCOrRECT
Brush-holders
lM
ake sure that the brush-holder is in working
condition and check the interior surface condition.
FIG. 2
lA
djust the d distance between brush-holder and
commutator to range from 2.5 to 3 mm (Fig. 2).
lA
lign the carbon brushes parallel to the commutator d
bars.
lC
heck with an appropriate gauge that the pres-
sures are equal on all the carbon brushes.
*More information can be obtained from our Technical data sheets, sent upon request, and also available from our web site www.mersen.com
RECOMMENDED PRESSURES
IN NORMAL WORKING CONDITIONS
On commutator
On slip ring Stationary Traction
Grade groups
kPa (PSI) machines machines
kPa (PSI) kPa (PSI)
23
18 - 20 18 - 20 35 - 45
Electrographite
(2.6 - 2.9) (2.6 - 2.9) (5.1 - 6.5)
18 - 25 35 - 55
Resin-impregnated electrographite
(2.6 - 3.6) (5.1 - 8)
18 - 20
Carbographitic & Resin-bonded n/a
(2.6 - 2.9)
* Please consult us
11 - 20*
Soft graphite
(1.6 - 2.9)
18 - 20
Normal speeds
(2.6 - 2.9)
Metal-graphite
25 - 27
Speeds < 1 m/s
(3.6 - 3.9)
Check that there is no out-of-round above 3 mils (75 m) or any obvious surface
defect (see Technical Data Sheet TDS-02*). If needed, grind or machine using a tool
support frame. Mill or undercut the commutator slots (Fig. 1).
Chamfer the bar edges 0.2 to 0.5 mm at 45 (Fig. 2).
Clean the surface with an M grade of grinding stone. Avoid the use of abrasive
paper or cloth. It is absolutely necessary to have sufficient roughness (1.3 to 2 m Ra)
in order to create and maintain a correct film.
Our experts are at your service for any on-site diagnostic, maintenance, or
refurbishment.
Fig.1 Fig.2
First make sure that all carbon brushes slide freely inside the brush-holders, the shunts
are correctly routed, and the terminals are properly tightened. Then start up the
machine, preferably at low load, and increase progressively until full load is reached.
*More information can be obtained from our Technical data sheets, sent upon request, and also available from our web site www.mersen.com
V isua l guide to s l i p ring /
commutator fi l ms
24
The film is a complex mix of metal oxides, carbon and water, which is deposited on the
collector / slip ring. A close look at the film can help in assessing the condition of your
electrical rotating machine.
Below are examples of various film conditions and commutator / slip ring faults, as
well as their causes.
P. Film types
SUITABLE FILMS
COLOR INTENSITY
lP
2 - P4 - P6: Normal films
lU
niform, light brown (P2) to darker brown (P6).
The machine and the carbon brushes work well.
P2 P4 P6
24
SUSPECT FILMING REQUIRING MONITORING
P16b P16FF*
lP
22: Uneven film, screw thread effect
l M
ost frequent cause: bad commutator machining during a maintenance
operation (chattering tool).
26 lP
24:
Dark in patches, often followed by lighter faded patches, signs of
commutator deformation
l M
ost frequent cause: defect affecting one bar or a group of bars, and making the
carbon brush bounce. Light bars are high bars, dark bars are low bars.
lP
26 - P28: Dark patches in the middle or on the edges
l hading in the middle of the bars (P26) or at the two bar edges (P28).
S
l Most frequent cause: poor maintenance of the commutator.
26
P22 P24
P26 P28
P42 P44
PATCHES DUE TO POLLUTION
P62
B. Burning
27
l B6: Spark burns at bar edges
l B8: Burning at center of bars
l B10: Pitted film
l V
ariable number of small light patches randomly spread on a normal filmed track.
l M
ost frequent cause: sparking under the carbon brushes.
B6 B8 B10
T. Marking
PARTICULAR TYPES
lT
14: Dark fringe due to low bar L4
lT
16: Dark fringes due to high mica L6
lT
18: Dark local patches due to burs L8
28
L2 L4 L6
lL
2: high bar
lL
4: low bar
lL
6: high mica
L8 L10
lL
8: burs at bar edges
lL
10: copper drag
lR
2:Commutator with axial profile showing metal wear on each track correct
stagger. This wear may appear after a very long period of operation.
lR
4:Commutator showing abnormal wear of the metal due to incorrect axial
stagger, unsuitable carbon brush material, various pollutions...
