INDEX TO SECTIONS FOR QUICK REFERENCfe

USE THE THUMB TABS

Sectiok
Units, Conversion Factors and Tables i

Electric and Magnetic Circuits -i,

Measurements and Measuring Apparatus. .... 3

Properties of Materials 4

Magnets, Induction Coils, Condensers and Resistors 5

Transformers and Rectifiers 6

Alternating-current Generators and Motors 7

Direct-cuirent Generators and Motors 8

Converters and Double-current Generators 9

Power Plants 10

Power Transmission 11

Distribution Systems 12

Irljterior Wiring 13

Illumination 14

Industrial Motor Applications 15

Electric Railways 16 •

Electric Vehicles 17

Electric Ship Propulsion 18

Electrochemistry 19

Bt.tteries 20

Tt^lephony, Telegraphy and Radiotelegraphy 21

i

Miscellaneous Applications of Electricity 22

Mechanical Section 23

Standards of the A. I. E. E 24

Engineering and Central Station Economics 35

^c)
STANDARD HANDBOOK
FOR

ELECTRICAL ENGINEERS
 LKXM LU
IrawOJillBook
H^Q QraW-J^Lii me
(hJn
PUDLISHERS OF BOOKS FO "^ B.^

Coal Age '' Electric Railway Journal

Electrical World r Engineering News -Record
American Machinist v Ingeniena Intemacional
Engineering 8 Mining Journal v- 'Power
Chiemical 6 Metallurgical Engineering
Electrical Merchandising

TliiMiilMM' iiiillliiiiiil i liii ni lllii i i lD liiiiiimiiiiiiHiiiiiiilli"^

 STANDARD
HANDBOOK FOR

ELECTRICAL ENGINEERS
PREPAEED BY A
STAFF OF SPECIALISTS

FRANK F. FOWLE, S. B.
Editor-in-Chiep
CONSULTING ELECTRICAL EXGINEEB, MEMBER AMERICAN INSTITUTE
OF ELECTRICAL ENGINEERS, ILLUMINATING ENGINEERING
SOCIETY, WESTERN 80CIETT OF ENGINEERS AND
NATIONAL ELECTRIC LIGHT ASSOCIATION

total issue, sixty-eight thousand

Fifth Edition
^JteOBOttGHb* Revised

McGR^^^fijJMl^^TOMPANY, Inc.
NEW YORK: 370 SEVENTH AVENUE
LONDON: 6 & 8 BOUVERIE ST., E. C. 4

1922
 Copyright, 1907, 1908, bt the McGraw Publishino Compant

COPyRIGHT, 1910, BY THE McOhaW-HiLL BoOK COMPANY

CopTBiGHT, 1915, BY thb McGraw-Hill Book Compant, Inc.

Copyright, 1922, by the McGraw-Hill Book Company, Inc.

yl () OH (I V^ /
First Edition
I i

First Printing, December, 1907

Sbcond Edition
LjL. fl May, 1908
First Printing,
Second Printing, March, 1910
r):ij:i
Third Edition
First Printing, September,1910
Second Printing September, 1911
,

Third Printing December, 1912

,

Fourth Edition
First Printing, July, 1915
Second Printing, November, 1915
Third Printing, December, 1916
Fourth Printing, April, 1918
Fifth Printing, May, 1919
Sixth Printing, June, 1920

Fifth Edition
First Printing, June, 1922

Total Ibsue, Sixty-eight Thodsand

Tfc
151

S83
nil

lT>I3V38 07K:yi:

THE MAFI>K PBESS XOHK FA

 PREFACE TO THE FIFTH EDITION

During the period of seven years since the first appearance

of the fourth edition of the Standard Handbook there have
been many new developments in the broad field of electrical
by the necessities
engineering, stimulated in frequent instances
of the World War, the first year of which had nearly passed
when the last edition came from the presses. The need for
revision at this time, in order to maintain the standard character
and authority of the Handbook, was self-evident, and therefore
the Piiblishers called upon the staff who prepared the fourth
edition to undertake the task. Several new Contributors were
also invited to join in the undertaking.
In the preparation of the fifth edition the general arrange-
ment and make-up of the fourth edition have been retained
without change and the general policy outlined in the preface
to that edition has also been the guiding policy in preparing the
new edition. Every section in the fourth edition has been
subjected to the scrutiny and criticism of the respective Con-
tributors who originally prepared the text, with the few excep-
tions of those who meantime have passed on, or who for
in the
special reasons requested to be relieved. Each author was also
furnished the comments or criticisms received from time to time
from those who have had occasion to use the fourth edition in
their own work.
Each section has been thoroughly revised by the substitution
of up-to-date material and data for such as had become obsolete
or of little practical value, and in some instances additional
material has been added, although the size of the book imposed
very definite limits in this direction. There have been sub-
stantial changes in every section with the exception of Sections
1, 23 and 25, which required only minor revision. In a few
instances the sections have been rewritten in large part; this
applies particularly to Sections 11, 14 and 17. New articles
have also been added to Sections 15 and 22. By the permission
 PREFACE

of the A.I.E.E. the present "Standards of the A.I.E.E.," are

given in Section 24, but are subject to the express stipulation
which appears on the title page of the section.
As a whole the make-up and arrangement of the fourth
edition seem to have met with the general approval of the large
body of users of the Handbook, and many favorable comments
have been received. In view, however, of certain suggestions
relative to the enlargement of the index, special pains have been
devoted to making it as comprehensiveand complete as the
space limitations will permit. It is hoped that the users of the
fifth edition will find the new index ample in all respects.
The Editor is again glad to express appreciation and sincere
thanks to the Contributors for their painstaking work and hearty
cooperation in a task whose difficulties and trials are fully
appreciated only by those who have been through them. The
Publishers have, as heretofore, given the Editor fuU authority
j urisdiction, from choice of contributors to
in all matters in his
selection of subject matter and make-up. They have also gone
to great expense to make the book satisfactory in appearance
and durability. Thanks are due to my assistant, Mr. V. H.
Dupr6,who has attended to many routine details of the editorial
work and who has prepared the index.
Frank F. Fowi^e,
Editor-in-Chief.
Chicago, June 10, 1922.
 PREFACE TO THE FOURTH EDITION

The present edition of the Standard Handbook for Elec-

trical Engineers, preparation of which was undertaken early
in the year 1913 under the editorial direction of the writer, em-
bodies so many changes and so much new matter that it is
virtually a new book, retaining, however, the general features
and scheme of arrangement which have received extensive en-
dorsement in the prior editions. As heretofore, the Standard
Handbook is intended primarily as a reference book of practical
information and data for practising engineers and a supplement
to the standard text-books employed in teaching electrical en-
gineering in colleges and universities. It is well recognized that
limitations of space within a single volume of this character, even
of the present size, render it impossible to treat each subject
exhaustively. Our have been concentrated chiefly on
efforts
the task of presenting as much information and data of a prac-
tical nature as space would permit, reducing descriptive mat-
ter to the reasonable minimum and relying on references to
standard works for extended dissertations on theory and highly
special topics. Perhaps the most difficult task of all, in the
present revision, was that of keeping the subject matter within
the confines of a volume which would not be impossible in
either the physical or the commercial sense.
Owing to the numerous advances in electrical science and the
electrical arts since the appearance of the third edition in
1910, and owing also to certain criticisms which had been
made concerning the earlier editions, the Publishers approved
at the outset a broad and liberal editorial policy which greatly
facilitated the work and minimized the burdens of a task that
at best is a difficult one.
The problem was the rearrangement of the sections
first
for the purpose of securing a rational classification of major
subjectsand insuring a well-balanced presentation. A great
deal oftime was spent in consideration of this question
before undertaking the details of the work. In the same
manner much attention was given to the grouping of subjects
under minor divisions in each main section, in order that the
 PREFACE

information on each subject might be presented in reasonaoiy

compact form, and at the same time be easily located.
Thus each numbered paragraph opens with a descriptive title
or phrase in bold-faced type, while in other respects the use of
such type has been limited to subheads and important key
words which should catch the eye upon a casual glance over
the pages. An entirely new feature is the consistent use of sub-
heads throughout each section and the grouping of these on
each section title page, for the double purpose of describing
the contents in some detail and serving as a ready guide to any
particular subdiyision or minor subject.
This general scheme
of presentation not intended to relieve the necessity for a
is

thorough and complete index, but rather to supplement the

latter and make the book of maximum usefulness. Another new
feature the addition of bibliographies at the end of each sec-
is

tion or subsection, and the insertion of numerous references

throughout the text to more extended or specialized literature.
In retaining the sectional or unit system of arranging a refer-
ence work of this character, both the Editor and the Publishers
are convinced from past results that there is no other form of
arrangement which is so well suited to the production of a useful
and convenient handbook, or which makes possible the segrega-
tion of all the material relating to each subject, presented in
logical sequence and so displayed as to give it the desired
prominence.
Sections 1 to 5 inclusive cover the same general ground as in
the third edition, but have been almost completely rewritten and
considerably extended.
Sections 6 to 9 inclusive embrace the same subjects as Sections
6 to 8 in the third edition, but conform to a revised classification
which is believed to be preferable to the former arrangement.
These sections have also been entirely rewritten and substan-
tially enlarged.
Section 10 covers the same general subject matter as the cor-
responding section in the last edition, but is entirely rewritten
and greatly enlarged.
Sections 11 and 12 cover the same ground as Section 11 in
the third edition, but are entirely new and much more
comprehensive.
Section 13 replaces Section 18 in the old edition, being entirely
 PREFACE

rewritten; Section 14 replaces Section 12, with entirely new

material; Section 15, Industrial Motor Applications, is a new
section with entirely new subject matter.
Section 16 covers the ground of Section 13 in the third edi-
tion, and has been thoroughly revised. Section 17, Electric
Vehicles, and Section 18, Electric Ship Propulsion, are both new
sections.
Section 19 replaces Section 14 in the third edition, many por-
tions of it being rewritten. Section 20 takes the place of old
Section 9 with new material, and Section 21 replaces old Sections
15 and 16, also rewritten and altered somewhat in scope.
Section 22 takes the place of Section 17 in the old edition,
with almost exclusively new material. Section 23, Mechanical
Section, is a new section; Section 24 corresponds to Section 19
in the last edition; Section 25, General Engineering Economics
and Central Station Economics, is entirely new. Section 20 in
the former edition has been abandoned and its contents, or
their revised equivalents, have been distributed among other
sections.
The Editor takes this occasion tothank his numerous associ-
ates for their cooperation and enthusiasm throughout a long
and difficult task, and to acknowledge the painstaking efforts
of the Publishers concerning the mechanical features and their
patience over the unexpected but seemingly unavoidable delays
in completing the editorial portion of the work. Acknowledg-
ment is also due to my assistant, Mr. J. C. Bogle, who has pains-
takingly performed a large share of the routine editorial work
to Mr. Walter Jackson, Associate Editor of the Electric Railway
Journal, who has read the complete proofs before going to
press; and to Mr. O. A. Kenyon, who has prepared the index.
Frank F. Fowle,
Chicago, June 15, 1915. Editor-in-Chief.
 PREFACE TO THE THIRD EDITION
The preface to the first edition of the Standard Handbook,
which appears on another page, describes the "unit" system on
which the work was developed. The present edition, the
pubhshers beheve, is somewhat of a triumph for this system.
The thorough revision of a book of this size, when manufac-
tured according to the usual plan, is commercially impossible
except at long intervals when the changes in the art become so
great as to demand an entirely new book. The "unit" system
employed in the Standard Handbook permits thorough revision
in part or as a whole without any of the usual limitations.
In the present revision the authors of the various sections
were allowed a free hand in so far as mechanical details were
concerned. They were not restricted in space or compelled to
cut and prune material to fit pages. The result is a book that
has been thoroughly revised from cover to cover so that it could
be fairly called a new Standard Handbook.
The following synopsis gives a brief outline of the changes
and additions that have been made to the various sections.
Section 1, Units, is corrected and slightly enlarged.
Section 2, Electric, Magnetic and Dielectric Circuits, is
greatly enlarged. The general theory of electric and magnetip^
circuits is entirely rewritten and the calculation of inductance
and capacity is given in greater detail than before.
Section 3, Measurements and Measuring Instruments, is
greatly enlarged. Several new instruments are described, tests
of self and mutual inductance have been added and a section
devoted to pyrometers and high temperature measurements has
been included. The design of rheostats and motor starters has
been transferred to Section 5.
Section 4, Properties of Conductor, Resistor and Insulating
Materials, is enlarged more than any other section. Many
tables have been added giving data on the latest types of
conductors and cables. An entirely new section giving the
properties of a large number of commercial resistor alloys has
also been added and the magnetic testing of iron has been en-
tirely rewritten and now forms a very comprehensive treatment
of the latest practice in this important subject.
 PREFACE

Section 5, Magnets, Resistors, Condensers and Reactors, has

been enlarged in scope to include resistors, condensers and react-
ors. In the sections on magnets, a discussion of the energy-
relations in a plunger magnet has been added. The section on
resistors contains the design of rheostats, formerly in Section 3.
To this section have been added the design of induction motor
starters, the heating of wires, cables and embedded conductors,
the calculation of fuses and tables for use in heating calculations.
A new skin effect for various metals has also been added. In the
condenser and reactor sections, the electrical calculations are
given, and considerable space is devoted to the electrolytic
condenser. Almost all of the material in this section is entirely
new.
Section 6, Transformers and Converters, is thoroughly
revised and considerably enlarged. The use of silicon steel has
revolutionized transformer design and hence this section has
been completely overhauled. As the book goes to press it
is the only available up-to-date treatment of transformers. In
the converter section numerous additions are made, the most
important being a discussion of the split-pole converter.
Section 7, Generators, has been corrected and slightly revised.
Section 8, Motors, has been revised, discussions of new motors
being added to the alternating current commutating motor sec-
tion. New design data are given for both a.c. and d.c. motors.
Section 9, Batteries, has been corrected and revised, with
slight additions.
Section 10, Central Stations, has been thoroughly revised
and largely rewritten. The scope is the same. Many cost data
have been added.
Section 11, Transmission and Distribution, excepting the
underground construction and mechanical transmission, has
been entirely rewritten. It is believed now to be thoroughly
abreast of the times in the calculation and construction of trans-
mission and distribution systems. Many tables have been
calculated especially for this section. Practically all of the old
tables have been discarded. Inductive reactance and charging
current for all sizes of wire and cable and
all spacings are given
for 25 and 60 Tables giving the stresses in wires and
cycles.
cables of various sizes for wind, and wind and sleet conditions
are also among the additions.
Section 12, Illumination, has been corrected and revised.
 PREFACE

Section 13, Traction, has been corrected, revised and enlarged.

The locomotive section has been entirely rewritten, and more
space has been given to the method of constructing speed-time
curves.
Section 14, Electrochemistry, has been thoroughly revised
and somewhat enlarged.
Section 15, Telephony, has been entirely rewritten. It is now
a comprehensive treatise and represents a new method of pre-
senting the subject.
Section 16, Telegraphy, is corrected.
Section 17, Miscellaneous Applications of Electricity, is
corrected and somewhat enlarged.
Section 18, Wiring, is corrected and brought to date.
Section 19, Standards, is considerably enlarged. The
latestchanges in the A. I. E. E. Standardization Rules have been
noted, and standard specifications for rubber insulation, copper
conductors and transformers have been added.
Section 20, Tables and Statistics, has been corrected and
enlarged by adding telephone, telegraph and central station
statistics and by general revision.

'i 1I
 PREFACE TO THE FIRST EDITION
In the preparation of the Standabd Handbook the pub-
lishers have adapted the "unit" system to bookmaking. The
entire field of electrical engineering was divided into twenty sec-
tions or units, each complete in itself.These twenty sections
were arranged in what seemed and each
to be a logical order
was assigned to a specialist. Each author was supplied with
a detailed outline of all the sections, thus avoiding repetitions
and duplication of material as far as desirable. All of the
material thus brought together was carefully edited to obtain
uniformity of style, symbols, abbreviations, units, etc., and to
connect the various parts by cross-references.
Some repetitions are purposely made to save the time of the
user. For instance, transformer oil is treated under Insulating
Materials in Section 4, but a brief outline of its important
qualities is again given in Section 6 under Transformers, with a
cross-reference to guide the reader to the fuller treatment in
Section 4.

The Index embodies some new features. All references are

made to section and paragraph. In each section the para-
graphs are numbered from one to the end, and the section and
paragraph numbers are set at the head of the page; the page
number appearing in an inconspicuous place at the foot, for the
guidance of the printer only. Cross-references are always made
through the index to avoid errors and to guide the user to all
other parts of the book where that subject may be treated.
The studied use of bold-face type is also intended to save time
by bringing out in a prominent way the real subject of each
paragraph.
Recognized standards have been followed wherever pos-
sible. Those recommended by the national societies or organi-
zations have usually been followed. Section 19 is entirely
given up to Standardization Rules and Reports, including the
full report of the American Institute of Electrical Engineers of
June, 1907, and that of the American Street and Interurban
Railway Engineering Association, ratified in October, 1907.
The publishers cannot hope for absolute accuracy in this
 PREFACE

first edition of a work containing such a mass of figures and

data, although the greatest care has been exercised in its prepa-
ration. Any suggestions, criticisms, or corrections from users
willbe of great service in making The Standard Handbook a
standard in fact as well as in name.

December 12, 1907.

PREFACE TO THE SECOND EDITION

No new material has been added to this edition of the Stand-
ard Handbook, with the exception of directions for resus-
citation from electric shock, which have been inserted at the end
of the book. However, every page has been most carefully read
and every possible effort made to insure the accuracy of all data
and perfection of the typographical work. Several of the ta-
bles, which were especially prepared for this book, have been
recalculated and others have been checked by plotting the values
and recalculating those which did not fall on a smooth curve.
The success of the Standard Handbook has been phenome-
nal. The general interest in the work has been manifested by
the many letters received from prominent men commending its
general character and offering suggestions and criticisms. It
has already been adopted for use as a text-book in thirty
universities and colleges.
The publishers take this occasion to express their appre-
ciation of its reception by the profession, and to thank those
who by their kindness in pointing out typographical and other
errors, have materially assisted in the work of correction.

New York, May, 1908.

 SECTIONS AND AUTHORS

SECTION 1

UNITS, CONVESSION FACTORS AND TABLES. By Arthur K.

Eennelly, A.M., Sc.D.
Systems of Units, Historical Sketch, Evolution of Practical Electromag-
netic System of Units, Definitions, IDimensional Formulas, Weights and
Measures, Conversion Tables and Mathematical Constants and Tables.
SECTION 2
ELECTRIC AND MAGNETIC CIRCUITS. By Vladimir Kaxapetofl
Electric Potential, Electric Currents, Continuous-current Circuits, Electro-
magnetic Induction, The Magnetic Circuit, Inductance, Hysteresis, Eddy
Currents, The Dielectric Circuit, Transient Currents, Alternating-current
Circuits, Complex Waves, Polyphase Systems and Transmission Circuits.

SECTION 3
MEASUREMENTS AND MEASURING APPARATUS. By F. Malcolm
Farmer; George K. Burgess, Sc.D.; Paul D. Foote, A.M.
Reginald J. S. Pigott and William J. Drisko, S.B.
Galvanometers, E.M.F. and Current Measurements, Resistance Measure-
ments, Power and Energy Measiu"ements, Curve-drawing Instruments
Measurements of Inductance, Capacity, Wave-form, Frequency, Slip, Torque
and Speed; Magnetic Measurements, Thermometry, Pyrometry, Heat
Conductivity, Fuel and Gas Analysis; Water, Gas, Air and Steam Meters;
Precision of Measurements.

SECTION 4
PROPERTIES OF MATERIALS. By Frank F. Fowle, S.B.
Conductor Materials, Wire Gages, Wire Tables, Copper, Aluminum,
Copper-clad Steel, Iron and Steel, Bronze, Miscellaneous Metals, Resistor
Materials, Carbon and Graphite, Skin EflFect; Magnetic Materials, Composi-
tion and Properties, Core Losses, Sheet Gages, Commercial Sheets, Magnet
Steel; Insulating Materials, Classification, Discussion of Properties, Solid
Natural Materials, Vitrified Materials, Fibrous Materials, Molded Com-
positions,Rubber and Its Derivatives, Varnishes and Compounds, Insulat-
ing Oils, Gases; Structural Materials, Cast Iron, Wrought Iron, Steel,
Annealing, Hardening, Tempering, Steel Wire and Cable, Non-Ferrous
Metals, Concrete, Brick, Stone, Timber, Belting and Rope, Properties of the
Elements, Atomic Weights, Densities, Specific Heats, Properties of Water
and Air.

SECTION 5
*•

AIAGNETS, INDUCTION COILS, CONDENSERS AND RESISTORS.

By Charles R. Underhill and Leonard Kebler
Permanent Magnets, Electromagnets, General Theory, Tractive Electro-
magnets, Conditions for Maximum Work, Standard Electromagnets, Por-
tative Electromagnets, Polyphase Electromagnets, Heating, Magnet Wires,
Calculations, Construction, Testing; Induction Coils, Types, Windings,
Interrupters; Condensers, Types, Plate Condensers, Electrolytic Conden-
sers; Resistors, Field Rheostats, Speed-regulating Rheostats, Dimmers,
Starting Rheostats, Battery-charging Rheostats and Resistance Units.
SECTION 6
TRANSFORMERS AND RECTIFIERS. By Charles Le G. Fortescue
Theory, Design, Insulation, Cooling, Coil Grouping, Transformers for
Power Service and Distribution Systems, Multiple Operation, Polyphase
Transformations, Constant-current Transformers, Auto-transformers, Instru-
ment Transformers, Miscellaneous Applications, Testing, Installation, Care
and Operation; Potential and Current Regulators, Reactors and Rectifiers.
 SECTIONS AND AUTHORS
SECTION 7
ALTERNATINO-CUKSENT OEMERATORS AND MOTORS
By Comfort A. Adams and Henry M. Hobart
Synchronous Machines, Armature Winding, E.M.F. Generation, The
Magnetic Circuit, Characteristics of Synchronous Alternators, Synchronous
Motors, Parallel Operation, Design, Insulation, EflBciency, Ventilation, Con-
struction and Testing; Induction Machines, Theory of Polyphase Motors,
Characteristics, Magnetizing Current, Leakage Reactance, Circle Diagram,
Efficiency, Standard Polyphase Motors, Induction Generators, Design,
Single-phase Motors and Their Speed Control; Commutator Motors, Auxil-
iary Commutating Machines, Phase Modifiers, Motor-generators and
Frequency Changers.

SECTION 8
DIRECT-CURRENT GENERATORS AND MOTORS. By Alexander
Gray, B.Sc, Whit. Sch.
Types, Windings, Armature Reactions, Commutation, Armature Desijgn,
Field Design, Construction, Insulation, Cooling, Efficiency, Characteristics,
Regulation, Weights, Costs, Standard Machines, Thury System, Motor-
generator Sets, Operation and Testing.

SECTION 9
CONVERTERS AND DOUBLE-CURRENT GENERATORS. By F. D.
Newbury, M.E. and Alexander Gray, B.Sc, Whit. Sch.
Synchronous Converters, Theory, Design, Characteristics, Applications,
Operation, Testing; Inverted Converters, Motor Converters, Direct-current
Converters, Dynamotors and Double-current Generators.

SECTION 10
POWER PLANTS. By Regrinald J. S. Pigott, Arthur T. Safford and
George I. Rhodes
Steam Power Plants, Laws of Heat Transfer, Boilers, Furnaces, Stokers,
Chimneys, Mechanical Draft, Fuel, Water Supply, Coal and Ash Handling.
Engines, Turbines, Condensers, Heaters, Economizers, Pumps, Piping and
Testing; Gas Power Plants, Producers, Superheaters, Condensers, Scrubbers,
Purifiers, Holders, Properties of Gas, Engines, Piping and Testing; Oil Power
Plants, Engines, Testing; Hydraulic Power Plants, Hydraulics, Flow For-
mulas, Stream Flow, Dams, Headworks, Water Wheels and Testing;_ Build-
ings and Foundations; Electrical Equipment, Generators, Excitation.
Voltage Control, Switching, Station Transformers, Lightning Arresters and
Wiring; Power-plant Economics.

SECTION 11
POWER TRANSMISSION. By Harry E. Clifford, S.B. and Chester
L. Dawes, S.B.
Transmission Systems, Electrical Calculations, Tables of Reactance and
Charging Current, Design, Corona, Insulators, System Connections, Switch-
ing,Spans and Supports, Construction, Cables, Substations, Operation,
Economics and Cost Data.

SECTION 12
DISTRIBUTION SYSTEMS. By Harry Barnes Gear, A.B., M.E.
Classification, Applications, Types of Circuits, Circuit Design, Substations,
Regulation, Secondary Distribution, Transformation, Protection, Construc-
tion and Economics.

SECTION 13
INTERIOR WIRING. By Terrell Croft
Fire Risk, Methods of Wiring, wlres ntid Cables, Fittings and Accessories,
Calculations, Lay-outs, Installation, Protection and Miscellaneous.
xvi
 SECTIONS AND AUTHORS \

SECTION 14
ILLUMINATION. By Preston S. Millar
Production of Light, Incandescent Lamps, Carbon Filament, Metallizey
Carbon Filament, Tantalum, Tungsten, Gas-filled Type; Arc Lamp Char-\
acteristics, Carbon-electrode, Flame Arc, Metallic Electrode, Tube Lampsi
Lighting Accessories, Reflectors, Indirect and Semi-indirect Lighting;
lUuiiiination Calculations, Flux, Candle-power, Intensity, Brightness,
Efficiency Applied Illumination, Fundamentals of Vision, Characteristics of
;

Illumination, Physiological and Psychological Effects, Methods, Design,

Costs; Photometry, Fundamentals, Standards, Apparatus, Spectropho-
tometers, Colorimeters and Testing.

SECTION 15
HTDUSTSIAL MOTOR APPLICATIONS. By the foUowingr
specialists :

Leon P. Alford Chester W. Drake . Arthur C. Eastwood

Wilfred Sykes David L. Lindquist Fred J. Postel
Joseph H. Brown Merton S. Leonard C. D. Gilpin
H. McL. Harding Graham Bright Augustus C. Smith
William W. Crosby Joseph H. Wallace Geo. B. Massey
C. W. Pendell Charles E. Carpenter A. E. Hall
Wirt S. Scott Fritz Balzer Bernard Lester
Clark T. Henderson Arthur Simon
Machine Tools, Wood-working Machinery, Traveling Cranes, Electric
Hoists, Elevators, Power Pumps, Air Compressors, Fans and Blowers, Coal
and Ore Handling Machinery, Telpherage Systems, Steel Mills, Cement
Mills, Coal Mining, Refrigerating Plants, Textile Mills, Paper and Pulp
Mills, Printing, Binding and Linotype Machinery, Flour Mills, Beet-sugar
Mills, Laundry Machinery, Small-motor Applications and Motor Control.

SECTION 16
ELECTRIC RAILWAYS. By Albert H. Armstrong, E. E. Kimball,
Norman W. Storer, Robert D. McManigal, Azel Ames,
Albert F. Oanz and Albert S. Richey
Electric Traction, Train Resistance, Speed-time Curves, Motor Character-
istics,Energy and Power Consumption, Motor Control, Types of Motors,
Braking, Trucks and Car Bodies, Self-propelled Cars, Locomotives, Distri-
bution, Substations, Railway Signalling, Types of Fixed Signals, Trolley-
operated Systems, Track Circuits, Interlocking, Block System; Electrolysis,
Surveys, Aleans of Prevention, Electrolysis in Concrete, Municipal and State
Regulations.
SECTION 17
ELECTRIC VEHICLES. By John G. Carroll av;AT8
Passenger Cars, Commercial Trucks and Tractors, Indus-
Classification,
trial Trucks and Tractors, Vehicle Motors, Control; Batteries, Charging,
Charging Equipment.
SECTION 18
ELECTRIC SHIP PROPULSION. By Henry M. Hobart
Ship Resistance, Propeller Characteristics, Systems of Propeller Drive,
Types of Vessel For Different Service, Electric Propulsion and Examples of
Electrically Propelled Ships.

SECTION 19
ELECTROCHEMISTRY. By E. P. Roeber, Ph.D. and J. W.
Richards, Ph.D.
Interpretation of Chemical Equations, Laws of Gases, Laws of Solutions,
Energy Relations, Electric Furnaces and Their Products, Electrolytic Proc-
esses and Reactions, Industrial Electrolytic Processes, Electroplating,
Refining of Metals; Electrolysis of Water, Alkaline Chlorides, Copper,
Nickel, Zinc, Aluminum, Sodium, Magnesium and Calcium; Discharges
through Gases, Fixation of Atmospheric Nitrogen, Electromagnetic and
Electrostatic Processes.
 SECTIONS AND AUTHORS

/ BATTKEIES.
SECTION
By Walter
20
E. Winship, Ph.D.
Primary Batteries, Wet Cells, Dry Cells; Storage Batteries; Lead Storage
Batteries, Electrolyte, Testing, Stationary Batteries, Vehicle
Batteries
Train-hghting Batteries, Miscellaneous Applications, Battery Rooms'
Regulating Equipment, Operation, Depreciation and Maintenance, Alka-
line Storage Batteries.

'
SECTION 21
TELEPHONY, TELEGRAPHY AND RADIOTELEaRAPHY. By
Frank F. Fowle, S.B., and Louis W. Austin, Ph.D.
Telephone Instruments, Switchboards, Intercommunicating Systems,
Phantom Circuits, Manual Telegraph Systems, Simplex and Composite Sets,
Dispatching and Patrol Systems, Fire and Police Alarm Systems, Cables,
Protectors, Cross-talk and Inductive Disturbances, Transmission, Construc-
tion, Testing; Radiotelegraphy, High Frequency Oscillations, Antenna,
Exciting the Antenna, Undamped Oscillations, Transmission of Waves,
Receiving Circuits. Detectors, Continuous Oscillations, Atmospheric Dis-
turbances, Measurements.

SECTION 22
MISCELLANEOUS APPLICATIONS OF ELECTRICITY. By the
following specialists:
E. N. Lightfoot Otis Allen Kenyon John C. Bogle
Harry B. Gear H. A. Hornor Major Edw. D. Ardery
John E. Newman Frank F. Fowle Milton W. Franklin
Edwin P. Adams Eugene W. Caldwell J. S.Shearer
Ernest J. Berg Elmer A. Sperry F. A. Annett
Resuscitation, Electric Heating and Cooking, Electric- Welding, Electrical
Equipment for Gas Automobiles, Thawing Water Pipes, Marine Applica-
tions, Electricity in the U. S. Army, Electricity and Plant Growth, Windmill
Electric Plants, Ozone Production, Radioactivity and the Electron Theory,
Roentgen Rays, Lightning Rods, Electrostatic Machines, Electric Piano
Players, Telegraphone, Telharmonium, Train-lighting Systems. Compasses,
Static Electricity in Industrial Equipment, Specifications and Contracts.

SECTION 23
MECHANICAL SECTION. Compiled from standard authorities.
Elements of Sections, Beams, Columns, Shafting, Gearing, Chain Drives,
Belts, Rope Drives, Pipe and Screw Threads.
SECTION 24
STANDARDS OF THE AMERICAN INSTITUTE OF ELECTRICAL
ENGINEERS. Approved edition of 1921
SECTION 25
GENERAL ENGINEERING ECONOMICS AND CENTRAL STATION
ECONOMICS. By Frank F. Fowle, S.B., and James Raley Cravath
General Engineering Economics, Definitions, Value, Price, Cost, Capital,
Rent, Interest, Annual Charges, Depreciation, Social-economic Investiga-
tions, Valuation and Rate Making; Central Station Economics, Factors
Relating to Utilization of Investment, Factors Relating to Territory Served,
Typical Earnings of Companies, Rate Making and Valuation.

zviii
 ((

SECTION 1

UNITS, CONVERSION FACTORS,

AND TABLES
BY ARTHUR E. KENNELLY, A.M., Sc.D.
rofessor of Electrical Engineering, Harvard University, and Mast, In»t.
Technology; Past President, American Institute of Elect. Engineers;
Ilium. Engineering Society and Inst. Radio Engineers; Honorary
Member, Institution of Elect. Engineers, London

CONTENTS
{Numhers refer to Paragraphs)
Systems of Units Definitions of Photometric Units 81
historical Sketch of English Definitions of Thermal Units 87
Units Dimensional Formulas 98
Historical Sketch of the Interna- Tabular Summary of Defini-
tional Metric System tions of Units 110
Kvolution of the Practical Elec- Weights and Measures 119
tromagnetic System of Units Conversion Tables 129
Definitions of Fundamental Bibliography 152
Units Mathematical Tables 153
Definitions of Electric and Mag-
netic Units
 SECTION 1

UNITS, CONVERSION FACTORS, AND TABLES

SYSTEMS OF UNITS
1. Nature of units. Engineering makes use of physical quantities in
the broadest sense of that term, i.e., including mechanical, chemical, physical,
thermal and physiological quantities. In order adequately to compare the
magnitudes of physical quantities of the same kind, unit magnitudes, or
units, are necessary for each kind of physical quantity dealt with.
2. Classification of units. The subdivisions and species into which
units may be divided are indicated in the scheme shown in Fig. 1, with ex-
planations which follow in Par.- 3.

>iLu

^
"\ m
f(£|)liitniutii«al C(^:; Praetical (di)a\<itt,\ (.dOii.O.S.i t H.
l" "•'•°"
C.G.8. Inteniatlon.l M.K.8. and
SjKem Q.E.8. Bjeteni MlsMllimeottt bjrtem
System BjBtom
,

I 1

C.G.8. 0.0.8.
Bjjtem BjMtm

(/l ) El«!tro.(/5)EIeotn>.(7«)ElMtK>- (/,)Electr<>.

magnetic static magoetic static
Sjstem 8jel«m Bjsltm Bjstem

Fig. 1.

3(ai) Standard units (see Fig. 1) may be said to include all units which
have received th»^ stamp of recognition in technical literature.
Z{a.-t) Empirical units, on the other hand, are units which have sprung
into existence locally, ordinarily without anv pretense to scientific deriva-
tion, and which have not been sanctioned by general usage. At various
times during recorded history, empirical units have appeared. Thus, in
the early history of electrical units, a unit of conductor resistance was used as
representing the resistance of a certain length of a certain size of telegraph
 UNITS, FACTORS, AND TABLES See. 1-3

wire, as embodied in a certain standard resistance coll. Similarly, the

average e.m.f. of a Daniell cell was originally an empirical unit e.m.f.
3(b0 Systematic units are units of any definitely related group. Thus
the units "pint," "quart," "peck," and "bushel" entering into "dry meas-
ure" are systematic units; because they stand in definite quantitative mutual
relation as a group or system. Again, the units "mill," "cent," "dime,"
and "dollar" entering into American currency are systematic units.
3(b2) Nondescript units may be defined as standard units which are
not systematic, or do not enter into any unit system. Thus, in Pennsylvania,
a "bushel" of coarse salt, as a weight-unit, is 80 lb. avoirdupois,* but in
lUinois it is 50 lb. avoirdupois.
S(B) Hybrid units, in contradistinction to systematic units, are units
which do not belong to any one system, but which are derived say from
a plurality of different systems; from a systematic and a general unit;
or from any combination of standard and empirical units. Thus, a "kilo-
gram" may be defined as a unit of weight in the international metric system;
while a "square foot" is a unit of area in the customary English system.
But the "kilogram-per-square-foot," as a unit of weight loading of floor-area,
is a hybrid unit. Occasionally the advantage of practical convenience in
the use of a hybrid unit may outweigh the disadvantage of its unsystematic
derivation. No stigma necessarily attaches to the use of a hybrid, as distin-
guished from a systematic unit; but great caution has to be used in pursuing
new and unfamiliar quantitative reasoning processes involving hybrid units,
lest numerical errors be introduced by neglect of coefficients.
3(Ci) Absolute units are units of physical quantities selected in a compre-
hensive scientific system based upon three or more fundarnental physical
properties, such as length, mass, time, energy, specific gravitational force,
etc.; so that simple and fundamental quantitative relations may subsist
between the members of the system and that each physical quantity may have
one and only one unit in the system. The particular basic units from which
a system of absolute units is derived are called the fundamental units
of that system ;t while the units so derived are called the derived units in
correlation thereto. In a dynamical system, the fundamental units
are three only and are: a unit of length, a unit of mass, and a unit of
time.t Consequently, unless otherwise specified, the term " absolute units"
is taken as referring to a scientific system based on fundamental units of
length, mass, and time. But whereas only one set of fundamental units has
—
come into recognition the length-mass-time set above mentioned several —
species of this set have been used to some extent; namely, the "foot-grain-
second" system,! the "meter-kilogram-second" system, the "centimeter-
gram-second" (C.G.S.) system, the "meter-ton-second" (M.T.S.)
system, and the "quadrant-eleventh-gram-second" (Q.E.S.) system.
Only the last three have come into extensive practical use. The C.G.S.
system has become the international scientific system, and the Q.E.S.
system an international electromagnetic system in electrical engineering.
Any complete electromagnetic absolute system involves five fundamental
units, two of which may be constants of the ether.
3(ci) Metric units are units pertaining to the international metric
system. This system, which was created in France in 1792, was adopted
in France in 1840, in Germany in 1872, in Austria in 1876 and so on from
||

one civilized country to another; until at the present date, the only great
communities which have not yet adopted the metric system are the British
Empire, the United States and the Russian Empire. The advantage of
the system is its simplicity. It is a decimal system, using a single funda-
mental unit of length (the meter) and one of mass (the gram). The decimal
multiples of these are distinguished by Greek and Latin prefixes common to
all branches of the system (Par. 102).

*"The World Almanac," 1920, NewYork, p. 84.

t Everett, J. D. "C.G.S. System of Units," Macmillan Co., 1891, p. 15.
X Strictly speaking, a dynamical system of absolute units may employ
any desired acceleration as unit acceleration, when the unit force acts on
unit mass, yet, if the unit of acceleration be the unit of length per unit of
time squared as in the C.G.S. system, the system is called an absolute kinetic
system.
§ " British Association Report on Electrical Standards," 1863.
Hallock and Wade. "Evolution of Weights and Measures and the Metric
I]

System," Macmillan Co., New York, 1906.

Sec. 1-3 UNITS, FACTORS, AND TABLES
3(Ca) Customary English units are the units of the English and Ainerj-
pan measures, viz., length measure, square measure, laud measure, cubic
measure, cord measure, dry measure, liquid measure, avoirdupois weight,
troy weight, apothecaries weight and jeweler's weight. Each of these meas-
ures may he regarded as a sy.stem. The complete list may be regarded as a
congeries of imperfectly connected systems. Empirical and hybrid units are
mingled with the rest.
3(di) C.Q.S. units are the units of that particular system of absolute
units which is based on the international centimeter, the international
gram and the mean solar second. That is, they are absolute units
employing the metric system in a definite way. A reason for the centimeter
having been selected in place of the meter as the fundamental unit of length
was that the mass of the cubic centimeter of water (at the temperature of
unit density) is the gram or unit mass; whereas the mass of a cubic meter of
water would be a metric ton as in the M. T. S. system.
3(d2) Q.E.S. units are units pertaining to the quadrant-eleventh-gram-
seeond absolute system; i.e., the system in which the unit of length is 10'
cm. or 1 theoretical quadrant of the earth as measured from a pole to the
equator, the unit of mass is 10~" g.,* and the unit of time the mean solar
second, or the 1/86, 400th part of the annual mean daily period of revo-
lution of the earth with respect to the sun. This is the system to which the
international ohm, volt, ampere, joule, watt, coulomb, farad and henry,
belong. The system was not intentionally established as a Q.E.S. system;
but the ohm having been arbitrarily selected, for convenience of magnitude,
as 10' C.G.S. electromagnetic units, and the volt similarly as 10' C.G.S.
units, the rest of the system necessarily coincides with the Q.E.S. system;
or is such a system as would be produced by the selection of the quadrant,
eleventh-gram and second as fundamental units, together with unity for
the permeability and unity for the dielectric constant of the ether.
SCds) Oiorgi units are units in a combined absolute and practical system
devised by Prof. G. Giorgi,t in which the fundamental units are: the raeter-
kilogram-second-international ohm, and the further assumption that the
permeability of free ether, instead of being unity as in the C.G.S. magnetic
system, is Mo = 47rX10~' henry/m. On this basis the ohm-volt-ampere
series of practical units become also absolute units. The electric inductivity,
instead of being unity, as in the C.G.S. electric system, becomes Ao = l/36ir
X 10~» farad/m. No distinction arises in the Giorgi system between electric
and magnetic units. The system is also rectified in regard to 4ir factors,
or is "rationalized" in the Heaviside sense; so that a number of fundamental
equations in the system differ from those of the C.G.S. system in regard to
such 4t factors.
3(d4) M.O.S. units, etc. Units in an absolute system whose fundamental
units are the meter-gram-second, the millimetcr-milligram-second, the foot-
grain second, etc. None of these extraneous absolute systems have come
into extensive use.
3(ei) B.A. units are the units of the C.G.S. system as established by the
British Association for the Advancement of Science} in 1802. The electro-
static subsystem was established on the basis of the unit quantity of elec-
tricity such that it repelled its prototype at a distance of 1 cm. with a force
of 1 dyne. The electromagnetic subsystem was similarly established on the
basis of the unit magnetic pole such that it repelled its prototype at a dis-
tance of 1 cm. with a force of 1 dyne. This procedure led to the anomalous
result that every electromagnetic quantity has a unit both in the electro-
static subsystem and in the magnetic subsystem.
Sioi) Heaviside units are units in that form of the C.G.S. system which
was first suggested by Mr. Oliver Heaviside in 1882. § He showed that if a
unit electric point charge and a unit magnetic point pole had been respect-
ively defined such that unit total flux emanated therefrom, the strength of
• Maxwell, J. C. "A Treatise on Electricity and Magnetism," 1881.
Chapter X. .

t Ascoli, M. "On the Systems of Electrical Units," Trans. Int. Electrical

Congress of St. Louis, 1904, Vol. I, p. 130.
5" British Association Report on Electrical Standards," 1863.
Heaviside, O. "The Relations between Magnetic Force and Electric
Current." The Electrician, London, Nov. 18, 1882.
 UNITS, FACTORS, AND TABLES Sec. 1-4

the field at unit distance would be l/(4ir), and this, not unity, should be the
force in dynes that the prototype would develop in repulsion. As a conse-
quence of this unnatural definition of the B.A. unit charge and pole, the
fundamental equations of the B.A. system become interlarded with 4ir-
factora in rectiUnear problems and denuded of them in spherical problems
where they should naturally be expected to occur. Mr. Heaviside proposed
to rectify the system by changing the fundamental definitions in the manner
suggested, and enunciating a new list of units in both the electrostatic and
magnetic subsystems; all related to the corresponding B.A. units in simple
powers or roots of 45r. He similarly proposed rectifying the practical or
Q.E.S. system of units by adopting a new ohm, volt, ampere, etc., all bearing
some ratio of simple power or root of 4jr to the corresponding existing
values. If Mr. Heaviside's proposals had been formulated and considered
f)rior to international adoption of the
ohm-volt-ampere series of units, and
egalized standards, they might have been adopted. * At the present time
a very few physicists employ Heaviside's "rational" units in theoretical
analysis.!
4. Fundamental principles concerning units in equations. Many
of the equations representing propositions in pure mathematics may
be satis-
fied by quantities of any kind. Thus taking the very simple equation
2{a + b)=2a + 2b
that the quantities a and b may be of the same kind or of different
it is clear
kinds, and their respective units may be any whatsoever, without affecting
the identity expressed, so long as a and 6 have respectively the same meanings
on the two sides of the equation.
When, however, as ordinarily in en-
gineering, physical magnitudes are
dealt with in an equation; then three
consequences ensue; namely:
(1) The equation can only be inter-
preted in terms of some unit of the par-
ticular physical quantity dealt with.
This is the unit of the equation.
(2) The unit employed on each side
of the equation must be the same.t
Fig
(3) If either side of the equation con-
tains a simple sum of positive or negative terms; then each of these terms must
employ the same unit as the equation.
For example, considering the case of a uniform pipe, discharging water at
a uniform velocity v meters per sec, from a reservoir A into a river B
(Fig. 2). Let H be the total head or elevation in meters between the water
levels A and B at the two ends of the pipe, and let a vertical pressure pipe
be inserted (Fig. 2) at any point P. Then we have the well-known hydraulic
relation:

(meters) (1)
2(7
where / the loss of head due to friction in ihe length of pipe AP, g is the
is
acceleration due to gravitation in meters per second per second, v'^/2g is the
loss of head due to velocity at the point P, hi is the remaining head above the
local level, and hj the height of P above the reservoir level at B. Then
according to the propositions above stated, each of the four terms on the
right hand of the equation must be a head, or height, in meters, and both sides
of the equation must be expressed in terms of the same unit. The left-hand
term i/ cannot be in meters and the right-hand terms or any of them in feet
or centimeters. The second term on the right hand (»V2ff) contains a
velocity v, and an acceleration g; yet the term as a whole must be a height,
if the equation is correct.
The equation might evidently be expressed in terms of any unit of length
such as inches, feet, cubits, yards, miles or millimeters. As an algebraic
equation entirely by itself, there is no reason for selecting one unit rather

* Heaviside, O. "Electrical Papers:" Macmillan Co., 1892, Vol. II, p. 575

tLorentz, H. A. "The THeory of Electrons." B. G. Teubner, 1909, p. 2.
t An exception is found in an equation expressing the relation between dif-
ferent units of the same species, as for example, in the equation 1 lb. = 16 oz.
Sec. 1-5 UNIT/i, FACTORS, AND TABLES
than another. The numerical values applying to any particular case cov-
ered by the equation will vary greatly according to the unit selected. If,
however, any one of the terms is expressed in a particular unit, all the other
terms must adopt the same unit. In all cases, however, it is helpful to the
reader to have the unit of the equation written out at the end of its line, as
above, in order to assist the numerical interpretation.
HISTORICAL SKETCH OF ENGLISH UNITS
6. The English weights and measures are based upon old Roman
weights and measures.* The troy pound is supposed to have been a weight
of silver referred to as a "pound sterling." This pound would be coined into
240 silver pennies or "pennyweights," each of 24 gr. (barley grain weights).
It would, therefore, contain 5,760 gr. Heavy bodies (substances in gross
outside of coins or bullion) were weighed by "avoirdupois" weight, authorized
by law early in the fourteenth century. Several slightly different avoirdu-
pois pounds were in use. Since Queen Elizabeth's reign the avoirdupois
pound has been fixed at 7,000 troy grains.
6. In regard to British lengths, the earliest seems to have been the
cubit or half yard. The cubit is a very ancient measure, and corresponds to
a forearm length from elbow to middle finger-tip. The royal iron standard
yard was constructed in the thirteenth century, after which the cubit or half
yard gradually fell out of use. The foot was standardized at one-third of
the yard. The mile was a relic of the Roman "millia passuum," or thousand
paces; the Roman pace was two of our paces, or counted between the lifts of
one and the same foot.
7. Qallon measures of volume existed at different times in England in
six different forms, such as the corn-gallon, the ale-gallon, etc. Among
these,
the wine-gallon of Queen Anne contained 231 cu. in. This gallon was brought
to America by the early colonists and remains to-day the U. S. gallon. In
1824, the British enacted a new "imperial gallon" to supersede all pre-
existing gallons, and defined it as the volume of 10 avoirdupois pounds of
distilled water at the temperature of 62 deg. fahr. with the barometer at
30 in. It was further defined as a measure containing 277.274 cu. in. of
distilled water. There is thus a difference between British and American
gallons in the ratio 277.274 to 231 = 1.204 1; so that the British gallons,
:

quarts, and pints are respectively about 20 per cent, larger than American
gallons, quarts and pints, a large discrepancy that has frequently led to
misunderstandings.
8. In land measure, since Anglo-Saxon times, a "perch" or "pole"
was 11 cubits in length = 16J ft., and such a pole was the surveyor's unit-
A length of 40 perches was a furlong, and 8 furlongs the statute mile.
An acre of land was the area of a rectangular strip a furlong in length and
4 perches in breadth, which breadth was known as the "acre's breadth."
An acre therefore included 40X4 = 160 sq. perches. Eight such strips end
to end made the statute mile, and 80 such strips side by side made a statute
mile breadth; so that a square statute mile contained 640 acres. Early
in the seventeenth century, Prof. Edmund Gunter of Gresham College
decimalized acre measure by inventing a 100-link "chain" of outstretched
length equal to 4 perches or the acre's breadth (66 ft.). The acre thus became
10 sq. chains.
HISTORICAL SKETCH OF THE INTERNATIONAL METRIC
SYSTEM
9. Prior to 1790, differences existed between the weights and measures
of different Departments of France. Reform in the directions of simpli-
_

fication and unification was promised in a decree of the National Assembly

under the sanction of Louis XVI in 1790. The metric system was actually
developed under the authority of the French Republic in 1793, in the hands
of a committee of scientists and engineers.
10. The decimal system, at the'base of the metric system, was originally
extended to angles and to time, the right angle being divided into 100 grades,
each subdivided into 100 min. and again into 100 sec. The day was divided
into 10 hr., each subdivided into 100 min. and again into 100 sec. The deci-
mal subdivision of time never came into extended effect, and the decimal
subdivi.sion of angles has only been used to a limited extent, except in France,
• Watson, Sir C. M. " British Weights and Measures." London, 1910.

6
 UNITS, FACTORS, AND TABLES SeC. 1-11

11. The meter was selected as a length equal to the ten millionth part
of the northern quadrant of the earth, or distance from pole to equator
at the meridian of Paris. Later measurements have shown that the inter-
national standard meter finally adopted is shorter than the 10~' quadrant
by 0.02* per cent. The advantage of such a basis for the meter is that by
the use of the decimal subdivision of angles; i.e., by the substitution of 100
grades for 90 deg., the kilometer becomes the natural nautical upit of dis-
tance, or the hundredth of the grade; just as the English nautical mile is
the sixtieth of a degree.
12. The metric system is universally used in all European countries,
except Great Britain and Russia. The quantitative literature of the scien-
tific world is almost exclusively written in the metric system. To express
quantitative relations exclusively in the English units is to conceal their
meaning, to a great extent, from all but English-speaking peoples; and also
to discredit them scientifically, by implication.
13. In the United States, the metric system has been a legally recognized
system since July 28, 1866. In 1893, the U. S. Office of Standard Weights
and Measures was authorized to derive the yard from the meterf at the ratio
1 yd. = 3600/3937 meter. The customary weights are likewise referred to
the kilogram. The customary weights and measures of the United States
are thus defined in terms of, and maintained with reference to, the inter-
national metric system.
14. The international metric standards, i.e., the standard meter
bar and the standard kilogram, are maintained at the International Bureau
of Weights and Measures at Sevres, near Paris, France, in a building which
has been declared internationally neutral or outside of French territory.
Copies or prototypes of these standards are maintained at the various
national laboratories and are occasionally intercompared.
EVOLUTION or THE PRACTICAL ELECTBOMAQNETIC
SYSTEM OF UNITS t
15. Brief historical outline. In 1861 a committee of the B.A. (British
Association for the Advancement of Science) was appointed to consider
standards of electrical resistance. The committee decided to adopt a series
of electrical units in the C.G.S. absolute system._
The unit of resistance in
the C.G.S. magnetic system was so small (one-billionth of an ohm) that it
was considered unfit for practical use and a unit 10' times greater than the
C.G.S. unit was selected as of convenient magnitude. This decimally derived
unit was called the ohm after the German scientist Dr. Ohm. Similarly,
the C.G.S. magnetic unit of electromotive force was regarded as unfit for
recommendation, and a unit 10' times greater than the C.G.S. unit was
selected, and called the volt, after the Italian electrician Volta. The ohm
having been selected as a unit, standard resistance coils had to be produced
—
and adjusted a work of great labor. In 1864 and 1865, certain standards
of resistance or B.A. ohms were produced and put into service. In 1872,
Mr. Latimer Clark produced the well-known zinc-mercury standard cell
which bears his name.
16. B.A. ohm too small. In 1878, it was realized that the B.A. ohm
was too small by over 1 per cent. That is, the B.A. ohm is now taken to
be 0.9866 of the existing international ohm.
17. In 1881 an international electrical congress at Paris recommended
that the standard ohm should be represented as the resistance of a uniform
column of mercury, 1 sq. mm. in cross-section, at deg. cent., the length of
such a column for the B.A. ohm being approximately 104.9 cm. The Paris
Congre.ss of 1881 also adopted the ampere, coulomb and farad, as the prac-
tical units of current, quantity and capacity. The practical system based
on the ohm and volt thus became virtually the Q.E.S. (quadrant-eleventh-
gram-second) system, in place of the C.G.S. system; i.e., as though 10» cm.
were substituted for 1 cm. as the unit length, and 10~" g. instead of 1 g. as
the unit mass.
* Annuaire pour I'an 1913, Paris. Gauthier-Villars.
t Tables of Equivalents of the U. S. Customary and Metric Weights and
Measures. Department of Commerce and Labor, Bureau of Standards,
Publication.
t Wolff, F. A. "The So-called International Electrical Units." Trans.
Int. El. Congress, St. Louis, 1904, Vol. I, p. 148.
Sec. 1-18 UNITS, FACTORS AND TABLES
18. In 1882, an international commission met at Paris and adopted
a length of 106 cm. as the length of the mercury column defining the ohm, as a
closer approximation to the true ohm than the B.A. ohm. This 106-cm.
ohm was called the "legal" ohm, as distinguished from the B.A. ohm.
Legal ohms, volts, etc., have at the present date almost completely dis-
appeared. They represented an intermediate stage of approximation to
the present international unit values.
19. In 1889, an international electrical congress at Paris adopted
the joule, the watt, and the quadrant, as the practical units of energy, power
and inductance, respectively.
20. Edinburgh conference. In 1892, a conference was held in connec-
tion with the B.A. meeting at Edinburgh. It was then decided to adopt
106.3 cm. as the length of mercury column whose resistance should embody
the ohm.
21. In 1893, the international electrical congress of Chicago adopted
the 106.3-cm. ohm, which was called the international ohm. The other
units of the practical system adjusted in conformity to this value were called
correspondingly the international ampere, volt, coulomb, etc. The
name of the unit of inductance was changed from the quadrant to the henry,
in honor of the American physicist of that name.
22. In 1900, an international electrical congress at Paris, after some
debate, adopted the maxwell as the unit of magnetic flux and the gauss
as the unit either of magnetic intensity or of flux-density in the C.G.S. mag-
netic system.
23. In 1908, an international commission at London considered the
order of sequence of resistance, current and voltage standards, which
had been left indefinite at preceding congresses. It was decided that the
ohm should be the first unit, and the ampere the second, as determined
by the rate of electrodeposition of silver under specified conditions. The
volt was to be determined from the ohm and ampere.
DEFINITIONS OF FUNDAMENTAL UNITS
24. Length. (L.) Linear distance between any two points. The unit of
length in the metric system is the meter, in the C.G.S. system the centi-
meter, in the customary system it is any one of the following: inch, foot, —
yard, pole, furlong, statute mile, nautical mile.
The fundamental unit of length of the United States is the international
meter, the primary standard of which is deposited at the International
Bureau of Weights and Measures near Paris, France. This is a platinum-
iridium bar with three fine lines at each end; and the distance between the
middle lines of each end when the bar is at the temperature of deg. cent.,
and is supported at the two neutral points 28.5 cm. each side of the centre is
1 m. by definition. Two copies of this bar (prototype meters) are in the
possession of the United States and are deposited at the Bureau of Standards.
The United States yard is defined by the relation
1 yd. = 3600/3937 m.
The legal equivalent of the meter for commercial purposes was fixed as
39.37 in. by the law of July 28, 1866, and experience haying shown that this
value was exact within the error of observation, the United States Office of
Standard Weights and Measures was, by executive order in 1893, authorized
to derive the yard from the meter by the use of this relation.
25. Mass. (M.) The quantity of matter in a body is estimated cither by
its inertia or by its weight. In the metric system, the unit of mass is
the gram, which, was originally defined as the mass of a cubic centimeter
of distilled water at deg. cent., although in practice it is taken as the
thousandth part of a standard kilogram. In the customary system, the
unit is ordinarily any one of the following: avoirdupois grain, ounce, pound,
or ton (long or short); occasionally, it is one of the Troy system (ounce,
pound). In the use of drugs, it is u.iually stated in apothecaries weight. The
mass of precious stones is commonly estimated in carats.
26. Time. (.T.) The interval elapsing between any two events. In the
C.G.S. system, the unit of time is the mean solar second, or 86,400th part
of the mean solar day. In the customary system, it is either the second, min-
ute, hour, day, week or year of mean solar time.

8
 UNITS, FACTORS, AND TABLES Sec. 1-27

27. Area. (A.) Space occupied in two dimensions. In the metiic sys-
tem, the unit is primarily the square meter but the square dekameter or
;

are is used in land measure; while square millimeter; square centimeter;

and square decimeter arc also used. In the customary English system the
unit may be the square mil, the square inch, square foot, square yard, square
chain or square mile.
28. Volurae. ( V.) Space occupied in three dimensions. In the metric
system, the unit is primarily the cubic meter or stere but the cubic deci-
;

meter or liter is much used, as well as the cubic centimeter and the cubic
millimeter. In the customary English system, the units are the cubic inch,
cubic foot, cubic yard, cubic-mile.
29. Density. (,5.) Ratio of mass to the volume it occupies. In the met-
ric system the unit is primarily the gram per cubic meter; but decimal deriva-
tives are more common. In the C.G.S. system, the unit is the gram per
cubic centimeter. In the M.T.S, system, it is the ton per cubic meter.
30. Force. (F.) That which tends to change the energy existing in a
given region of space. In mechanics, force is that which t nds to produce
change of motion in matter. In the C.G.S. system, the unit is the dyne, or
that force which after acting on a free gram during Isec, creates therein
a velocity of 1 cm. per sec. In mechanics, the unit force is the force
required to support unit mass against standard gravity; i.e., gravity at the
standard locality; the weight, at standard latitude and level, of a gram, a
kilogram, a pound, etc., according to the system considered. In the M.T.S.
system, the unit is the sthene, or the force which acting on a metric ton
accelerates it one meter per second.
31. The weight of a body is the gravitational force acting upon it.
Its standard weight is its weight under standard gravitational force. Its
local weight is its weight under local gravitational force. In the C.G.S.
system the unit for weight is the dyne. It is also expressible in the various
systems as the gram weight, kilogram weight, the pound weight, etc.
Important differences of usage and terminology frequently exist be-
tween text-books on physics and text-books on applied mechanics, in regard
to the units of mass and of force. These differences are not essentially con-
nected with English weights and measures, because they exist in the text-
books of several European countries where the metric system is exclusively
employed. In physics, it is customary to regard the terms gram, milli-
gram, kilogram, pound, etc., as designating a mass in the sense above
defined. _
The force exerted gravitationally on such a unit is called the weight
of the unit, and is derived from the product of the mass and the gravitational
acceleration constant g. Thus in an absolute kinetic system, if a body has
a mass of m grams, its local weight or gravitational force F is
F = mg (dynes) (2)
g being the local gravitational acceleration. If the body is transferred to a
place where there is standard gravitational acceleration go, then:
Fo = mgo (dynes) (3)
In applied mechanics, it is customary to regard the terms gram, kilo-
_

gram, pound, etc., as designating a weight or gravitational force in the

sense above defined; that is, to say one and the same term, "kilogram" say,
ia used with a different meaning in the two cases here compared. If a body
has a standard weight of Wo grams, then by (3),
Fo = {Wo/go)go (grams standard weight) (4)
BO that in the books on applied mechanics, where a mass has to appear in
an equation, it is represented by such a term as TFo/so. The same is true
for any_ system of units. Thus in (3), if wi is a mass expressed in pounds,
and go is the gravitational constant in customary measure, then we might
find in a text-book on physics:
Fo = mgo (poundals) (5)
whereas in a text-book on applied mechanics (4) would have to be written
Fo = (TFo/ffo)ffo (standard pounds weight) (6)
The centrifugal force of a mass m pounds whirling with a peripheral
velocity v feet per sec. at a radius of r feet would be, according to (5)
F = m(tV) ('poundals) (7)

• Everett. "C.G.S. System of Units." Macmillan Co., N. Y. 1891, p. 28.

Sec. 1-32 UNITS, FACTORS, AND TABLES
a poundal being the force which acting on a pound mass for 1 sec, develops
in it a velocity of 1 ft. per sec. A pound weight is equal to 32.2 poundals.
But if we consider a pound to be a force, represented by a weight W,
=E
"'
;? . ( * pounds force) (8)
r
between the two contrasted modes of
It is evident that there is no difference
presenting the facts, provided that we distinguish carefully between a
" pound-xnasB " and a "pound-force." If, however, we use the same word
"pound" to do duty in the two cases, contradictory and illogical results may
be obtained.
It follows that the terms gram, kilogram, pound, ton, etc., are sus-
ceptible of either of two distinct meanings ; namely, a unit of mass of
matter or a unit of force equal to the gravitational force exerted on that
mass by the earth. Confusion can be avoided in all cases, however, by using
distinguishing terms, as "gram-mass," "gram force," or "gram weight."
32. Linear velocity (v). Rate of movement along a line, and ordinarily
along a straight line; also, time rate of change of space. The unit in the
C.G.S. system is the centimeter-per-second, in the metric system the meter-
Eer-second, or per minute or per hour. In the customary system, it would
e any of the customary English units of length per second, minute, hour
or day, etc. Velocities may be either + or — with respect to a selected
point on the line of motion.
S3. Linear acceleration (a). Time rate of change of linear velocity.
The C.G.S. unit is the (cm. per sec.) per sec. or the cm. per sec.'. The
;

metric unit may be a meter per sec. 2, or a meter per hour^, or any decimal
derivative of the meter, per square of the second, minute, hour, etc._ A
useful hybrid unit is the (kilometer per hour) per second. Accelerations
may be either + or —
34. Plane angle {a,0,y). In plane circular trigonometry, the ratio of
a circular arc to its radius. The C.G.S. unit is the radian, or 1 cm. of arc
drawn with a radius of 1 cm. The metric unit is the grade or one-hundredth
of the quadrant with unit radius. The customary unit is either the degree
—
one-ninetieth of the unit-radius quadrant or the revolution of four
quadrants.
35. Angular velocity (w). In plane circular trigonometry, the time rate of
change of angle at any given instant. The C.G.S. unit is the radian per
second. The customary unit is either the degree per second, or the revolu-
tion per second, or per minute, etc. Angular velocities may be either -(- or — .

36. Angular acceleration. In plane circular trigonometry, the time

rate of change of angular velocity. The C.G.S. unit is the radian per second
per second. Customary units are the degree per sec. 2, the revolution per
sec. 2, or per min.^ etc.
37. Energry (W). The capacity of doing work. Energy may be consid-
ered as the fundamental entity in terms of which all dynamical quantities
may be defined. In the C.G.S. system, the unit is the erg, or dyne-centi-
meter. In mechanics, it may be any product of a unit wciKlit and unit
distance such as kilogram-meter, foot-pound, etc., according to the system.
An industrial unit in the moter-kilogram-second system is the watt-hour.
38. Power (P). Activity or the rate of working. The rate of expending
energy. The C.G.S. unit is the erg per second. The metric gravitational
unit is the gram-meter per second, or a decimal derivative, such as the kilo-
gram-meter per second. The absolute unit in the meter-kilograni-second
system is the watt. The customary unit is the foot-pound per second,
or the horse-power of 550 ft.-lb. per sec. It may be either local or
standard.
89. Momentum. The product of the mass of a body and its velocity.
The C.G.S. unit is the gram-centimeter per second. A customary unit
is the pound-mass X (foot per second).
40. Torque (r). Twisting effort. The moment of a twisting couple
ordinarily exerted about a shaft axis. The C.G.S. unit is the dyne-perpen-
_

dlcular-centimeter ; i.e., a dyne acting at right angles to a radius arm 1 cm.

• Prof. W. J. M. Rankine. "Applied Mechanics," 0th edition, 1877, page 491.

10
 UNITS, FACTORS, AND TABLES Sec. 1-41

in length. The customary unit is the pound-weight perpendicular foot.

If the word "perpendicular" is omitted from the unit, care must be taken to
distinguish from a dyne-centimeter or a foot-pound weight, which are units
of work or energy. A torque is not a work, and can do no work until it
advances through an angle.
41. Pressure (p). A force integral, or summation of a force, over a
surface. A pressure may be either total or specific. A total pressure, as
its namesuggests, is the force integral or total force with reference to some
particular direction or set of directions. A specific pressure, or intensity
of pressure, is the ratio of a pressure to the surface area over which it is
applied, or the pressure per unit area. Unless otherwise specified, a
pressure is ordinarily understood to be a specific pressure. The C.G.S. unit of
pressure is the dyne per square centimeter, sometimes called a "bar."*
The metric gravitation unit is the gram weight per square meter, or
some decimal derivative, such as the kilogram weight per square milli-
meter. The standard atmospheric pressure of 760 mm. mercury
at sea-level and deg. cent, at latitude 45 deg., is 1.01321X10' bars or
1.01321 megabar.f Pressures are thus frequently reckoned in atmospheres.
They are also frequently expressed as heights of a column of uniform liquid.
42. Strain. A change in the shape or size of a body due to the application
of a force or set of forces. In the simplest cases, strains are (1) voluminal
compressions or dilations; (2) extensions or compressions in one direction with
corresponding lateral compressions or dilations (such an extension is called an
elongation) (3) a twist or shear. These various strains, when small, are
;

expressed as small numerical fractions, in which the numerator expresses the

distortion and the denominator the original undistorted value. These strains
are ordinarily independent of the system of units employed.
43. Stress. The force or set of forces applied to a body, and which tend
to produce a strain. They may be either simple forces, pressure intensities,
_

twists, or combinations of the foregoing, and are expressible in the corre-

sponding units.
44. Young's modulus of elasticity. The specific tension which would
have to be applied to a uniform prism of a substance in order to double its
original length, as judged from a small extension under a measured tension.
It is a specific ten.sion or a longitudinal force per unit area of prism. The
C.G.S. unit is the dyne per square centimeter. The metric gravitation
unit is the grani-weight per square meter or some decimal derivative.
A customary unit is the pound-weight per square inch.
45. Moment of inertia of a body with respect to an axis (J). The
product of the mass of the body and the square of its radius of gyration
with respect to the axis considered. It is therefore the product of a mass and
a distance squared. The C.G.S. unit is the_g-cm.2 The metric unit is
a gram-mass-meter. 2 A customary unit is the pound-mass-foot.^
The radius of gyration of a body with respect to an axis is the square root
of the mean square of the distances of all the particles of the body from the
axis. It is therefore a length. The C.G.S. unit is the centimeter. A
metric unit is the meter, or decimal derivative. A customary unit is the foot.
DEFINITIONS OF ELECTRIC AND MAGNETIC UNITS
46. Electric quantity (Q). The amount of electricity present in any
electric charge or passed through a circuit during any time interval by an
electric current. The practical unit is the coulomb, the C.G.S. units are the
abcoulomb and statcoulomb.
47. Electric e.m.f. or pressure (E). That which tends to make an
electric current flow. E.m.f. is ordinarily accompanied by a difference of
electric potential; but an e.m.f. may occur without difference of potential, as
for example, when a straight bar magnet is thrust symmetrically into a cir-
cular loop of uniform wire. A
brief current will thus be set up in the wire
due to an e.m.f. induced by the magnet's motion; but there will be no differ-
ence of electric potential in or around the wire. The practical unit is the
volt. The C.G.S. units are the abvolt and statvolt.
* Richards and Carnegie Institution Publication No. 7, p. 43, Dec,
Stull.
1903.
t Gauthier-Villars. "Les R^cents Progrfes du SystSme Metrique." Paris,
1907, pp. 30-31. Meteorologists commonly call this 1.01321 bars.