R2 R4
28
M ersen s services
29
For any technical expertise, maintenance or training, Mersen experts offer their
extensive knowledge, years of experience and global reach.
Expertise
lO
n-site practical support throughout the world
lC
ommutation expertise
lM
easurements and diagnostics
lS
upport service on a daily basis
lT
echnical assistance by phone
lT
echnical documentation on-line on our website: www.mersen.com or upon request
WindtrackerTM services
Mersen created the WindtrackerTM Service in order to support wind farm operators.
WindtrackerTM services
WindtrackerTM experts, dedicated wind engineers and technicians, bring you up
tower services, diagnostic capabilities, specific technical support and training,
allowing you to optimize your wind turbine performance. They are supported by a
large network of specialists in five continents, allowing Mersen to respond to your
needs, wherever the location.
Training
Maintenance
lD
iagnostics
l I n situ commutator, slip ring and brush-holder refurbishment:
Surface re-conditioning
Mica undercutting (commutators)
Bar edge chamfering (commutators)
Helical groove edge chamfering (slip rings)
Out-of-round machining
Carbon brush pressure measurement
Proposal of suitable carbon brush grade
Redesign of the complete carbon brush, brush-holder and commutator / slip ring system
I nstallation of features to improve the performance of your machines (remote
carbon brush wear monitoring, DustCollector dust extraction solutions...)
Retrofit solutions
lS
upport services on a daily basis
29
Tools and accessories
Mersen offers tools and accessories for carbon brush use and electrical rotating
machine maintenance:
30
lC
L-Profiler:
To measure commutator / slip ring profiles
Low speed inductive probe
Contact measurement
Ruby tip for live measurements
lC
omPro2000TM:
To measure commutator profiles during operation
Any speed, non-contact eddy-current transducer
lD
iaMeter, for diameter measurement of commutators and slip ring assemblies prior
to any possible machining
lE
lectronic force gauges for measuring brush-holder pressure systems
lS
troboscopes for slip ring, commutator and carbon brushes control on rotating machines
l Roughness meters
lC
ommutation Indicator (for spark intensity measurement)
l Carbon brush wear indicator systems
lT
ools for maintenance of electrical rotating machine surfaces:
Grinding stones (abrasive cloth, brush seating stones)
Scrapers and slotting files
lM
ica undercutters
lC
omplete toolkit for maintenance of slip rings and commutators (Please consult us):
0-2.5 daN force gauge for measuring spring pressure
Battery-operated illuminated magnifier, for monitoring films and carbon brushes
Thickness gauges (11 blades) for measuring carbon brush / brush-holder clearance
0-200 mm caliper for measuring carbon brush wear
Insulated probe for assessing carbon brush vibrations
Grinding stones
Abrasive cloth
30
H OW TO O R D E R
CARBON BRUSHES?
31
DRAWING CATALOGUES
We can produce brush drawing catalogues containing the drawings and carbon brush
model references used in our customers plants. These catalogues make it easier for the
maintenance people to identify and order spare carbon brushes. Each carbon brush is
taken up by drawing and code number. To place an order you just have to quote the code
mentioned in the drawing catalogue.
Delivery
We can supply most of the carbon brushes fitting any motor type within one week, or
even one day under certain conditions.
31
CARBO N BRUSH
APPL I C AT IO N D E S C R IP T IO N FO RM
(Text conforms with IEC norm 60136)
Date Email
Questions in grey-blue are essential information for us to determine the best brush grade appropriate to your machine.
APPENDICES
32 Please fill this form out to help us find the most suitable carbon brush for your specific application(s).
WHEN POSSIBLE PLEASE SEND US A SAMPLE OF THE CARBON BRUSH IN USE
(even if worn) or a detailed sketch of the brush with its shunt and terminal
(Use sketch Fig. 10 below as a guide).