11
Sec. 1-48 UNITS, FACTORS, AND TABLES
£.m.f. may be reckoned for a complete circuit or for any portion thereof;
that is, each and every portion of a closed circuit in the steady state obeys
Ohm's law.
48. Potential diflerence (TJ or V). A condition in virtue of which an
electric current tends to flow from a place of higher to a place of lower poten-
tial. The numerical measure of the potential difference is the work done on
a unit quantity of electricity in passing between the two points. The prac-
tical unit is the volt. The C.G.S. units are the abvolt and statvolt.
49. Potential gradient. The space rate of change of potential, or the
change with respect to distance. An electric potential gradient is the space
rate of change of electric potential, and similarly for magnetic, thermal or
gravitational potential. The systematic unit in the practical system is the
volt per quadrant, but a hybrid unit such as volt per centimeter is gener-
ally used. The C.G.S. unit is either the abvolt or statvolt per cm.
60. Electric current (I). The rate at which electricity flows through a
conductor or circuit. The practical unit is the ampere, which is a current
of one coulomb per second. The C.G.S. unit is either the absampere or
statampere.
61. Electric current density. The ratio of the current flowing through
a conductor to the cross-sectional area of that conductor. More strictly,
the current density at a point in a conductor is the ratio of the current through
a very small plane element of section containing the point and perpendicular
to the current, to the area of the element. The systematic practical unit is
the ampere per square quadrant. In practice, a hybrid unit is preferred
such as the ampere per square centimeter or square inch. The C.G.S.
unit is either the absampere or statampere per square centimeter.
62. Electric resistance (E). Obstruction to electric flow. The ratio
of voltage to current in a conductor or closed circuit. The practical unit is
the ohm. The C.G.S. unit is either the absohm or statohm.
63. Electric resistivity (p). The ratio of potential gradient in a con-
ductor to the current density thereby produced. Also the specific resistance of
a substance numerically equal to the resistance offered by a unit cube of the
substance as measured between a pair of opposed parallel faces. The sys-
tematic practical unit is the ohm-quadrant or numerically equal to the
resistance in a cubic earth-quadrant. A hybrid unit such as the ohm-cm.
is usually preferred. The C.G.S. magnetic unit is the absohm-cm. See 146.
64. Electric conductance (O). The conducting power of a conductor
or circuit for electricity. The inverse or reciprocal of electric resistance.
The practical unit is the mho. The C.G.S. unit is either the abmho or the
Btatmho.
66. Electric conductivity (7). The specific electric conducting power
of a substance. The reciprocal of resistivity. The systematic practical
unit is the mho
per ouadrant. A hybrid unit, such as the mho
per cm.
is usually preferred. The C.G.S. magnetic unit is the abmho per cm.
66. Inductance (L). The capacity for electromagnetic induction pos-
sessed by an active circuit either on itself or on neighboring circuits. The
ratio of the magnetic flux linked with and due to an active conductor (num-
ber of turns X total flux) to the current strength carried. The practical
unit is the henry. The C.G.S. units are the abhenry and stathenry.
The term "inductance" seems to have been first introduced by Heaviside*
as a brief equivalent for "coefficient of self-induction." Inductance may be
divided into two species; namely, self -inductance and mutual inductance.
The unit is the same for both species.
67. Electric capacitance (C). Sometimes called permittance or capa-
city. The power of storing or holding an electric charge. The ratio of an
electric charge on a conductor to the electric potential difference producing
the charge. The practical unit is the farad. The C.G.S. unit is either the
abfarad or the statfarad. The term "permittance" was introduced by
Heavi.side.t It should be noted that capacitance is used by a few writers as
synonymous with capacity-reactance.
• Heaviside, O. "Thfe Electrician," 1884, May 3, p. 583; also "Electrical
•

Papers," Macmillan Co.. 1892. Vol. l,p.-354.

f Heaviside, O. "Electrical Papers.'' 1892. Vol. II pp. 302 and 327.
,

12
 UNITS, FACTORS, AND TABLES Sec. 1-58

68. Permittivity is the specific permittance of a substance and numer-

ically equal to the permittance offered by a unit cube of the material as
measured between a pair of opposed parallel faces. In the C.G.S. electric
system it is equal to k, the dielectric constant. _ Analogous to electric
conductivity and magnetic permeability. A term introduced and defined
by Heaviside. *
09. Dielectric constant or specific inductive capacity (k). The
ratio of the capacity of a condenser whose coatings are separated by a given
substance, to the capacity of a similar condenser whose plates are separated
by a vacuum. A pure numeric in any system of units.
60. Elastance. The reciprocal of the capacitance of a condenser or di-
electric. No unit for elastance has been agreed upon in any system. The
term "daraf" has, however, been suggested for this unit in the practical
system, so that a condenser having a capacity of one farad would also have
an elastance of one daraf. The C.G.S. unit would be a statdaraf.
61. Elastivity. The specific elastance of a substance, and numerically
equal to the elastance offered by a unit cube of the substance as measured be-
tween a pair of opposed parallel faces. In the C.G.S. electric system it is
the reciprocal of permittivity. Analogous to electrig resistivity.
62. Frequency (f). In a simple alternating-current circuit the number of
cycles executed by the current per second. The unit is the cycle per second.
63. Angrular velocity (w) of a simple alternating-current circuit. The
product of the numeric 2x and the frequency / of the current in cycles per
second. The unit employed is the radian per second.
64. Reactance (X). In a simple alternating-current circuit, the reactive
component of the impedance, as distinguished from the active component,
resistance. Reactance may be divided into two species of mutually opposite
signs; namely, inductive reactance or that species of reactance developed
in an inductance, 2irfL, and condensive reactance, or that species of re-
actance developed in a condenser, 1 /2ir/c. Inductive reactance is denoted
(when using the method of complex imaginary quantities) by the sign -f y or
-|-V— 1, and condensive reactance by the sign — ; or— v — 1. The unit of
reactance in the practical system is the ohm. The C.G.S. unit is either the
absohm or statohm.
65. Impedance (Z). The apparent resistance of an alternating-current
circuit or path. The vector sum of the resistance and reactance of the
path. The practical unit is the ohm. The C.G.S. unit is either the absohm
or statohm.
66. Admittance (Y). The reciprocal of the impedance of an alternating-
current circuit or path, a complex quantity. Units mho, abmho or statmho.
67. Conductance (O). In a direct-current circuit, the reciprocal of
the resistance. The practical unit is the mho. In Germany it is called
the Siemens. The C.G.S. unit is either the abmho or the statmho.
In a simple alternating-current circuit, the conductance is the active com-
ponent of the admittance, or the quantity which multiplied by the root-
mean-square impressed alternating voltage gives the active component of
root-mean-square current, or the component in phase with the e.m.f. The
practical unit is the mho. The C.G.S. unit may be either the abmho or
statmho.
68. Susceptance (B) . The reactive component of admittance in a simple
alternating-current circuit. The practical unit is the mho. The C.G.S.
unit may be either the abmho or statmho.
69. Magnetic poles. Those portions of the surface of a magnetic source
where the magnetic flux enters or leaves the surface. Magnetic poles appear
wherever there is an abrupt change of permeability.
70. Magnetic pole strength. The total flux entering or leaving a pole
divided by 4Tr. No name has been provided for this unit. The product
of magnetic pole strength and the length of the magnet (interpolar distance)
is magnetic moment.
the
Magnetic flux (</>)
71 . The magnetic flow or current that passes through
.

any magnetic circuit. The C.G.S. magnetic unit is the maxwell.

t Heaviside, O. "Electrical Papers." 1892, Vol. II, p. 329.

13
Sec. 1-72 UNITS, FACTORS, AND TABLES
72. Magnetic flux-density ((B). The ratio of the magnetic flux in any
cross-sectional element of a magnetic circuit to the area of that element.
The C.G.S. magnetic unit is the gauBS, which is also a maxwell per square
centimeter.
73. Magnetomotive force (m.m.f.). That which produces magnetic
flux. The analogue in the magnetic circuit of electromotive force in the
electric circxiit. No namehas been provided for the unit of m.m.f. either
in the practical or in the C.G.S. magnetic system. The name of gilbert
has, however, been suggested for the latter. A convenient practical unit
is the ampere-turn which is 47r/10 = 1.257 gilberts.
74. Magnetic field intensity (3C) or gradient of magnetic potential,
also termed magi etizing force. The rate of change of magnetic potential
with respect to distance. In a region of unit permeability, the field intensity
is numerically equal to the magnetic flux density. The provisional name
of the C.G.S. magnetic unit is the gilbert per centimeter. Anumerically
related hybrid unit is the ampere-turn per centimeter.
76. Reluctance ((R). Obstruction to magnetic flow. In a simple mag-
netic circuit, the ratio of the m.m.f. to the magnetic flux. A provisional
name for the C.G.S. magnetic unit is the oersted. One gilbert m.m.f. acting
on a magnetic circuit of one oersted reluctance produces one maxwell of flux.
76. Reluctivity (v). A specific reluctance, numerically equal to the
reluctance of unit cube of a substance between any pair of opposed parallel
faces. The C.G.S. magnetic unit is the oersted-cm.
77. Permeance. The reciprocal of reluctance. Conducting power for
magnetic flux. No naine has been adopted for this unit.
78. Permeability (^). The reciprocal of reluctivity, or specific perme-
ance. No name has been adopted for this unit. In the dimensional
formulas of the C.G.S. system, if the electric and magnetic constants of the
tether are considered as mere numerics; both permeability and reluctivity
are also mere numerics. Also magnetic intensity has the same dimensions
as flux density;* so that on this basis, which was at one time undisputed,
there would be no difference between gilberts-per-centimeter and gausses
except numerically. It is now generally admitted,t however, that the electric
and magnetic constants of the aether should not be taken as mere numerics;
although their dimensional formulas are not defined. On the latter basis,
there is a dimensional difference .of some kind between magnetic intensity
in gilberts-per-centimeter and flux-density in gausses. The permeability can
also be expressed ii =1-{-4.wk where k is the susceptibility.
79. Names for the units in the C.O.S. magnetic and electric sub-
systems. Although the practical ohm-volt-ampere series of units is uni-
versally employed in the great majority of electrical applications, yet it is
sometimes desirable to use the C.G.S. parent sy.stem of units and names for
such units have only been assigned authoritatively in a few instances, such
as the "dyne" for the unit of force, and the erg for the imit of work. It has
been suggestedj that the C.G.S. magnetic units might be distinguished from
thoir prototypes in the practical system by the prefix ab- or abs- and also
that the C.G.S. electrostatic units might be similarly distinguished by the
prefix abstat- or stat-, as indicated in the following table, Par. 80.
It should be borne in mind that the prefixes "ab" and "stat" have never
been authorized by any technical society or institution, and terms bearing
these prefixes are therefore technically irregular. The excuse for thi.s irregu-
larity is that no proper terms exist by which to describe these units, since the
phrases "C.G.S. magnetic unit," or "C.G.S. electric unit," are cumbersome
and insufficiently descriptive. Their merit is that there can be no ambiguity
concerning the meaning of these irregular terms.

•Maxwell, J. C. "A
Treatise on Electricity and Magnetism." 1881,
Vol. II, p. 244,
t Rttcker. Phil. Mag., Feb., 1889.
t Trans. A. I. E. E., July, 1903, Vol.
XXII, p. .529. FrankUn, W. S.
"Electric Waves," Now York, Macmillan Co., 1909, p. 67. Bering, C. "Con-
version Tables," New York, John Wiley &
Sons, 1904. Pender, Harold.
"American Handbook for Electrical Engineers," New York, John Wiley &
Sons, 1914.

14
UNITS, FACTORS, AND TABLES Sec. 1-80
Sec. 1-81 UNITS, FACTORS, AND TABLES
DEFINITIONS OF PHOTOMETRIC UNITS
81. Luminous flux (F), (light) is tlie physical stimulus produced by ra-
diation, which excites vision. It is proportional to the rate of flow of radiant
energy and to a stimulus coefficient which depends chiefly on the spectral
distribution of that energy. The stimulus coefficient for radiation of a par-
ticular wave-length is the ratio of the luminous flux to the radiant power
producing it. The conventional unit of luminous flux is the lumen or the
flux emitted by one international candle through one steradian.
82. Luminous intensity (I), or candle-power. The luminous inten-
sity of a point source of light is the solid-angular density of the luminous
flux emitted by the source in the direction considered; or it is the flux per
steradian in that direction. The conventional unit is the candle-power, or
the (candle) lumen per steradian.
83. International candle. A standard of luminous intensity, con-
ventionally equal to the bougie decimal, maintained between the national
laboratories of England, France and America through the medium of groups
of standard incandescent lamps seasoned and intercompared. The intensity
given by this standard is the conventional unit or candle.
84. True specific luminous intensity (bo) of an element of a luminous
surface is the ratio of the luminous intensity of the element, taken normally,
to the area of the element. The conventional unit is the candle per square
centimeter ; or the lumen per sq. cm.
85. Apparent specific luminous intensity, or brightness (b) of an ,

element of a luminous surface, from a given position, is the luminous intensity

per unit area of the surface projected on a plane perpendicular to the line of
sight, and including only a surface of dimensions small in comparison with
the distance from the observer. The conventional unit is the candle per
square centimeter of projected area; or the apparent lumen per sq. cm.
For luminous surfaces obeying Lambert's law, or the "cosine law," the true
and the apparent specific luminous intensities are equal. In practice, the
apparent specific intensity is ordinarily observed. It has been proposed to
call a brightness of one apparent lumen per sq. cm. one "lambert."

86. Illumination on a surface (E) is the luminous flux-density over

the surface, or the flux per unit of intercepting area. The practical unit is
the lumen per square foot or the foot-candle. The conventional unit
is the lumen per square centimeter which has been termed the "phot" by
Blondel. It is a cm-candle. The meter-candle, or 10~< phot, is sometimes
called the candle-lux. The milliphot (10"' phot = millilumen per square
centimeter) is roughly equal to a foot-candle, since 1 foot-candle =1.0764
niilliphots. A perfectly diifusing surface having a reflection coefficient of
unity, and illumined with 1 phot, would have a brightness of 1 lambert.

DEFINITIONS OF THERMAL UNITS

87. Temperature. The thermal condition of a bodj' considered with
reference to its capability to communicate heat to other bodies. Bodies
at the same temperature do not communicate heat to one another at their
bounding surfaces. The conventional unit is the degree centigrade.
Other units in practical use are the degree fahrenheit, and occasionally the
degree r^aumur.
88. Quantity of heat. The amount of heat energy contained in a body
or transferred from one body to another, by virtue of which temperatures
are established or changed. Since heat is a form of energy, a quantity of
heat may be expressed in units of energy of any kind. Two types of units
are employed, one thermal, the other dynamical. As thermal units the
C.G.S. unit is the "lesser-calorie" or "therm" or "water-gram-
degree centigrade." i.e., the quantity of heat required to raise 1 g. of
water 1 deg. cent.; and as this differs slightly with the temperature, the
interval from 15 deg. to 16 deg. cent, is given in the definition. A larger
decimal multiple of this unit, called the "greater calorie" or "kilogram-
calorie" is much used and is equal to 1,000 lesser calories. A i)ractical unit
is the "British thermal unit" (B.t.u.), or the heat required to raise 1 lb.
of water 1 deg. fahr. Dynamic units are the erg, the joule, the watt-hr.,
etc.

16
 UNITS, FACTORS, AND TABLES See. 1-89

89. Specific heat the ratio of the quantity of heat required to raise unit
is
mass of the substance througli unit difference of temperature, to that re-
quired to raise unit mass of water the same interval. In the C.G.S. thermal
system this is numerically the same as the quantity of heat required to raise
1 g. of the substance 1 deg. cent, at the temperature considered. The unit is
a mere numeric in any system.
Thermal conductivity. A specific thermal conducting power. It
90.
is numerically equal to the flow of heat occurring through a 1-cm. slab of
the material, through a cross-sectional area of 1 sq. cm., when the difference
of temperature between the surfaces of the slab is 1 deg. cent. The C.G.S.
dynamical unit is the abwatt per centimeter and pei degree centigrade.
91. Thermal resistance. Opposition to the flow of heat by conduction.
Unit thermal resistance in a heat conductor permits unit flow of heat under
unit difference of temperature. If the flow of heat is measured in abwatts or
ergs per second, and the difference of temperature is in deg. cent., the unit
has been called the thermal absohm. If the flow of heat is measured in watts,
the unit has been called the thermal ohm.
92. Thermal resistivity. The reciprocal of thermal conductivity, and
measurable in thermal ohm-cm. or absohm-cm.
93. Latent heat. The quantity of heat required to change the physical
state of unit mass of a substance without changing its temperature, as for
instance to convert 1 g. of water at 100 deg. cent, into saturated dry steam
at 100 deg. cent. The dynamical C.G.S. unit is the erg per gram.
94. Entropy. A quantitative property of a body which is constant
when the quantity of heat contained in it is constant; but which increases
or decreases as the body gains or loses heat. In any small change of the quan-
tity of heat contained in the body, the change in entropy is the ratio of the
change in quantity of heat to the absolute temperature at which the change
took place. The C.G.S. unit is the erg per degree absolute.
96. Coefficient of expansion, at any temperature, is the ratio of the
change in dimensions of a body to the original dimensions, per degree centi-
grade of temperature increase. The expansion may be linear, as in the case
of a metallic wire; or it may be voluminal as in the case of a fluid. In either
case the unit is a numeric divided by a change of temperature.

96. Emissivity. The rate of emission of heat from a body per unit of
surface area and per degree centigrade elevation of temperature above its
surroundings. The C.G.S. dynamical unit is the erg per second, per square
centimeter and per degree centigrade.
97. Mechanical equivalent of heat. The value in mechanical units
of energy corresponding to a given quantity of heat; and, in particular, the
value in mechanical units corresponding to a unit quantity of heat such as
a lesser calorie, a therniie or a B.t.u.

DIMENSIONAL FOBMULAS
98. Each and every derived unit in an absolute system is necessarily
formed from the fundamental units of that system in one and only one com-
bination. The particular combination of fundamental units entering into a
derived unit expresses its dimensions, and when presented algebraically, is
called the dimensional formula of the unit. Any statical or dynamical
unit in a kinetic absolute system involves only three fundamental units, or
has dimensions in three fundamental units. Electric or magnetic units
involve five fundamental units.

99. As a simple example, we may consider the unit of velocity. A

velocity is necessarily a length divided by a time. The notion of mass is
not involved in the concept of velocity. Consequently, if we denote the units
of length, mass and time by L, M, and T, respectively, the nature of unit
velocity V is expressed by the formula

V-=-L/T=LT-i (velocity unit) (9)

a 17
Sec. 1-100 UNITS. FACTORS, AND TABLES
The dimensions of velocity are therefore LT~^, or the first positive power of
length and the first negative power of time. Since mass does not appear in
this dimensional formula we may write the formal dimensions of velocity as
L'Af" J'''.^ The three exponents 1, and — 1 completely define the nature of
velocity in any absolute system whose fundamental units are length, mass
and time. Moreover, the dimensional formula of a unit assigns at once the
size of a unit when systems employing different fundamental units are
compared. Thus if wo should compare the unit of velocity in the C.G.S. sys-
tem with that, say, in the meter-kilogram-day system; then in the latter
the unit would be the meter per day while in the former it would be the
centimeter per second.
100. Taking the more complex case of the magrnetic unit of, say.
current-density in a system whose fundamental units are those of both the
practical and C.G.S. systems; namely, length, mass, time, magnetic aether
constant n, and dielectric aether constant k. Then the dimensional formula
of current-density is L~ Jl/ ^7" ii~^. If now we compare the size of the prac-
tical unit with that of the C.G.S. unit the former has a unit length of a quad-
rant or 10' cm., and a mass unit of 10~" g. Consequently, the size of the
X
practical unit is to the size of the C.G.S. unit in the ratio (10»^~^ (IQ-y)^-
10~"; so that the practical unit, the ampere per square quadrant, is less
than the C.G.S. unit or absampere per square centimeter in the ratio 10~i'.
For practical purposes, we should probably ignore the systematic practical
unit of current density, the ampere per square quadrant, and select a hybrid
unit, say the ampere per square centimeter or per square inch. By such a
departure from the absolute system, however, the fundamental equations
of the system involving lengths, areas, or volumes, may become erroneous
unless we introduce compensating numerical coefficients.
100a. Vector units and complex quantities. As is explained in Sec.
2, at Par. 163 and elsewhere, vector alternating quantities are much used
in electrical engineering, and call for corresponding vector units, as well as
vector symbols, in the formulas relating to such quantities. Strictly speak-
ing, such quantities and units are not vectors in the mathematical sense of
that term, but are "complex" quantities and units, because when two such
quantities are multiplied together, they do not possess both a "vector prod-
uct" and a "scalar product" as is the case when two mathematical vectors
are multiplied. Nevertheless, such alternating quantities may be called
"plane vectors" to avoid conflict with mathematical usage, and the word
"vector," which is much used in alternating-current literature, may then be
interpreted, in this sense, as subject to the algebra of complex quantities in a
plane.
It is not only logical but also very desirable to distinguish between simple
and complex quantities, i.e., between scalars and vectors in alternating-cur-
rent formulas employing both. There are three ways in which this is done:
1. Distinctive symbols, or types of symbol, are used to designate vectors.
Thus a scalar e.m.f. in volts might be represented by E and a vector by E or
F, i.e., by a black letter capital, or by a gothic capital, of the same letter.
This method has the disadvantage of calling for and reserving special fonts
in representing vectors.
2. The same symbol may be used, but a distinctive mark, such as an
"under dot," may be applied to symbols representing vector quantities.
Thus a scalar e.m.f. in volts might be represented by£, and a vector e.m.f. by
E. In any formula or equation, if any one term is a vector, all of its terms
must be vectors; so that the under dot must be applied to each and every
term of a vector equation. This method has the disadvantages that it is
difficult to print or to set up in type, and that a page containing many vector
formulas presents a speckled appearance.
3. No special symbols or symbol marks may be used for vector quantities,
but the unit at the end of the line on which the equation appears may have a
distinctive sign, such as an angle mark ( Z. ), to indicate that the equation
employs vectors. Thus the equation
E = IZi+IZt-\-IZt volts Z
would indicate that the e.m.f. .B is a vector, and can be represented by the
polygonal or vector sum of three vector elements. In this ease the unit of the
equation becomes a "vector volt."
101. The international metric system. There are only three units

18
 UNITS, FACTORS. AND TABLES Sec. 1-102

—
in the metric system the meter, the gram and the liter, with decimal deriva-
tives denoted by prefixes common to all parts of the system, including all
C.G.S. units and electric or magnetic units.
102. The
Metric Prefixes
r Mega- = 1,000,000 = 10« Greek for great
Ma Myria- = 10,000=10* Greek for 10,000 as in word myriad
So Kilo- = 1,000 = 10* Greek for 1,000
n2 Hecto- =
I
100 =10^ Greek for 100
IDeka- = 01 = lOi Greek for 10
as fDeci- F=l/10. =10-1 = = Latin for 10 as in U. S. dime
i'i,

"SSlCenti- =1/100 =10-= = iSn = Latin for 100 as in U. S. cent

^2 (Milli- =1/1000 =10-» = ioVo = Latin for 1,000 as in U. S. mill
Greek Micro- = 1/1,000,000 = lO"' = Greek for small
Millimicro is used for lO"' and micromicro for IQ-'^.
103. Examples of use of prefixes. The length of 1 statute English mije
is expressed in the metric system as 1609.33 meters or 1609.33 m. This
may also be expressed as: 1.60933 kilometers or 1.60933 km.
or 16.0933 hectometers or 160933 centimeters
" 160.933 dekameters " 1609330 millimeters
" 16093.3 decimeters " 1 60933 X 10» microns
.

The prefix may be regarded either as designating a secondary

unit decimally related to the primary unit, or as indicating a
change in the decimal point of the number expressing the di-
mensions, without changing the unit. Just as the unit of
American currency, the dollar, may be expressed either as 1
dollar, 10 dimes, 100 cents, or 1,000 nulls, so each of the terms
dime, cent, and mill may be regarded either as defining a sec-
ondary unit decimally_ related to the dollar; or as changing the
place of the decimal in expressing a sum of money, without
departing from the dollar unit; since $10.93 = 109.3 dimes
= 1093 cents =
10,930 mills.
104. Tig. 3 shows toscale, a length of 1 decimeter, or
about one hand's breadth. This is one-tenth of a meter.
It is divided into 10 parts, each 1/lOOth of a meter or 1 centi-
meter. Each centimeter is again divided into 10 parts, each
1/lOOOth of a meter or 1 millimeter.
§5
105. If a cube is formed of decimeter edg^es, the volume
of the cube is a cubic decimeter, and is called a liter. It is
about midway between a dry U. S. quart and a liquid U. S.
quart; so that a liter may be regarded for rough purposes as o « —
a quart. One cubic centimeter of water weighs 1 g. So go ^ ft,
that a liter of water weighs 1,000 g. or a kilogram, which is
roughly 2 lb. avoirdupois (2.205 lb.)
106. Metric length. 1 meter = 39.37 U. S. inches or o «> —
roughly a yard or exactly 3 ft. 3 in. -|- | in. -|- 3^ in. + jj^ in.
Common decimal derivatives are the kilometer (km.) of
roughly i statute mile; the centimeter (cm.) roughly §inch;
the millimeter (mm.) roughly j^ inch.
107. Metric area. 1 sq. m. = 1.196 sq. yd. or roughly
a square yard, and decimal derivatives, such as the square
centimeter, or square millimeter. In land measure, a square
a
dekameter or an area 10 m. by 10 m. = 100 sq. m. is called an
ar. A square 100 m. by 100 m. = 10,000 sq. m., contains 100
ars oris 1 hectar and forms the metric acre. 1 hectar = 2.471
acres. The square kilometer contains just 100 hectars.
108. Metric volume. 1 cu. m., sometimes called a stere.
= 1.308 cu. yd. or roughly 1\ cu. yd.
109. Metric mass._ 1 g. the mass of 1 cu. cm. of water. o -
Common decimal derivatives are the kilogram, or the mass
of 1 liter of water; the megagram, or metric ton, the mass
of 1 cu. m. of water. The metric ton (1,000 kg.) is a little less
than the long ton (0.984) so that for many purposes it may
be taken as a long ton.
19
Sec. 1-110 UNITS, FACTORS, AND TABLES
 UNITS, FACTORS, AND TABLES Sec. 1-113

6
X
IN
Sec. 1-113 UNITS, FACTORS, AND TABLES

a
UNITS, FACTORS, AND TABLES See. 1-113 ^
Sec. 1-114 UNITS, FACTORS, AND TABLES

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 UNITS, FACTORS, AND TABLES Sec. 1-114

-
Sec. 1-115 UNITS, FACTORS, AND TABLES
in
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units

units

of
electromag-

netic

Value
tical
 units;, factors, and tables Sec. 1-115

li
Sec. 1-115 UNITS, FACTORS, AND TABLES
UNITS. FACTORS, AND TABLES Sec. 1-116
Sec. 1-117 UNITS, FACTORS, AND TABLES
UNITS, FACTORS, AND TABLES Sec. 1-118
Sec. 1-119 UJVITS, FACTORS, AND TABLES
o^
UNITS, FACTORS, AND TABLES Sec. 1-120
Sec. 1-122 UNITS, FACTORS, AND TABLES
UNITS, FACTORS, AND TABLES Sec. 1-124
Sec. 1-126 UNITS, FACTORS, AND TABLES

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36
UNITS, FACTORS, AND TABLES Sec. 1-127
Sec. 1-129 UNITS, FACTORS, AND TABLES
CONVKBSION TABLES
*
129. Density
Gram8 per
Reciprocal
ou. cm.

1 lb. av. per sq. mil. ft. . 2.936X10* 0.3406X10-

1 lb. av. per circular mil-ft. 2.306X10* 0.4337X10-
1 lb. av. per cu. in 27.68 0.03613
1 lb. av. per cu. ft 0.01602 62.43
1 grain per cu. in 0.003954 252.9
1 lb. av. per cu. yd 0.0005933 1,685

• Tables for converting deg. Baum6 (liquid density) to specific gravity at

60 deg. falir.,and vice versa, are given in Circular No. 19, Bureau of
Standards, pp. 31-35.
130. Time Intervals

Mean solar

days hours sees.

1 mean solar year. . 365.2 8,766 5.26X10' 3.156X10'

1 week of 7 days . . 7.0 168 1.008X10* 6.048X10*
1 mean solar day . 1.0 24 1.440X10' 8.640X10*
1 siderial day 0.9973 23.93 1.436X10' 8.616X10*
1 mean solar hour 4.167X10-^ 1 60 3.60X10"
1 siderial hour . . . 4.155X10-2 0.9973 59.83 3.590X10'
1 mean solar minute. 6. 944X10-' 1.667X10- 1 60
 UNITS, FACTORS, AND TABLES Sec. 1-133

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Sec. 1-134 UNITS, FACTORS, AND TABLES

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41
Sec. 1-136 UNITS, FACTORS, AND TABLES
136. Torque
 UNITS, FACTORS, AND TABLES Sec. 1-141

oo «oii III III

Qgoo oo OOOOOt^OoO-^OOO
I I I I I

^
Soc^^too XxXC
_
xxxxxSxxxgxxx
OXOTOOt^ -rooiN -OtOIN
00 00
OSiOCOINN
» fH t^ OM * O -^ tS 05
t--*<0 <OMW
1-1

ooooo ooo ooo

^S2 xxSgxxxx o5o5 o o S 5,
ooo-i~2o=='^'^'^^ xxxxi --'^-'^'^^
CONdOC^tON,
<.-(CV)Tj< ^ ^ rt

• =°
^ 2 ^ 00 g o "- -to m
rtO
xs gx '^ Xtg-.1<10X(NU5
O'-itc'^t^ooNro
O>00 I I I

MOO O lO <N 50 (M
10-4 0'-il--t,00t r^'
Tji<-'co -tOOO

^S-^SooSoXX XX
z^ z: o o o 00 ra
•: .

oo.©"oow
_•-:
°0 =° .

(-50 TJ<T|<

oo do 0)lMi-IU5 r-l lO (N 2 00 !0 t»
o
t^ *^ - o o »o -^ t: I
CD .XT)(g--<i>.t>. SiN'fi
"^ o-o
o >o « OS•OMcoSco*
C^OOt- N e<5 IN r-, ^**
.
r;-_-to • •

-< oo>
„U5iCWSOco
iO«> ,o5!«Oc.,-S^.3
WrJtOO -ObS ooo
CO
•

•'-'®ot»_o MO •

do
inS"'-*
:^?:i§^S2i§*2 ^* •'-l-^t^cD

?"o§2:5SoX-g^

C.2 S-S ^g'S'«

o 9 o a "0 K
« S «2 S t; 3 a S*a «> I'
. . . . fe 5?

_ B g g aja °-fl 3 a;c«in,-c»ii>aao

4) t. '^ u"3 u h 9 >-;!-;©»(nB . .T3-ao3o3fl
aat<^ie8ca.t;.S™„
S n,
i'
_^^-t3-o aa > > K m i-

43
Sec. 1-143 UNITS, FACTORS, AND TABLES
143. Storage of Water
1 acre-f t. = 325,800 U. S. gal. = 43,560 cu. ft. = :
1613 cu. yd. - 1234 cu. m.
1 gal. =0.3069X10-' acre-(t.
1 cu. ft. =0.2298X10-* acre-ft.
1 cu. yd. =0.00062 acre-ft.
1 cu. m. =0.000811 acre-ft.

144. Temperature

Scale
UNITS, FACTORS, AND TABLES Sec. 1-147
Sec. 1-150 UNITS, FACTORS, AND TABLES
ISO. Conversion of Logarithms. For converting logarithms to the
base a, to another base 6:

.og..4^^ (12)

loga&Xlog6a = l (13)
Common or Briggs logarithms are computed from the base of 10,
while hyperbolic logarithms are computed from the base t or 2.7183.
Therefore
, logiox „..
logrf;=, (14)
logio «

161. The Greek Alphabet

Name
 UNITS, FACTORS, AND TABLES See. 1-153

MATHEIOATICAL TABLES
153. Natural Sines and Cosines
Note. — For cosines use right-hand column of degrees and lower line of tenths.

Deg. "0.0 °0.1 °0.2 °0.3 °0.4 "0.5 °0 .6 °0 .7 °0.8 "0.9

0.0000 0.0017 0.0035 0.0052 0.007C 0.0087 .0105 .0122 .0140 .0157
.0175 .0192 .0209 .0227 .0244 .0262 .0279 .0297 .0314 .0332
.0349 .0366 .0384 0.0401 .0419 .0436 0.0454 0.0171 .0488 .0506
.0523 .0541 .0558 .0576 .0593 .0610 .0628 .0645 .0663 .0680
.0698 .0715 .0732 .0750 .0767 .0785 .0802 .0819 .0837 0.0854

.0872 .0889 .0906 .0924 .0941 .0958 .0976 .0993 0.1011 .1028
.1045 .1063 .1080 0.1097 0.1115 0.1132 0.1149 0.1167 .1184 0.1201
0.1219 .12.36 .1253 0.1271 .1288 .1305 0.1323 0.1340 .1357 0.1374
.1392 .1409 .1426 .1444 0.1461 0.1478 .1495 0.1513 .1530 .1547
.1564 .1582 .1599 0.1616 0.1633 0.1650 .1668 0.1685 .1702 0.1719

.1736 0.1754 0.1771 0.1788 0.1805 .1822 0.1840 0.1857 .1874 0.1891
0.1908 .1925 0.1942 0.1959 0.1977 .1994 0.2011 .2028 0.2045 .2062
.2079 .2096 0.2113 .2130 0.2147 0.2164 0.2181 0.2198 .2215 .2232
.2250 .2267 .2284 .2300 .2317 .2334 .2351 .2368 .2385 .2402
.2419 .2436 .2453 .2470 .2487 .2504 .2521 .2538 .2554 .2571

.2588 0.2605 .2622 0.2639 0.2656 .2672 0.2689 .2706 .2723 .2740
.2756 .2773 .2790 .2807 .2823 .2840 .2857 .2874 .2890 .2907
.2924 .2940 .2957 .2974 0.2990 .3007 .3024 .3040 .3057 .3074
.3090 .3107 0.3123 .3140 .3156 0.3173 .3190 .3206 .3223 .3239
.3256 .3272 .3289 .3305 .3322 .3338 .3355 .3371 .3387 .3404

0.3420 0.3437 0.3453 0.3469 0.3486 0.3502 0.3518 0.3535 0.3551 0.3567
0.3584 0.3600 0.3616 0.3633 0.3649 0.3665 0.3681 0.3697 0.3714 0.3730
.3746 .3762 .3778 .3795 0.3811 .3827 .3843 .3859 .3875 .3891
.3907 .3923 .3939 .3955 .3971 .3987 0.4003 .4019 .4035 0.4051
.4067 .4083 .4099 0.4115 0.4131 .4147 0.4163 .4179 .4195 .4210

.4226 .4242 .4258 .4274 .4289 .4305 .4321 .4337 .4352 0.4368
.4384 .4399 .4415 .4431 .4446 .4462 .4478 .4493 .4509 .4524
.4540 .4555 .4571 .4586 .4602 0.4617 .4633 .4648 0.4664 .4679
.4695 .4710 .4726 .4741 .4756 .4772 .4787 .4802 .4818 .4833
.4848 .4863 .4879 .4894 0.4909 .4924 .4939 .4955 .4970 .4985

.5000 .5015 .5030 .5045 .5060 .5075 .5090 .5105 .5120 0.5135
.5150 0.5165 .5180 .5195 .5210 .5225 .5240 .5255 .5270 .5284
.5299 0.5314 .5329 .5344 .5358 .5373 .5388 .5402 .5417 .5432
.5446 .5461 .5476 .5490 .5505 .5519 .5534 .5548 .5563 .5577
.5592 0.5606 .5621 .5635 0.5650 0.5664 .5678 .5693 .5707 .5721

.5736 .5750 0.5764 .5779 .5793 .5807 .5821 .5835 0.5850 .5864
.5878 .5892 .5906 .5920 .5934 .5948 .5962 .5976 .5990 0.6004
.6018 .6032 .6046 .6060 .6074 .6088 0.6101 0.6115 0.6129 0.6143
.6157 .6170 .6184 .6198 0.6211 .6225 .6239 .6252 .6266 .6280
.6293 .6307 .6320 0.6334 0.6347 .6361 0.6374 .6388 0.6401 0.6414

0.6428 0.6441 0.6455 0.6468 0.6481 0.6494 0.6508 0.6521 0.6534 0.6547
.6561 0.6574 0.6587 .6600 0.6613 .6626 .6639 0.6652 .6665 .6678
.6691 0.6704 0.6717 .6730 .6743 .6756 .6769 .6782 .6794 .6807
.6820 0.6833 .6845 0.6858 .6871 .6884 6896 .6909 .6921 .6934
.6947 .6959 0.697210.6984 .6997 0.7009 .7022 .7034 0.7046 0.7059

"1.0 "0.9 "0.8 "0.7 "0.6 "0.5 "0.4 "0.3 "0.1

47
Sec. 1-153 UNITS, FACTORS, AND TABLES
Natural Sines and Cosines. — Concluded
Deg.
 UNITS, FACTORS, AND TABLES Sec. 1-154

164. Natural Tangents and Cotangents

Note. —For cotangents use right-hand column of degrees and lower
tenths
line of

Deg. °0.0 "0 .1 °0 .2 °0 .3 "0.4 °0.6 °0 .7 °0 .8 "0.9

.0000 .0017 .0035 .0052 .0070 .0087 .01050 .0122 .0140 .0157
0.0175 0.0192 0.0209 0.02270.0244 .0262 .02790 .02970 .0314 .0332
.0349 .0367 .0384 .0402 .0419 0.0437 .0454 .0472 .0489:0 .0507
.0524 .0542 .0559 .0577 .0594 .0612 .0629 .0647 .0664:0 .0682
.0699,0 .0717 .0734 .0752 .0769 .0787 .0805 .0822 .084010 .0857

.0875 .0892 .0910 .0928 0945 .0963 0981 . 0998 .1016'0.1033

0.1051 0.1069 0.1086 0.110410 1122 0.1139 0. 11570 11750 .11920.1210
0.1228 0.1246 0.1263 0.1281 1299 0.1317lc. 1334 1352 .1370:0.1388
0.1405 0.1423 0.1441 0.1459 1477 0.1495:0. 15120 1530 .1548 0.1566
.1584 .1602 .1620 .1638 1655 0.167310.1691,0 1709,0 .1727,0.1745
i
I I !
i

0.1763'0.1781 0.1799 0.1817 1890 ,1835 0.1853J0 1871 .1908,0.1926

.1944 .1962 .1980 2071 .1998 ,2016 0.2035 2053 .2089 0.2107
0.2126 0.2144 0.2162 0.21800 2199 0.22170 2235 2254 .2272 .2290
.2309 .2327 .2345 .2364 2382 0.2401 2419 2438 .2456 .2476
.2493 .2512 .2530 .2549 ,2568 0.258610 26050 2623 .2642 .2661

.2679 .2698 .2717 .27360 .2754 .2773 1 .2792 .281 1 .2830 .2849
.2867 .2886 .2905 .2924 iO .2943 .2962 .2981 .3000 .3019 .3038
.3057 .3076 .3096 .3115 C .3134 .3153 .3172 .3191 .32110 .3230
.3249 .3269 .3288 .3307 .3327 .3346 .3365 .3385 .3404 .3424
!3443 !3463 13482 ^3502 !3522 13541; ^3561 !3581 !3600i0 !3620

.3640 .3659 .3679 .3699 .3719 .37390 .3759 .3779 .3799iO .3819
.3839 .3859 .3879 .3899 .3919 .3939^0 .3959 iO .3979 .4000 .4020
.404C .4061 .40810 .4101 .4122 .4142|0 .41630 .418310 .4204:0 .4224
.4245 .4265 C .4286 .4307 .4327 .4348 .4369 .4390 .4411 .4431
.4452,0 .4473 .4494 .4515 .4536 .455710 .4578 .4599,0 .4621 :0 .4642

0.4663 0.4684,0.4706 .4727 ,4748 ,477010 ,4791 .48130 .4834^0 .4856

0.4877 0.4899,0.4921 ,4942 4964 .4986 ,5008 .5029 .5051 ;o .5073
0.5095 0.5117 0.5139 ,5161 5184 ,5206 ;0 ,5228 .5250 .5272 .5295
0.5317 0.5340 0.5362 5384 5407 ,54300 ,5452 .5475 .54980 .5520
0.6543 0.5566 0.5589:0 56120 5635 1 ,5658:0 .5681 5704 .5727.0 .5750

.5774 .5797
.5820 .5844 : 5867 ,589o'o ,5914 .5938 .59610 .5985
.6009 .6032
.6056 .6080 6104 iO ,6128,0 6152 .6176,0 .6200,0 .6224
.6249 .6273
.6297 .6322 634610 6371 |0 6395 .6420: .6445 .6469
.6494 .65190 .6544 .6569 6594 6619!o 6644 .6669 .6694 .6720
. 6745 iO. 6771 ;0.6796iO. 6822 ,684710 6873 iO ,6899,0 .6924,0 .6950 .6976

.7002iO .7028 .7054 .7080 .7107 .713310 .715910 .7186 .7212 .7239
.7265i0 .7292i0 .7319,0 .7346 .737310 .7400 .742710 .7454 .7481 .7508
.7536 .7563 .7590'0 .7618 .7646 .7673 .7701 .7729 .7757 .7785
.7813,0 .7841 :0 .7869 .7898 .7926 .7954 .798310 .8012 .8040 .8069
0.8098,0.8127,0.8156,0.8185 0.8214,0.8243 0.8273 0.8302 0.8332 0.8361
I I
I I I
I I
I

0.839! 0.8421 0.8451 0.8481 0.8511 .8541 .8571 .8601 .8632 0.8662
.8693 .8724 .8754 .8785 .8816 .8847;0 .8878 .8910 .8941 .8972
.9004 .9036 C .9067 .9099 .9131 .9163,0 .9195 .9228 C .9260 .9293
.9325 .9358 .9391 ,0 .9424 .9457 .94900 .9523 .9556 .9590 .9623
.9657 .9691 .9725 .9759 .9793 .9827 .9861 .9896 .9930 .9965

1 .0 °0 .9 j
°0 .8 °0 .7 °0 .6 "0 .5 °0 .4 °0 .3 !
°0 .2 "0 .1 Deg
I

49
Sec. 1-154 UNITS, FACTORS, AND TABLES
Natural Tangents and Cotangents — Concluded
Deg.
 UNITS, FACTORS, AND TABLES . SeC. 1-155

155. Logarithxas of Numbers

N
Sec. 1-155 UNITS, FACTORS, AND TABLES

Logarithms of Numbers. Concluded

N
 UNITS, FACTORS, AND TABLES Sec. 1-156

166. Hyperbolic Logarithms

N 8
—CO 0.00000.6931 0986 1 1 . . 3863 1 6094 1
. . 7918 1 . 9459 2 0794 2 1972
. .