APPENDICES
33
a
w
Shunt entry
Top bevel angle
if present
Bottom bevel
angle if present
t
Fig.10
33
S TA N D A R D S H A P E S
STANDARD SHAPES
SHAPES OF NEW TERMINALS (recommended)
Special shapes
of terminals
APPENDICES
34 34
34
34
Shape of the terminal SHUNT LOCATION
and bolt diameter
Top view
Length of the shunt Commutator Slip ring
to the axis of the bolt
APPENDICES
APPENDICES
Shape of the brush
Shapes in accordance with NEMA standard
(National Electrical Manufacturers Association) N CB-1-1995
35
35
35
35
QU EST I ON N A I RE
FOR TH E C H O IC E O F A B RU S H - H O LD ER PRE SS U RE SYSTEM
Date Email
A B C
36
D E F G
H I J K
If the spring you need is not shown above, please provide a sketch on the reverse side of the form, showing front and side views or
alternatively send us a sample. Minimum order quantity: 4 pieces.
Other information
Yes
Carrier engraving: .................................................................. Quantity: ............................................... Delivery with brushes
No
36
Sketch for front and side views
APPENDICES
37
Special request
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37
Occurrence of technical
terms in this guide
Apparent density.....................................................................................................................14, 15
Bakelite graphite or resin-bonded carbon brush (grade).......................................11, 15
Bar edge chamfering.............................................................................................................3, 29
Carbographitic (grade).................................................................................................10, 14, 23
Carbon brush bedding / seating...........................................................................................22
Carbon brush guiding / Brush-holders..........................................................................4, 22
Carbon brush position..........................................................................................................18, 31
Carbon brush pressure............................................................. 4, 5, 6, 13, 16, 22, 23, 29, 30
Commutation, commuting..............................................................................3, 5, 6, 11, 26, 29
Contact surface..............................................................................................................6, 7, 19, 22
Corrosive vapors or gases....................................................................................................7, 25
Current density........................................................................................6, 9, 10, 11, 12, 13, 16, 17
Current distribution..............................................................................................................4, 5, 6
Dual grade (composite) carbon brush............................................................................5, 20
Dust.......................................................................................................................................6, 7, 8, 29
Electrographitic (grade)..................................................................................................9, 14, 23
Flexural strength......................................................................................................................14, 15
friction coefficient / Friction...................................................................................4, 6, 7
Humidity..............................................................................................................................5, 6, 7, 25
Impregnation..............................................................................................................................9, 12
Maximal load, underload, overload.......................................................................4, 6, 25, 27
Metal content (grade).............................................................................................................12, 15
Metal-graphite carbon brush (grade) .......................................................................12, 15, 23
Mica, mica undercutting................................................................................... 3, 23, 28, 29, 30
Multi wafer carbon brush.....................................................................................................5, 20
Oils and hydrocarbons....................................................................................................7, 25, 27
Out-of-round, run out, deformation.............................................................. 3, 4, 23, 25, 29
(Peripheral) speed..........................................................4, 5, 9, 10, 11, 12, 13, 14, 15, 16, 17, 23
Resistivity..............................................................................................................................6, 14, 15
Sandwich carbon brush....................................................................................................5, 6, 20
Shore hardness.........................................................................................................................14, 15
Skin, film.................................................................................. 5, 6, 7, 22, 23, 24, 25, 26, 27, 30
Soft graphite carbon brush (grade)............................................................................10, 15, 23
Staggering carbon brushes.........................................................................................................5
Surface condition / Roughness..................................................................... 3, 4, 22, 23, 29
t, a, r dimensions...............................................................................................................18
Temperature.................................................................................................................5, 9, 11, 12, 13
Voltage drop / Contact drop......................................................................................................5
Vibration............................................................................................................................4, 5, 10, 30
LIST OF MERSENS TECHNICAL DATA SHEETS
(also available from WWW.MERSEN.COM )
OTHER DOCUMENTS RELATED TO MERSEN'S RANGE OF SOLUTIONS CAN BE SUPPLIED UPON REQUEST.
DO NOT HESITATE TO CONTACT US.
TDS-01 Functions of a good carbon brush, what TDS-13 Aspects of commutator / slip ring skins
you should know
TDS-14 Brush sparking
TDS-02 Condition of the surface of commutators
and slip rings - Roughness
TDS-15 Brush wear
TDS-12 Ventilation
TDS-25 Underloaded machines
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