102.30262.3979 2.4849 2 5649 2 . . 6391 2 7081 2

. . 7726 2 . 8332 2 8904 2 9444
. .

202.99.573.04453.0910 3 1355 3 . . 1781 3 2189 3

. . 2581 3 . 2958 3 3322 3 3673
. .

30|3. 4012 3. 4340 3. 4657 3 4965 3 . . 5264 3 5553^3

. . 5835 3 . 6109,3 6376 3 6636
. .

6889 3. 7136 3. 7377 3 76123 7842 3 8067 3 8286 3 8501:3 8712i3 8918
4o|3. . . . . . . .

91203. 93183. 9512 3 9703 3 9890 4 0073 4 0254 4 0431 4 0604 4 0775
50i3. . . . . . . .

604.09434.11094.1271 4 143 1 4 1589 4 1744 4 1897 4 2047 4 .21954 234

. . . . . .

4 2485 4 2627 4 2767 4 29054 3041 4 3175 4 3307 4 3438 4 3567 4 3694
. . . . . . . . . .

4.38204.3944 4.4067 4 4 188,4 4308 4 4427 4 4543 4 4659 4 4773 4 4886

. . . . . . .

4.49984.51094.5218 4 5326 4 5433 4 5539 4 5643 4 5747 4 5850 4 5951

. . . . . . .

!
I I I !

1004. 605214. 61514. 6250 4 . 6347j4 . 6444,4 65404 6634 4 67284

. . . . 6821j4 . 6913
1104 7005:4 7095:4 .7185 4
. . . 727414 . 7362!4 7449 4 7536 4 7622 4
. . . . 7707:4 . 7791
1204 78754 795814 8040 4
. . . . 812214 . 8203 4 8283 4 8363 4 844214
. . . . 8520:4 . 8598
130l4 8675 4 8752 4 8828 4
. . . . 8903:4 . 8978 4 9053 4 9127 4 9200 4
. . . . 9273 4 . 9345

140 4 941 6 4 9488 4 9558 4 9628 4 9698 4 9767 4 9836 4 9904 4 9972 5 0039
. . . . . . . . . .

150 5.0106 5.0173 5.0239 5 0304 5 0370 5 0434 5 0499 5 0562 5 0626 5 0689
. . . . . . .

160 5.0752 5.0814 5.0876 5.09385.0999 5.1059 5.1120 5.1180 5.1240 5.1299
:
1 !
i t ! i ! !

1705.13585.141715.1475 5. 15335. 1591 5. 16485. 17055. 1761 5. 18185. 1874

1805.19305.19855.2040 5.209515.21495.2204 5.2257 5.23115.2364 5.2417
190 5.24705.2523 5.2575 5 2627j5 2679 5 2730 5 2781 5 2832 5 2883 5 2933
. . . . . . .

! I 1

200 5 2983 5 3033 5 3083 5 3132 5 .31815 3230 5 3279 5

. . . . . . . 3327 5 . 3375 5 3423
.

2105.34715.3519 5.3566 5.361315. 3660 5 3706 5 37.53 5 . . . 3799 5 . 3845 5 389

.

220 5 3936 5 3982 5 4027 5 4072 5.41165.41615. 42055

. . . . . 4250 5 . 4293 5 4337
.

230 5.43815.4424 5.4467 5 4510 5 4553 5 459615 4638 5

. . . . . 4681 5 . 4723i5 4765
.

24015 4806i5 4848I5 4889

. . . .4931 5.4972 5.5013 5.5053 5.5094 5.513415.5175
25015.521.55.52555.5294 .5334 5.5373 5.5413 5.5452 5.54915.55305.5568
260,5 5607 5 5645 5 5683
. . . .5722 5.5759 5.5797,5.58355.5872 5.5910:5.5947

2705. 5984:5. 6021 '5. 6058 .6095 5. 61315. 6168:5.62045.62405. 6276 5.6312
2805 63485, 6384 5. 6419 .6454 5. 6490 5 6525 5.6560 5.6595 5. 6630 5.6664
2905. 6699 5 6733 5. 6768 .680215. 6836 5. 68705.6904 5.6937 5. 69715.7004
1

1
i

3005. 7038 5, 70715. 7104 .7137(5. 7170 5, 7203 5.7236 5.7268 5. 73015.7333
3105. 7366 5, 7398 5. 7430 .746215. 7494 5 7526 5.7557 5.7589 5. 76215.7652
3205. 7683 5. 7714:5. 7746 .7777 5. 7807 5. 7838 5.7869 5.79005. 7930 5.7961
330l5. 79915, 802 1;5. 8051 .80815. 81115. 8141:5.81715.82015. 82305.8260
3405.82895, 8319 5.8348 5 8377 5 . . 8406 5 8435 5 8464 5 8493 5 8522,5 8551
. . . . .

350i5. 85795, 8608 5.8636 5 8665(5 . . 8693 5 872 1 5 8749 5 8777 5 8805 5 8833
. . . . .

360!5. 8861:5. 888915.8916 5 8944 5 . . 8972 5 8999 5 9026 5 9054 5 9081 5 .9108
. . . .

1
: I i
i i

3705.9135 5, 9162 5.9189 5 9216 5 9243 5 9269 5 9296 5 9322 5 9349 5 9375
. . . . . . .

380 5 9402 5 9428 5.9454 5 9480 5 9506 5 9532 5 9558 5 9584 5 9610 5 9636
, . . . . . . .

39015.9661:5. 96875.9713 5 9738 5 9764 5 9789 5 9814 5 98395 9865:5 9890

. . . . . . .

400i5 9915 5
. 9940 5 9965 5 998916 0014 6 0039 6 0064 6 0088 6 01 13 6 0137
. . . . . . . . .

4106.01626.01866.0210 6 0234 6 0259 6 0283 6 0307 6 0331 6 0355 6 0379

. . . . . . .

420,6 0403 6 0426 6 04.50 6.0474:6.0497 6.05216.0544 6.05686.05916.0615

. . .

430 6 0638 6 0661 6 0684 6 0707 6 0730 6 0753 6 0776 6 0799 6 08226 0845
. . . . . . . . . .

i
i I
I I
1

4406 0868 6 08906 .0913 6. 0936:6. 0958 6. 0981i6. 1003 6. 1026 6. 1048 6. 1070
. .

4506.10926.11156.1137 6. 11.596. 11816. 1203 6. 1225 6. 1247 6. 12696. 1291

4606.1312 6.1334 6.13.56 6. 1377,6. 1399 6. 1420|6. 1442 6. 1463 6. 1485 6. 1506
4706.1.527 6.1549 6.1570 6. 1.591 6. 16126. 16336. 16.546. 16756. 16966. 1717
4806.17386.1759 6.1779 6. 1800 6. 1821 6. 1841 6. 1862 6. 1883 6. 1903 6. 1924
490 6 19446 1964 6 1985 6 2005 6 2025 6 2046 6 2066 6 2086 6 2 106 6 ,2126
. . . . . . . . .

53
 Sec. 1-156 UNITS, FACTORS, AND TABLES
Hyperbolic Lograrithms. — Concluded
N
500 214616 2166!6. 21866. 2206 6.222616.2246 6.2265 6.228516.230516.2324
5106 2344 6 2364'6.2383 6.2403 6.2422:6.2442 6.2461 6.2480 6.25006.2519
> 520 6, 25386 25586.2577 6.2596 6.261516.2634 6.2653 6.2672 6.26916.2710
530!6, 2729:6 2748:6.2766:6.2785 6.280416.2823 6.2841 6.2860 6.2879 6.2897

54o'6, 29166 2934'6 295316 2971 6 2989'6

. . . . 3008 6 3026 6 3044 6 3063 6 3081
. . . .

550|6, 309916 3117 6. 3135 6. 3154 6. 3172i6. 3190 6.3208 6.32266.3244|6.3261

560 6, 327916 3297 6 3315 6 3333 6 33516. 3368 6 3386 6 3404 6 342 1 6 3439
. . . . . . .

5706.3456|6.3474 6.34916.3509 6.352616.3544 6.3561 6.3578 6.35966.3613

5806.3630 6.3648 6.36656.3682 6.3699:6.37166.3733 6.3750 6.3767J6.3784
5906.38016.3818 6.3835:6.3852 6.3869 6.38866.3902 6.3919 6.39366.3953
6.4036 6.4052 6.4069 6.4085 6.4102 6.4118
600:6. 3969'6. 3986 6. 400316. 4019
6.4200 6.4216 6.4232 6.4249 6.4265 6.4281
610:6, 4135!6. 4151 6.4167|6.4184
620 6 42976 4313 6 4329 6 4345
. . .6.4362 6.4378 6.4394 6.4409 6.4425 6.4441
.

630 6 4457 6 44734 4489 6 4505 6.4520 6.4536 6 4552 6.4568 6.4583 6.4599
. . . . .

6406.4615 6,46306.4646 6.46616.4677 6.4693 6.47086.4723 6.4739 6.4754

65016.4770 6.4785 6.4800 6.48166.4831 6.4846 6.486216.4877 6.4892 6.4907
660j6.4922 6.4938,6.4953 6.4968 6.4983 6.4998 6.5013 6.5028 6.5043 6.5058

670(6 5073 6.508816.5103 6.5117 6.5132 6.5147 6.51626.5177 6.5191 6.5206

.

6806.5221 6.5236 6.5250 6 5265 6.5280 6 5294 6.5309 6.5323 5338 6.5352
. .

6906.5367 6.53816.5396 6.5410 6.5425 6 5439 6.5453 6.5468 6.5482 6.5497

.

700:6 551 1 6
. . 5525 6 . 5539 6 5554 6.5568 6.5582 6.55966.56106.5624 6.5639
.

7106. 5653 6 . 5667 6 . 5681 6 5695 6.5709 6.5723 6,5737 6.57516.5765 6 5779
. .

720 6 5793^6
. . 5806 6 . 582016 5834 6.5848 6.5862 6. 587616. 588916. 5903 6.5917
.

7306 5930 6
. . 5944 6 . 595816 5971 6.5985 6 5999 6.6012 6.60266.6039 6.6053
. .

740-6 6067 6 6080 6.6093i6.6107 6.6120 6.6134

. . .6147 6.61616.6174 6.6187
7506. 620116. 6214 6.6227:6.6241 6.6254 6.6267 .6280 6.6294 6.6307 6.6320
760:6.6333 6.6346 6.6386 6.6399 .6412 6.64256.6438 6.6451
6.6359J6.6373
77016.6464 6.6477 6.64906.6503 6.6516 6.6529 6.6542 6.6554 6.6567 6.6580
780!6. 659316. 6606 6.66196.6631 6.6644 6.6657 6.6670 6.6682 6.66956.6708
7906.67206.6733 6.6746 6.6758 6.6771 6.6783 6.6796 6.6809 6.682116.6834
800 6 6846'6 6859 5
. , . 6871 6 6884 6 6896 6 6908;6 6921 6 6933 6 694616 6958
. . . . . . .

810 6 6970 6 698316

. . . 6995 6 7007:6 7020 6 7032:6 70446 7056 6.70696,7081
. , . . .

820 6, 7093 6. 7105 6. 71176. 713016. 7142:6. 7154 6. 716616. 7178 6.71906.7202
830|6 .72146. . 7238l6 7250:6 7262 6 7274 6
, . . 7298 6.73106,7322
. .

7226J6 7286J6
840 6 733416 7346 6 735816 73706 7382 6.7393 6.7405|6.7417 6.7429 6.7441
. . . . .

850 6 7452J6 7464i6 747616 748816 7499 6.7511 6.752316.7534 6.7546 6 7558
, . . . . ,

8606. 756916. 7581:6. 7593J6. 7604 6. 7616 6.7627 6.7639 6.76506.7662 6.7673

870 6 7685 6 7696 6 7708*6 771916 773 1 6 7742 6 7754'6 7765 6.7776 6 7788
, . . , . . . . .

880 6 7799 6 7811 6 7822i6 783316 7845 6 7856 6 7867 5 7878 6.7890 6.7901
. , . . , , . ,

890 6 7912 6 7923 6 7935J6 7946 6 7957|6 79686 79796 7991 6 8002 6,8013
. . . . . . . , .

9006. 8024 6, 80356. 8046 6, 80576. 8068'6. 8079|6. 80906. 8101 6.8112 6.8123
9106, 8134 6. 8145 6. 81566.816716. 8178:6. 818916. 8200!6. 8211 6 8222 6,8233
.

920 6 8244 6 82556 82656 827616 8287l6

. . . . . . 82986 8309 6 8320 6.8330 6.8341
. .

930 6 8352 6 8363 6 8373 6 8384 6

. . . , . . 8405 6 84 1 6 6 8427 6.8437 6 8448
. . ,

8395J6
940 b 84596 8469 6 8480 6 8491 16 8501 \g 851 216 8522 6 8533 6 8544!8 8554
. . . . . . . . . .

950 6 8565 6 8575 6 8586 6 8596 6 8607 6 861 7 6 8628 6 8638 6 86486 8659
. , , . , . . ,
. ,

9606,8669 6,86806.86906.87016.87116,87216.873216.8742 6.875216.8763

i
'
'
1 : ! 1 1

970 6 8773 6 8783 6 8794 6 8804 6 8814 6 8824 6 8835 6 8845 6 8855 6 8865
, , , . . . . . . .

980 6 8876 6 8S86 6 8896 6 8906 6 8916 8926 6 8937 6 8947 6 8957!6 8967
, . , . , , , . . .

990 6 8977 6 8987 6 8997 6 9007 6 901 7 6 9027 6 9037:6 9047|6 9057 6 9068
. . . . . . . . . .
 SECTION 2

ELECTRIC AND MAGNETIC CIRCUITS

BY VLADIMIR KARAPETOFF,
Professor of Electrical Engineering, Cornell University, Fellow, American
Institute of Electrical Engineers

CONTENTS
(Numbers refer to Paragraphs)
Electric Potential Alternating-Current Circuits
1 151
Electric Currents 9 Non-Sinusoidal or Complex Waves 190
Continuous-Current Circuits 19 Polyphase Systems 213
Electromagnetic Induction 36 Uniformly Distributed Resiat-
The Magnetic Circuit 43 ance, Reactance, Capacity and
Inductance 67 Leakage 233
Hysteresis and Eddy Currents 89 Capacity in Alternating-current
The Dielectric Circuit 106 circuits 241
Transient Currents and Voltages 138 Bibliography 248
 SECTION 2

ELECTRIC AND MAGNETIC CIRCUITS

ELECTRIC POTENTIAL
l.The cause of an electric current in a circuit is termed the electro-
motive force or voltage. The latter name is derived from the practical
unit of electromotive force called the volt. The current between two points
in a circuit is due to a different electric state or "potential" at each point;
for this reason the electromotive force or voltage is sometimes called the
dlfierence of potential.
2. The electric energy (W) developed or absorbed by an electric circuit
may be cons^idercd due to the actual flow of an incompressible something
which we call electricity. From this point of view, tlie quantity of electricity
Q which is transferred between two points of the circuit is the quantity factor
of the energjf, while the difference of potential, or the voltage E between the
same points, is the intensity factor of the energy or ;

W^QE. (1)
When Q is coulombs, and E in volts,
in W
is in joules (watt-seconds).
Hence, electromotive force or voltage may also be defined as electrical energy
developed or work done per unit quantity of electricity.
3. Electric Power. —
Dividing both sides of the preceding equation by
the time which it takes for the quantity Q to flow through a cross-section of
the circuit, we get
P = IE, (2)
where P is the power, and I the rate of flow or the current. The e.m.f. can
thus be defined as the power developed per unit of current.
4. The principal sources of electromotive force or difference of poten-
tial are the following:
(a) Electromagnetic induction (see Par. 36)
(b) Contact of dissimilar substances (see Par. 6)
(c) Thermo-electric action (see Par. 6);
(d) Chemical action (Sec. 20);
(e) Friction between dissimilar substances (see Sec. 22).
In the light of the modern electrical theory, all these phenonema, with the
exception of (a), appear to be but special cases of the general contact action.
6. In a circuit made up of several substances, a difference of potential
(e.m.f.) exists at each junction of two unlike substances. However, from
the law of conservation of energy it follows that unless the circuit contain
a source of energy, the resultant e.m.f. in the circuit must be zero and no
current can be established. This phenomenon also takes place in circuits
made up of a single substance whenever the substance is not physically and
chemically homogeneous. The following are the principal cases of thermal
and contact action:
(a) Seebeck effect. In a closed circuit consisting of two different metals, if
the two junctions are kept at different temperatures, a permanent current
will flow. Thus, if one junction of a copper-iron circuit be kept in melting
ice and the other in boiling water, it will be found that a current passes from
copper to iron across the hot junction. If, however, the temperature of the
hot junction be raised gradually, the e.rn.f. in the circuit slowly reaches a
maximum, then sinks to zero, and finally is reversed.
(b) Peltier effect. When a current is passed across the junction between
two different metals, an evolution or an absorption of heat takes place.
This effect is different from the evolution of heat (I'V), due to the resistance
of the junction, and is reversible, heat being evolved when the current

50
 ELECTRIC AND MAGNETIC CIRCUITS SeC, 2-6

passes one way across the junction and absorbed when the current passes in
the other direction. There is a definite relation between the direction of the
thermo-electric current and the sign of the Peltier effect. If a current be
forced across a junction in the same direction as the thermo-electric current
flows at the hot junction, the junction will be cooled, that is, heat will be
absorbed. Conversely, a current passing in the normal direction across the
cold junction of a thermo-electric circuit evolves heat. In general, then, a
thermo-electric current absorbs heat at the hot junction and gives up heat at
the cold junction. Therefore, a current produced in the same direction by
external means must cool off the junction which serves as the "hot" junction
and warm up the "cold" junction.
(c) Thomson effect. In a copper bar, heat is carried with the electric
current when it flows from hot regions to cold ones; on the other hand,
when the current flows from cold regions to hot ones, these hot parts of the
bar are cooled. In iron these effects are reversed. The conductor may be
thought of as composed of a number of little elements of volume, at the
junctions between which occur reversible heat effects, similar to Peltier
effects at the junctions between different metals.
(d) Volta effect, or contact electrification. When pieces of various
materials are brought in contact, an e.m.f. is developed between them.
Thus, in the case of zinc and copper, zinc becomes charged positively and
copper negatively. According to the electron theory, different substances
possess different tendencies to give up their negatively charged corpuscles.
Zinc gives them up very easily; therefore a number of negatively charged
particles pass from it to copper. Measurable e.m.fs. are observed even
between two pieces of the same substance, having different structures; for
instance between a piece of cast copper and electrolytic copper. Frictional
electricity is explained in a similar way, only a more intimate contact is
necessary where the conductivities of the substances are small.
6. Literature references. For a detailed treatment, curves and mathe-
_

matical theory of thermo-electric and contact phenomena see Maxwell, J. C,

"Electricity and Magnetism," Vol. I, Arts. 246 et seq.: Encyclopedia Bri-
tannica, under "Thermo-electricity"; Whetham, W. C. D., " The Theory of
Experimental Electricity," Chap. 6; Brooks and Poyser, "Magnetism and
Electricity," Chap. 28. For an explanation of thermo-electric effects in the
language of the electron theory see Fournier d'Albee, " The Electron
Theory," Chap. 5; Thomson, J. J., "The Corpuscular Theory of Matter,"
pp. 73 and 97; Campbell, N. R., " Modern Electrical Theory," pp. 118-124.
7. The value of the e.m.f. at a junction of unlike substances
depends upon the kind of substances, and is approximately proportional to
the temperature. The e.m.f. generated in this way can be utilized as a
measure of temperature. For temperature rises up to 200 deg. cent.
e = kit + k2t% (3)
and for temperature rises above 200 deg. cent.
log e = ki log t + ki (4)
A more general formula is
e = a+bt+ct^ (5)
The quantities ki, fo, ki, ki, a, b and c are constants.

8. Thermocouples and batteries. In order to utilize these contact

e.m.fs., means must be devised to supply energy to the system continuously.
There are two ways of doing this, namely, by heat and by chemical reaction.
The thermocouple is an example of the former, and the battery an example
of the latter. For further discussion of thermocouples see Sec. 3. Batteries
are treated in Sec. 20.

ELECTRIC CURRENTS
9. An electric current is defined as the rate of flow of electricity, or the
quantity of electricity which flows through a cross-section of the circuit per
unit time. If the current / is steady, then

/ = !• (6)

If Q is the quantity of electricity in coulombs, and T the time in seconds,

57
Sec. 2-10 ELECTRIC AND MAGNETIC CIRCUITS

the current / is in amperes. When the rate of flow is non-uniform, the in-
stantaneous current is

for a classification of electric currents see the Standardization Rules of the

American Institute of Electrical Engineers, Sec. 24.

10. Steady and transient states. An electric circuit may be in a

steady or in a transient state. When a current is continuous, or when it
varies periodically between the same limits and according to the same law,
the circuit is said to be in a steady state. For instance, the circuit of an
alternator is steady as long as the load, speed and field excitation are kept
constant. The same circuit is in a transient state when the load is switched
on or off, or when it is varied in such a way that the same conditions do not
repeat themselves periodically. A transient current may be periodic, for
instance in a rectifier, in which cycles follow in such rapid succession that
the current is very different from the permanent value which it would grad-
ually assume.
11. A direct current given out by a chemical battery is constant in
value, or continuous, when the load is constant. A current delivered under
the same conditions by an electric generator or a rectifier is pulsating,
that is, it varies periodically due to a finite number of commutator segments.
12. An alternating; current may vary according to the simple sine law
(Par. 182), or according to a more complicated periodic law. In the
latter case the current may be resolved, for purposes of theory and analysis,
into a fundamental sine wave, and sine waves of higher frequencies (Par.
209). Sometimes a complex alternating current or voltage is replaced for
practical purposes by an equivalent sine-wave.
13. Transient currents may be oscillating or non-oscillating, ac-
cording to the conditions in the circuit. Oscillations are due to periodic
transformations of the electrostatic energy stored in the dielectric into the
electromagnetic energy of the magnetic flux linking with the current.
During these transformations part of the energy is converted into the
Joulean (i-r) heat in the conductors^ and in surrounding metallic objects,
including the iron of the magnetic circuit. Part of the energy is also con-
verted into the heat caused by magnetic and dielectric hysteresis. The
oscillations are thus damped out, and their amplitude decreases. When the
conditions are particularly favorable for the conversion into heat (high
resistance in series, or low resistance in parallel), both the electrostatic and
the electromagnetic energy are directly converted into heat, instead of being
partly converted into one another. This conversion into heat is an irre-
versible phenomenon, so that in this case the current is non-oscillating, but
gradually reaches its final value. When it is desired to maintain oscilla-
tions as long as possible (wireless telegraphy) the series resistance must be
kept down as low as possible. When oscillations are harmful (switching in
long cables or transmission lines), extra resistance is temporarily connected
in the circuit.
14. Conductors and insulators. For practical purposes, materials
used in electrical engineering are divided into conductors and insulators. A
conducting material allows a continuous current to pass through it under the
action of a continuous e.m.f. An insulator (more correctly called a dieleo^
trie) allows only a brief transient current which charges it electrostatically.
This charge or displacement of electricity produces a counter-e.m.f. equal
and opposite to the applied e.m.f., and the flow of current ceases. The di-
vision into conductors and dielectrics is not strictly correct, but is convenient
for practical purposes. A substance may practically stop the flow of current
when the applied voltage is sufficiently low, and at the same time be unsuit-
able as an insulator at high voltages. Some materials which are practically
non-conducting at ordinary temperatures become good conductors when
sufficiently heated. For numerical data and tables of conducting and
insulating properties of the principal materials used in practice see Sec. 4.
IB. The electronic theory of conduction. According to the modern
electronic or corpuscular theory of electricity, there is an indivisible atom of
negative electricity, called the electron or the corpuscle. Atoms of matter
consist of one or more electrons and an unknown something which has the

58
 ELECTRIC AND MAGNETIC CIRCUITS Sec. 2-16

nature of positive electricity. A

negatively charged particle of matter is
one in which there are more electrons than necessary to neutralize its positive
electricity. A
positively electrified body is one which has lost some of the
electrons it had in the neutral state.
16. Metals and other solid conductors supposedly possess free or
roaming electrons, in addition to those associated with the molecules.
These free electrons are in rapid motion as if they were the particles of a gas
dissolved in the metal. When an e.m.f. is appUed, each electron gains a
component velocity which, on account of its negative charge, is in the oppo-
site direction to the e.m.f. This drift of electrons is equivalent to a current.
In their motion the electrons come in collision with the molecules and give
up part of their momentum. This loss is supposed to account for the
Joulean {i'h) heat set free in all conductors. Also see Sec. 22.
17. Electrolytes. In liquids which are chemical compounds (electro-
lytes) the passage of an electric current is accompanied by a chemical
decomposition. Atoms of metals and hydrogen travel through the liquid
in the direction of the positive current, while oxygen and acid radicals
travel against the positive current. Thus, while in solid conductors elec-
tricity travels across the matter, in electrolytes it travels with the matter.
For details of electrolytic conduction see Sec. 19.
18. Oases in the normal state conduct electricity only to a slight
degree. _A gas may be put in the conducting state by different means, such
as raising its temperature, drawing it from the neighborhood of flames, arcs,
or glowing metals or from a space in which an electric discharge is passing,
etc. This conductivity is due to electrons which form electrified particles
mixed up with the gas (ions). The process by which a gas is made into a
conductor is called the ionization of the gas. The movement of free
electrons constitutes the current through the gas. * Also see Sec. 19.

CONTINUOUS-CURRENT CIRCUITS
19. Ohm's When the current in a conductor is steady and there
law.
are no electromotive forces within the conductor, the value of the current t
isproportional to the voltage e between the terminals of the conductor, or
e = ri (8)
where the coefficient of proportionality r is callec^ the resistance of the
conductor. The same law may be written in the form
1 = 176 (9)
where the coefficient of proportionality (/= 1/r is called the conductance
of the conductor. When the current is measured in amperes and the elec-
tromotive force in volts, the resistance r is in ohms and g is in mhos.
When there is a counter-electromotive force ec within the conductor,
Ohm's law becomes
et — ec = ri, (10)
or
i = g(et — ec), (11)
where et is the voltage between the terminals of the conductor.
20. For cylindrical conductors the resistance is proportional to the
length I, and inversely proportional to the cross-section A, or
r = Pj, (12)
where the coefficient of proportionality p (rho) is called the resistivity (or
specific resistance) of the material. For numerical values of p for various
materials see Sec. 4.
The conductance of a cylindrical conductor is
6' = X^, (13)

For the original development of the electronic theory and its application
•
to various electric and magnetic phenomena see numerous books and articles
by SirJ. J. Thomson. A popular exposition of the results will be found in
Fournier d' Albee's " The Electron Theory " and in a somewhat more advanced
"Modern Electrical Theory" by N. R. Campbell and in "The Electron
Theory of Matter " by O. W, Richardson.
59
Sec. 2-21 ELECTRIC AND MAGNETIC CIRCUITS

where X (lambda) is called the conductivity of the material. Since g = 1/r,

the relation also holds, tliat
X='. (14)
p
of resistance of non-cylindrical conductors see the
For the calculation
author's "Electric Circuit," Chap. Ill, and the references given there.
21. Temperature coefficient. The resistance of a conductor varies
with the temperature according to a rather complicated law. The resistance
of all metals and of practically all alloys increases with the temperature.
The resistance of carbon and of electrolytes decreases with the temperature.
For numerical values see Sec. 4. For many materials the variation of re-
sistance with the temperature can be represented by the relation
rt = ro{l+at) (15)
where rt is the resistance at t deg. cent., r<, the resistance at deg. cent., and
a (alpha) is called the temperature coefficient of the material. For numerical
values of a for various materials see Sec. 4. When the resistance of a material
_

increases with the temperature, a is positive; otherwise it is negative. For

other formulae see Sec. 4.

22. Kesistances and conductances in series. When two or rnore

resistances are connected in series the equivalent resistance of the combina-
tion is equal to the sum of the resistances of the individual resistors, or
re, = n+r2+etc. (16)
When conductances are connected in series, the equivalent conductance
Otq is determined from the relation
— =-+-+etc.. (17)

in other words, when two or more conductors are connected in series, the
reciprocal of the equivalent conductance is equal to the sum of the reciprocals
of the individual conductances.
23. When resistances are connected in parallel, the equivalent re-
sistance Teq is determined from the relation
— = -+-
Tea ri r2
+etc. (18)

or simply
Ofq^gt+Qi+CtC. (19)
24. The simple rule is: Resistances are added when in series; con-
ductances are added when in parallel. In the case often met in practice
when two resistances are connected in
parallel

^"' = r;-frV '^

' Ao VA/>,

25. Series-parallel circuits. In

a combination like the one shown in
Fig. 1, where some of the resistances
are in series, some in parallel, and
where required to find the equiva- "
it is t^
lent resistancebetween A and B, the
Eroblemis solved step by step, by com-
ining the resistances in series, con-
Fig. 1. Series-parallel circuit, —
verting them into conductances and
adding them with other conductances in parallel. For instance, in the case
shown in Fig. 1 begin by combining tlie resistances n and R into one, and
determine the corresponmng conductance .

1 .

(/J+rj)'
add this conductance to the conductance 1/ro. This will give the total con-
ductance V)etween the points M
and N. The reciprocal of it gives the equiva-
lent resistancebetween the same points. The total resistance between the
points A and B is found by adding n to this resistance. When a network of _

conductors cannot be reduced to a series-parallel combination, the problem

ia solved as shown in Par. 29.

(JO
 ELECTRIC AND MAGNETIC CIRCUITS SeC. 2-26

26. Power and energy. When a steady current i flows through a con-
ductor and the voltage across the tenninala of the conductor is e, the power,
or the energy per unit time, delivered to the conductor is
P = ei. (21)
If the current is expressed in amperes and the potential in volts, the power
P in watts (joules per second).
is When the voltage and the current are
variable, their instantaneous values being represented by e and i respect-
ively, the preceding equation gives the instantaneous power, that is the
instantaneous rate at which energy is being delivered to the conductor.
The total energy delivered to the conductor during a time ( is
W= eit = eQ, (22)
where Q the total quantity of electricity (coulombs) which passed through
is
the conductor. If Q is in coulombs (ampere-seconds), W
is in joules (watt-
seconds). When the voltage and the current are variable the total energy
is expressed by

W=
'= 1
I eidt, (23)

Jh
where the time interval is ti — ti.
27. Joule's law. When the conductor contains ohmic resi-stance only
and no counter-electromotive forces, we have e = ri = i/g, so that the power
4*2

P = i2r=.~^ — = e'-g.
fii
(24)
g r
This expression is known as Joule's law.
28. If the conductor contains a counter-e.m.f., cc, for instance,
that of a motor or of a battery, the power is given by
P = eti = eci-hi'h, (25)
where et is the voltage across the terminals of the conductor. In this expres-
sion ed is the useful power, and I'-r is the heat loss in the conductor. See
Par. 19.
29. KirchhoS's laws. In an arbitrary network of conductors (Fig. 2)
with sources of continuous e.m.f. connected in one or more places, the dis-
tribution of the currents is such that two conditions are satisfied, namely,
Si = 0, and 2e=2:tr. (26)
The first equation refers to any junction point of three or more conductors
and states the fact that as much current flows toward the junction as away
from it, because electricity behaves like an
incompressible fluid. In this equation all
the currents which flow toward the junction
are taken with the sign plus (_+); all those
which flow away from it with the sign
minus ( — ), or vice versa. The second law
refers to any closed circuit taken at random
in the network. The voltages e are the
local electromotive forces in such a circuit
and the currents and the resistances refer to
the individual conductors of the circuit.
The directions of flow of the currents can
be assumed arbitrarily to start with, and in
writing the second equation one follows a
selected circuit in a certain direction, clock-
wise or counter-clockwise, talcing as positive
Fig. 2. —
Network of con- the currents which flow in this direction and
ductors. the e.m.fs. which tend to produce currents
in the same direction. The currents and the
voltages in the opposite direction are entered in the equation with the sign
minus. For a given network of conductors the total number of equations of
the first form is equal to the number of junction points less one; the number
of equationsof the second kind is equal to the number of independent
closed paths in the network. The total number of equations of both kinds
is equal to the number of unknown currents so that these currents can bo

61
Sec. 2-30 ELECTRIC AND MAGNETIC CIRCUITS

determined by solving simultaneous equations. For an example of such

equations see Par. 31 below.
30. Wheatstone bridge. The combination of six resistances shown in
Fig. 3 is called the Wheatstone bridge. The resistances are denoted by
a, b, c, a, p, T,, the currents by x,
y< 2i f »;. f
. An electric battery
•
.

of e.m.f. E is connected in the

branch BC, and the value of a
includes the internal resistance
of the battery. In practice a
galvanometer is usually con-
nected inthe branch OA, and a
includes its resistance. When
the four resistances h, c, /9, y, are
so adjusted that no current flows
through OA, the bridge is said
to be balanced, and the condi-
tion holds that,
5/3 -C7. (27)
ITnbalanced bridge.
31.
When the Wheatstone bridge is
not balanced. Ohm's law and
Kirchhoff's laws give the follow-
ing equations: FiQ. 3. —Wheatstone Bridge.
ax = C-B+E, al = A, i+y-z^O,
by = A-C, Pv=B, n+z — x = 0, (28)
cz = B~A, 7f = C. {+x-j/ = 0.
Here E is the battery e.m.f., and A, B, C, denote the potentials of these
points below that at O. These nine equations contain nine unknown
quantities, viz., six currents and three potentials. Solving them as simul-
taneous equations any of the unknown quantities may be determined. For
instance, the current in the galvanometer circuit is

f = ^(6/3-C7), (29)

where the "determinant" D is given by

D<='abc + bc(fi+y)+ca(rr + a)-{-ab(a+p) +
(,a + b + c)
(fiy+ya aP).* +
32. Networks of conductors. In a general case (Fig. 2) as many
KirchhofF equations (Par. 29) may be written as there are conductors; the
unknown quantities may be
the currents, the resistances
or the voltages; also any com-
bination of these, provided
that the total number of un-
known quantities is equal to
the number of equations. The _

equations are conveniently

solved by the method of deter-
minants, found in most text-
books on algebra.
33. Maxwell's solution.
In some cases it is convenient
to consider, instead of the ac-
tual currents, fictitious cur-
FlQ. 4. — rents
Method of simplifying networks. ibid., in
each mesh (Maxwell,
Art. 2826). The actual
current in each conductor is
equal to the algebraic sum of the fictitious currents. For instance, in
Fig. 4 the current in conductor / is the difference of the fictitious currents
X and Y. The Kirchhoff equations are written for the fictitious currents.

'Maxwell, J. C. "A
Treatise on Electricity and Magnetism," Vol. I,
Art. 347.
For practical forms of the Wheatstone bridge and its application to the
measurement of resistance see Sec. 3.
C2
 ELECTRIC AND MAGNETIC CIRCUITS Sec. 2-34

An example of such a solution will be found in Del Mar's "Electric Power

Conductors," p. 34.
34. Equivalent star and mesh (delta). The number of meshes, and
consequently the number of equations, may be reduced, when some of the
meshes are in the form of a triangle, like o6cin Fig. 4. For the three resistances
forming the triangle may be substituted the three resistances a, /3, and y, which
radiate from, one point.
The currents and the voltages in the rest of the network remain the same,
provided that
_ be ,
ca _ ab
^"^"^
"~{a+b + c)' ^~{a + b+c)' '^~(a + b+c)
The number of meshes is thus reduced by one.
See Kennelly, A. E., Elec-
trical World and Engineer, Vol. XXXIV (1899), p. 413. For a discussion of
equivalent star- and delta-connected impedances for alternating currents
see his "Application of Hyperbolic Functions to Electrical Engineering
Problems," Appendix E.
36. In the practical case of distributing networks and feeders, the
determination of the currents and voltages at the junction points is simplified
by using the following laws of superposition of currents and voltages.
(1) The true current at any point in the network is the algebraic sum of
the currents which would flow if the consumers' currents were taken in
succession instead of simultaneously. (2). The voltage drop to any point
in the network is equal to the sum of the drops to the same point calculated
under the assumption that the consumers' currents are taken in succession,
and not simultaneously. Some simplification in the solution of the Kirchhoff
equations is possibly due to the fact that the voltage drop along a conductor
is usually small as compared to the voltage between it and the return con-
ductor. For details of such calculations see Teichmuller, "Die Elektrischen
Leitungen;" F. B. Crocker, " Network of Electrical Conductors," .BZ. JTorW,
Vol. LIX (1912), pp. 799, 847, 901; Alex. Russell, "The Theory of Electric
Cables and Networks," Chap. 4; Nowak, J., " A Machine for the Calculation
of Supply Networks," The Electrician, Vol. LXVIII (1912), p. 748; Herzog
and Feldmann, " The Distribution of Voltage and Current in Closed Con-
ducting Networks," Trans. Inst. Elec. Congress, St. Louis, 1904, Vol. II, p.
689; also their book entitled " Die Berechnung Elektrischer Leitungsnetze,"
and Hziha und Seidener, " Starkstromtechnik," Sec. 8.

ELECTROMAGNETIC INDUCTION
36. Faraday^s law of induction. When a magnetic flux * within a
loop of wire varies with the time, an e.m.f. is induced in the loop, the instan-
taneous value e of the e.m.f. being proportional to the rate of change of flux;

e--k-^> (31)

where d^/dt is the rate of change of flux <E> with respect to the time t, and k
is a constant which depends upon the units of voltage, flux, and time. When
* is in maxwells, e in volts, and time in seconds, i=10~*. If the flux is
expressed in webers, A; = 1. 'The sign minus determines the relative directions
of the flux and the e.m.f. Namely, when the circmt is closed, the induced
e.m.f. tends to produce a current in the direction such as to oppose the change
in flux. This latter statement follows from Lenz's law, which is stated by
Maxwell* as follows: If a constant current flows in the primary circuit A,
and if, by the motion of .A, or of the secondary circuit B, a current is induced
in B, the direction of this induced current will be such that, by its electro-
magnetic action on A, it tends to oppose the relative motion of the circuits.
See the right-hand screw rule (Par. 66) or Fleming's rule (Par. 67). For
practical purposes three particular cases of electromagnetic induction are
considered below.
37. Stationary conductor and variable flux. This is the case when
both the exciting m.m.f. which produces the flux, and the winding in which
an e.m.f. is induced, are stationary, relatively to one another. The voltage
is induced by a varying magnetic flux, the changes in the flux being produced
by varying either the magnitude of the m.m.f. (stationary transformer) or
•Maxwell, J. C. "A Treatise on Electricity and Magnetism," Vol. II,
Art. 542.
Sec. 2-38 ELECTRIC AND MAGNETIC CIRCUITS

the reluctance of the magnetic circuit (inductor-type alternator) If the .

flux is linked with A'^ turns and varies harmonically with the time, at a fre-
quency of / cycles per second, the mazimuiu induced e.m.f is .

JB^mai='25r/A^*maxlO-8 volts, (32)

where *max is the maximum instantaneous value of the flux, in maxwells.
The effective value of the induced e.m.f. is

£ = 4.44/A''*mojlO-8 volts. (33)

When the flux varies according to a law different from the sine law the
effective voltage is
£ = 4x/iV*moxlO-8, (34)
where x is the form factor (Par. 207).
The average e.m.f. induced in one turn, no matter what the law of
variation of the flux with the time, is

K„™=^pf?-, (35)

where the subscripts 1 and 2 refer to the initial and the final instants
respectively.

38. Stationary flux and moving conductor. When the exciting m.m.f.
which produces the flux, and the winding in which the e.m.f. is induced, move
relatively to each other, as in a generator, so that the conductors cut across
the lines of flux, the instantaneous induced e.m.f. in a conductor is
e = miv, (36)
where (B is the flux density, I the length of the conductor, v the relative veloc-
ity between the flux and the conductor, and k a coefficient which depends
upon the units selected. When e is in volts, (B in maxwells per square centi-
meter (gausses), I in centimeters and v in centimeters per second, k= 10"'.
The three directions, (B, I, and v, are supposed to be at right angles to each
other; if not, their projections at right angles to each other are to be used in
the preceding formula. For practical formulas giving the e.m.f. induced in
direct-current and alternating-current machinery see Sec. 7 and Sec. 8.
39. Variable flux and moving conductor. When coils or conductors
are moving through a pulsating magnetic field, as for instance in single-phase
motors, the induced e.m.f. is due to a combined transformer and generator
action (Par. 37 and 38), and is equal at any instant to the sum of the e.m.f.
induced by a constant flux in a moving coil and that induced by a pul-
sating flux in a stationary coil. Let the frequency of the pulsating field be
/ cycles per second; that of the rotating coil /' cycles per second. A pul-
sating field can be resolved into two revolving fields, one rotating clock-
wise, the other counter-clockwise. Therefore, the induced e.m.f. is a result
of the superposition of two e.m.fs., one of the frequency /+/', the other
/ — /'. In the particular case of /=/' the e.m.f. induced in the rotating coil
is of the frequency 2/, the frequency /— /' being equal to zero.
40. Force on a conductor carrying a current in a magnetic field.
Let a conductor carry a current oft amp. and be placed in a magnetic field
the density of which is (B maxwells per square centimeter ((B gausses). Then,
if the length of the conductor is I cm., the force tending to move the con-
ductor across the field is
F=10.2i(BaO-9 (kg.) (37)
It is of the axis of the conductor
presupposed in this formula that the direction
is at right angles to the direction of the field. If the directions of i and B
form an angle a, the preceding expression must be multiplied by sin a. _

The force F is perpendicular to both i and B, and its direction is determined

by the right-hand screw rule (Par. 66). Namely, the effect of the magnetic
field produced by the conductor itself is to increase the original flux density
((B) on one side of the conductor and to reduce it on the other side. The
conductor tends to move away from the denser field.
41. The attraction or repulsion between two parallel straight con-
ductors, carrying currents u and ii (amp.) and placed in a non-magne(ic,
medium, ia calculated according to the formula
F-2.04!ifi(~)10-» (kg.) (38)
 ELECTRIC AND MAGNETIC CIRCUITS Sec. 2-42

where l/h is the ratio of the length of each conductor to the axial distance
between the conductors. The force is an attraction or a repulsion according
to whether the two currents are flowing respectively in the same or in the
opposite directions.
Mechanical force exerted between magnetic flux and a current-carrying
conductor is also present inside the conductor itself, and is called pinch efiect.
The force between the infinitesimal filaments of the current is an attraction,
so that a current in a conductor tends to contract the conductor. _
This
effect is of importance in some types of electric furnaces where it limits the
current w^hich can be carried by a molten conductor. The same stress also
tends to elongate the conductor.
42. Interlinkage of electric and magnetic circuits. The most general
relations between the electric and the magnetic quantities are expressed by
two laws of circuitation. * Stripped of the vector-analysis terms in which
these laws are usually expressed, they are as follows: Let Hbe the magnetic
intensity or the m.m.f. gradient at a point in a medium of constant permea-
bility, and let O be the electric intensity or the e.m.f. gradient at a point.
The first law of circuitation states that the line integral of H
along a closed
curve is proportional to the volume of the total current (conduction current
and displacement current) linked with this curve. The second law of
circuitation states that the line integral of the electric intensity along a closed
curve is proportional to the rate of change of the total magnetic flux linked
with this curve. The coefficients of proportionality depend only upon the
units u.sed. The theory of propagation of electromagnetic waves is based
upon these two laws. See for instance W. S. Franklin's "Electric Waves,"
Art. 57.

THE MAGNETIC CIRCUIT

43. The simple magnetic circuit. Tlie simplest magnetic circuit is a
uniformly wound torus ring (Fig. 5). The relation between the m.m.f. ff
and the flux * is similar to Ohm's law
(19), viz.,
J = (Jl* (39)
where (R is called the reluctance of the
magnetic circuit. The same relation is
sometimes written in the form
* = (PSF (40)
where (P= 1/(R is called the permeance
of the magnetic circuit. Reluctance is
analogous to resistance and permeance
is analogous to conductance of an elec-
tric circuit.
44. The m.m.f. does not depend
alone on either the current in the wind-
Fig. ing or on the number of turns, but on
-Closed magnetic circuit.
the product of the two; therefore, the
natural unit for the m.m.f. is 1 amp-turn, but in the practical system
1 amp-turn is 1.257 units of m.m.f. If the flux in the preceding equations
is expressed in webers (one weber== 10' maxwells) the permeance is expressed
in henrys (being of the nature of inductance). It has been proposed to call
the corresponding unit of reluctance the yrneh, this being the word henry
spelled backward, corresponding to ohm and mho. It has also been pro-
posed to name the unit of permeance a perm, and the unit of reluctance a
rel.t when the flux is in maxwells and the m.m.f. in ampere-turns, but no
names have yet been generally accepted. In the C.G.S. electromagnetic
system the unit of m.m.f. is the gilbert, equal to 10/4x = 0.7955 amp-turn.
Therefore the m.m.f. in gilberts, expressed as a function of ampere-turns, is

J = ^^nJ=1.257n/ (41)

* Heaviside, O. "Electromagnetic Theory," Vol. I.

t Karapetoff, V. "The Magnetic Circuit;" McGraw-Hill Book Co. Inc.,
New York, 1912, Chap. I, and appendices.

6 65
Sec. 2-45 ELECTRIC AND MAGNETIC CIRCUITS

where nl is the product of the number of turns and the current in amperes.
For further information about magnetic units see Sec. 1.
45. Permeability and reluctivity. The reluctance of a uniform mag-
netic path (Fig. 5) is proportional to its length I and inversely proportional
to its cross-section .4, or
(R = v-^ (42)

and
(P = MY- (43)

In these expressions y is called the reluctivity and m the permeability of the

material of the magnetic path. For air and all non-magnetic substances,
V and li are assumed to be equal to unity per centimeter-cube, corresponding
to centimeter measure for I and A in (42) and (43), and the gilbert as the
unit of m.m.f. This is the conventional assumption in the C.G.S. elec-
tromagnetic system and is the one generally employed. See also Par. 63
and 64.
The method preferred by the author, and expounded in his "Magnetic
Circuit" (see footnote reference in Par. 44), is to take the ampere-turn as
the unit of m.m.f. In such cases, with the maxwell as the unit of flux, the
permeability and, the reluctivity of air, respectively, are
K = 0.7955 per cm.' = 0.3132 per in.'
(44)
M = 1.257 per cm.' = 3.193 per in.'

This method has the advantage of greater simplicity in calculations, but is

not yet in general use (see Sec. 1; Giorgi system of units. Par. 3(d3)).
46. Magnetic field intensity 3C is defined as the m.m.f. per unit length
of path. In any uniform field
3C = (45)
p
In a non-uniform magnetic circuit

3C = (46)
^-f.
Inversely
JF = 3Cr or ?F = y3Cai. (47)
X is also known as the magnetizing force or as the magnetic potential
gradient.
• If 3^ is in ampere-turns, 3C is in ampere-turns per centimeter (or per inch)
of length. If fF is in gilberts, 3C is in gilberts per centimeter (or per inch)*.

47. Flux density ((B) is defined as the flux per unit area perpendicular
to the direction of the lines of force. In a uniform field

. (B = |. -

(48)

In a non-uniform field

(B = -. (49)

Inversely
* = (B4, or * = y(BdA. (50)
Ifthe flux is measured in maxwells and areas in square centimeters,
flux density is expressed in maxwells per square centimeter; one maxwell
per square centimeter is sometimes called a gauss. In this country flux
density is also expressed in maxwells, or in kilolines, per square inch.
It follows at once from (40), (43), (45) and (48) that

(B=m3C (51)

which is the familiar relationship between flux density, permeability and mag-
netic field intensity.

48. Reluctances and permeances in series and in parallel. Reluct-

ances and permeances are added like resistances and conductances (Par. 22

66
 ELECTRIC AND MAGNETIC CIRCUITS See. 2-49

_ i
_ - 144-U- - -
 Sec. 2-53 ELECTRIC AND MAGNETIC CIRCUITS
intensity of induced magnetization. The coeflBcient k is called the susceptl'-
bility of the material. The total flux density in iron also consists of two
parts, viz., that due to X
and to 5, or, in the C.G.S. system,
(B = X + 4x3. (54)
> Dividing both sides of this equation by 3C, gives
/ii=H-4 7nc, (55)
where /i is the permeability of the material (Par. 63). Susceptibility is equal
to zero for non-magnotic materials, is positive for paramagnetic and nega-
'
tive for diamagnetic substances. It is seldom used in practice.
63. The permeability (^i) and the reluctivity (v) of a material (Par.
46) are also defined as the ratios
/' = g^and = ^- i' (5C)

Their values depend upon the units selected for (B and 3C. In the C.G.S.
electromagnetic system (B and 3C are numerically equal for non-magnetic
materials, consequently = v—\. When (B is expressed in maxwells per
ti.

square centimeter (or per square inch) and in ampere-turns per unitK
length, fi and v for air and other non-magnetic materials have values given in
Par. 45, Eq. 44.
64. Two different scales of permeability. For steel and iron the per-
meability /x = (B/3C is frequently calculated from the magnetization curve
(Par. 49), and is usually plotted against (B as absciss® (see curves in Sec. 4).
One must be careful to distinguish between the absolute permeability
and the relative permeability. The former is equal to (B/3C, the latter is
the ratio of the permeability of a sample to that of the air. In the C.G.S.
electromagnetic system both permeabilities are numerically the same,
because n is assumed to be unity for the air; nevertheless they have different
physical dimensions in any system of units.
66. Magnetic calculations. In practice, calculations of magnetic
circuits with iron are usually arranged so as to avoid the use of permeability /j
altogether, using a (B-3C curve directly (Par. 49 and 60). In some special
investigations it is convenient to use the values of permeability and also an
empirical equation between /i and (B. For smalland medium flux densities m
may be expressed as a parabolic curve, of the form
;i = a-b((Bo-(B)nO-6 (57)

r^ '•«.
Motion

Fio. 7a. — Relation between directions Fro. 7b. — Fleming's rules,

of current and flux.

For numerical values of the coefficients see Sec. 4. It is also possible to

represent the relationship between (B and 3C for a magnetic material
empirically by a hyperbola (Frohlich's formula)

(B = __:^*' (58)
a+^OC'
or also in the form
nn 1

reluctivity y = ^ = a +/33C = -. (59)

The coefficients a and /3 must be so determined as to satisfy the saturation

curve of the particular material used.
66. The right-hand screw rule. The direction of the flux produced
by a given current is determined as shown in Fig. 7a (see also Fig. 5). If the

•Maxwell, J. C. "ATreatise on Electricity and Magnetism," Vol. II.,

Arts. 426 to 428.

68
 ELECTRIC AND MAGNETIC CIRCUITS SeC. 2-57

current flows in the direction of rotation of a right-hand screw, the flux is in

the direction of the progressive movement of the screw. If the current in a
straight conductor is in the direction of the progressive motion of a right-
hand screw, then the fiux encircles this conductor in the direction in which
the screw must be rotated in order to produce this motion. The dots in the
figure indicate the direction of fiux or current toward the reader; the crosses,
that away from him.
67. The relative direction of fiux, e.m.f. and motion in a generator
may be determined witii the right hand by placing the thumb, index- and
middle fingers so as to form the three axes of a coordinate system and then
pointing the index-finger in the direction of the flux (north to south) and
the thumb in the direction of motion, the middle finger will give the
direction of the generated e.m.f. (Fig. 7b). In the same way in a motor,
using the left hand and pointinc; the index-finger in the direction of tlie flux
and the middle finger in the direction of the current in the armature con-
ductor, the thumls will indicate the direction of the force, and, therefore,
the resulting motion. These two rules, indicated in Fig. 76, are known
as Fleming's rules.
68. Laplace's law. In a medium, the permeability of which is the same
at all points, the magnetic field intensity produced at a point A by an
element of a conductor ds (in cm.) through which a current of i amp. is flow-
ing, is
^^^taswna (gilberts per cm.) (60)
ll)r*

where the distance between the element ds and the point A in centimeters,
r is ,

and a is the angle between the directions of ds and r. The intensity d3C is
perpendicular to the plane comprising ds and r, and its direction is deter-
mined by the right-hand screw rule given above. The field intensity pro-
duced at A by a closed circuit is obtained by integrating the above expression
for dX over the whole circuit.
69. The magnetic field due to an indefinite straight conductor
carrying a current of i amp., consists of concentric circles which lie in planes
perpendicular to the axis of the conductor and which have their centres on
this axis. The field intensity at a distance of r cm. from the axis of the
conductor is

3C =— (gilberts per cm.), (61)

jts direction being determined by the right-hand screw rule (Par. 66).
60. Magnetic field due to a closed
circular conductor. If the conduc-
tor carrying a current of / amp. is
, bent in the form of a ring of radius r
-
cm. (Fig. 8), the magnetizing force at
a point along the axis is

(gilberts per cm.). (62)

When I =
X = ^^
r
(63)

and when I is very great in comparison

Fig. 8. — Magnetic along the axis
field °
'^

*
of a circular conductor. X = q--2^,2J. (64)

61. The magnetic intensity within a solenoid made form

in the of
a torus ring, and also in the middle part of a long straight solenoid, is

= — nji
47r
3C (gilberts per cm.) (65)

where i is the current in amperes, and m is the number of turns per centi-
meter length.
The determination of the field intensity produced by short coils is
69
 Sec. 2-62 ELECTRIC AND MAGNETIC CIRCUITS
usually a complex matter, and the results are expressed by complicated
formulse. See references in Par. 74.
62. The stored magnetic energry in a single loop of non-magnetic wire,
when the dimensions of the wire are small compared to those of the loop (so
tliat the flux inside the wire is negligible), is

W- M* = ii^(P = (joules) (66)

|^
where the current in amperes, <I> the flux linking with the loop, in webers,
i is
and (P the permeance of the magnetic path, in henrys.
63. Effect of leakage. When the flux linking with part of the turns of a
coil C is not negligible (see Fig. 9), the total stored energy may be expressed
in the following forms:

(67)
TF = Ji'n'i-CPc + S7ip2A(P,I.
The last expression is identical with
W-=\Li"- (68)
where L is the inductance of the coil (Par. 67). The subscripts c in the fore-
going expressions refer to complete linkages, that is those which embrace

Fig. 9. — Magnetic field due to a coil.

all the turns of the coil, the subscripts p to partial linkages. See the
author's " Magnetic Circuit," Art. 57.
64. The density of magnetic energy, or the magnetic energy stored
per cubic centimeter of a magnetic field is
„,,m3C2
W =-^- (B3C
= -^ 5—
(B2
— = ojr/i ^. , ,.
(joules per cubic cm.).
^ __
(69)
ojr ox
Here 3C is the intensity in gilberts per centimeter, (B is the flux density in
webers per square centimeter and ii is the relative permeability; or if 3C is
inampere-turns per centimeter, then

TF'=i;»3C2=i(B3C = (joules per cubic cm.) (70)

2m
where n is the so-called absolute permeability (see Par. 64). To find the
total energy of a field the preceding expressions are multiplied by the element
of the volume dv and integrated within the desired limits of volume. For
an interesting comparison of practical possibilities as to the amount of
energy stored in the magnetic form per unit volume, compared with other
forms of energy, see Steinmetz, C. P., General Electric Review, 1913, p.
536,

70
 ELECTRIC AND MAGNETIC CIRCUITS See. 2-65

66. Magnetic tractive force. * Tlie carrjrlngr weight of a lifting mag-

net is

(^«-) (^^>
^=2lS
where ®the flux density in the air-gap, expressed in kilolines per square
is
centimeter, and A is the total area of the contact between the armature and
the core, in square centimeters. See also Sec. 5.
66. Magnetic force or torque. The mechanical force or the torque
between two parts of a magnetic circuit may in some cases be conven-
iently calculated by making use of the principle of virtual displace-
ments. An infinitesimal displacement between the two parts is assumed,
and the assumption is made that the work necessary for this displacement
is equal to the change in the stored magnetic energy, plus the electrical
energy added during the change from the source of the exciting current. For
details see the author's "Magnetic Circuit," Art. 71.

INDUCTAKCE
67. The electromagnetic inductance, or the coe£Scient of self-in-
duction L, is defined from any of the following three fundamental equations:

.= -4- (72,
Pr= ii2Z,; (73)

L = nc^<Pc+ r
I np'd(Pp. (74)

These expressions are true only when the permeability of the medium is con-
stant. The first equation expresses the fact that the self-induced voltage
isproportional to the rate of change of the current in the circuit, andZ/ is the
coefficient of proportionality. According to the second equation, the mag-
netic energy stored in a circuit is proportional to the square of the current
(Par. 63), and L is the coefficient of proportionality. In the third formula
L is expressed through the permeances (P of the magnetic paths linking with
the circuit (Fig. 9), and the number of turns with which these paths are
linked. The subscripts c and p refer to complete and partial linkages respec-
tively (Par. 63). For practical purposes both inductance and permeance
are expressed in henrys (Par. 44 and Sec. 1). The first expression is conven-
ient for measurements of inductance, the third one for calculations in those
cases where the shape of the magnetic paths is known or can be estimated.
68. Closed magnetic circuit. For a torus ring (Fig. 5) uniformly
wound with one layer of thin wire the partial linkages may be neglected,
80 that np = 0, and 6'c=iiA/l, where for non-magnetic materials m = 1-000;
A is the cross-section of the flux within the ring, and I is the average length of
the flux. Consequently

L = ^-^^^^p-^,irlO-'> = 1.2o7nhlA10'* (henrys) (75)

In this expression nc is the total number of turns, and m

= nc/l is the number
of turns per centimeter length of the magnetic path; I and A are in square
centimeters; /ir is the relative permeability of the core with respect to the air
(Par. 54).
69. For a torus ring of rectangular cross-section wound with several
layers of wire the inductance is

L = OA~lbh+%{b + h+t)]lO-» (henrys) (76)

In this expression 6 and h are the dimensions of the non-magnetic core on

which the wire is wound, D is the mean diameter of the ring, n is the total
number of turns, and t the thickness of the winding (all in centimeters).
If the core is magnetic, the product bh must be multiplied by the relative

• Maxwell, J. C. "Treatise on Electricity and Magnetism;" Cambridge

University Press; Vol. II, Art. 643.

71
 Sec. 2-70 ELECTRIC AND MAGNETIC CIRCUITS

permeability of the steel. If the magnetic core occupies only a part o of

the cross-section bh, use the expression bh[an,-\-{l—a)], in place of hh.
70. For other calculations of inductance using formula (68) see the
author's "Magnetic Circuit," Chaps. to XII. X
) 71. Thin solenoids. For a straight coil uniformly wound with turns m
per centimeter length, provided that the length of the coil is large com-
pared to its transverse dimensions, and that the winding consists of one layer
of comparatively thin wire, the inductance is
L = 1.257ni2?A10^8 (henrys) (77)
the notation being the same as in Par. 68.
72. The Inductance of a long straight coil wound with several layers
of wire, and with an iron core of radius a inside,

Z, = 4ni<idV^-[l+(Mr-l)^%^+^]lO-« (henrys) (78)

where the inside radius of the winding, and

r is
d its radial tliickness; nv is the number of turns
per centimeter length, and all the dimensions
are in centimeters. If there is no iron core,
put a = 0.
73. Prof. Morgan Brooks has derived a
universal semi-empirical formula for the In-
ductance of short and long coils without
iron cores. His formula is given below in
two forms, one (79) for dimensions in centi-
meters, the other (80) for dimensions in En-
gUsh units. Both give results in henrys. The
notation is explained in Fig. 10.
Cm^ f^F^
(henrys) (70)
"b+c+R^ 10»
/Ft \i
L= - XF'F" (henrys) (80)
b + c+R
In Eq.(80) the conductor length is in thousands
of feet, and the coil dimensions in inches; 0.36G
is the conver.sion factor. F' and F" are em-
pirical coil-shape factors dependent upon the
relative, and independent of the absolute
dimensions of the winding. Values of />'' and
F" are as follows: 10. — See Par. 73.
UR s
lAR"^ =0.5 logio(100+j .
^=-7^;.-;i7;- 7 ,-.-£,! =""'""' (81)
lOb + lOc + 26 + 3c/'
Cm indicates the length of the conductor in centimeters;
Ft indicates the length of the conductor in feet, and jF'</1000 = thousands of
feet;
N is the total number turns in the winding, whence
of
Cm = 2waN, when a is in centimeters, and (82)
Ft 2waN .... ,„„.
looo = 12006-
^*'''' " '' '" "*'^'''- ^^^^
.

Numerous tables, curves, and charts which simplify the use of this formula
for practical design will be found in the Bulletin No. 53 of the University
of Illinois, by Morgan Brooks and H. M. Turner, entitled "Inductance of
Coils." For another empirical formula see Doggett, L. A., "The Inductance
of Air-cored Solenoids," Elec. World, Vol. LXIII (1914), p. 259.
74. Bureau of Standards, formulas for inductance. For a thorough
analysis and comparison of various formulas for the inductance of coils the
reader i.s referred to the following excellent series of articles published in the
Bulletin of the Bureau of Standards:
"Formula and Tables for the Calculation of Mutual and Self-inductance"
(Revised), E. B. Rosa and L. Cohen, Vol. VIII, p. 1; 1912; "Calculation of

72
 ELECTRIC AND MAGNETIC CIRCUITS SeC. 2-75

the Self-inductance of Single-layer Coils," Edward B. Rosa. Vol. II, p. 161;

1906; "The Self-inductance of a Coil of any Length Wound with any Number
of Layers of Wire," Edward B. Rosa. Vol. IV, p. 369; 1907; " Self-Inductance
of a Solenoid of any Number of Layers," Louis Cohen. Vol. IV, p. 383; 1907;
"Construction and Calculation of Absolute Standards of Inductance,"
J. e. Coffin. Vol. II, p. 37; 1906.
" Revision of the Formulas of Weinstein and Stefan'for Mutual Inductance
of Coaxial Coils," Edward B. Rosa. Vol. II, p. 331; 1906; "The Mutual
Inductance of Two Circular Coaxial Coils of Rectangular Section," Edward
B. Rosa and Louis Cohen. Vol. II, p. 359; 1906. See also E. Orlich,
"Kapazitat und Inductivitat" (Vieweg), p. 74. and Louis Cohen, " Formulffi
and Tables for the Calculation of Alternating-current Problems," Chap. 2.
76. The inductance of a concentric cable is (Fig. 11)

L = 0.4605 logio(-) +0.05+L' (millihenrys per km.) (84)

where

156L 10\bJ ^40U/ ^•\ ^ J

The foregoing expression for L

true at low frequencies only.
is At high
frequencies an unequal distribution of currents reduces the partial linkages
so that in general

L = 0.4605 logio (-) + k (0.05 +L') (86)

Here /i; =l at usual industrial frequencies, and gradually approaches zero

as the frequency increases to infinity.
76. N-conductor cables. For the field
distribution in and the inductance of non-
concentric cables see Alex. Russell, "Alter-
nating currents," Vol. I; for the inductance
of armored cables see J. B. Whitehead,
"The Resistance and Reactance of Armored
Cables," Trans. A. I. E. E., Vol. XXVIII
(1909), p. 737.
77. The inductance of a single-phase
transmission line is given by
L =
0.4605 logio-+ 0.05, in millihenrys per
a
kilometer of one conductor, (87)
where o is the radius of the conductors, and h
Fig. 11. —
Cross-section of is the distance between their centres. To find
concentric cable. the inductance per mile multiply by 1.609.
To find the inductance per thousand feet
divide by 3.281. For tables of reactance (Par. 164) at usual frequencies
and spacings see Sec. 11.
78. For iron conductors use O.OoMr instead of 0.05 in the above formula,
where tir is the relative permeability of the iron with respect to the air. The
value of y.r varies with the current, and also depends upon the quality of the
iron. For good telegraph wire Mr is equal approximately to 150.
79. For stranded conductors the actual radius is too large to be used
in the formula for inductance. For all practical purposes, the equivalent
radius of a stranded conductor may be assumed the same as that of a solid
round conductor of the same sectional area. For an accurate calculation
of the inductance of stranded conductors see Dwight, H. B., Electrical
World, 1913, Vol. LXI, p. 828.
80. The inductance of a three-phase line with symmetrical spacing,
per wire, is the same as the inductance of a single-phase line per wire, with
the same size of wire and the same spacing. It is expressed by tiie formula
(87) in Par. 77. This formula holds true for balanced as well as unbalanced
loads, for balanced and unbalanced line voltages, for a three-wire two-phase
system, three-wire single-phase system, monocyclic system, etc.
81. For a semi-symmetrical spacing of a three-phase line, that is
when two spacings are equal, and the third is different, formula (87) in

73
 Sec. 2-82 ELECTRIC AND MAGNETIC CIRCUITS

Par. 77 holds true only for the conductor situated symmetrically with respect
to the other two. The inductance of the other two wires cannot be cal-
culated in a simple manner. For practical purposes it is sufficient to take
the inductance of all three wires as equal to that of a line symmetrically
spaced, the equivalent spacing being equal to the geometric mean of the three
actual spacings, or

6e3 = ^bibibi. (88)

For the equivalent resistance and reactance of a three-phase
82.
line with unequal spacings of wires see the writer's " Magnetic Circuit",
Art. 63. In this case the e.m.f. induced in a conductor by the varying mag-
netic fluxes consists of two components, one being in quadrature, the other
in phase with the current in the conductor. The first component corresponds
to the inductance of the conductor, the other represents transfer of power
from one phase to the others. In general, these components are different
for the three conductors, and in order to equalize them for the whole line
conductors are transposed after a certain number of spans. This transposi-
tion of conductors is used on power lines (Sec. 11) as well as on telegraph
and telephone lines (Sec. 21) to reduce the unbalancing effect of mutual in-
duction. See also Par. 87 below. The inductance of two or more parallel
cylinders of any cross-section can be expressed through the so-called geo-
metric mean distance introduced by Maxwell.* For details also see Orlich,
"Kapazatit und Inductivitat," pp. 63-74.
83. Mutual inductance. When two independent electric circuits,
(1) and (2), are in proximity to each other, their electromagnetic energy may
be said to consist of three parts: the part due to the linkages of the flux pro-
duced by the circuit (1) with the current in (I); that due to the flux produced
by the circuit (2) with the current in (2) and that due to the current in each
;

circuit linking with the flux produced by the other circuit. Employing the
notation in Par. 67, the total energy of the system is expressed by
W = hu'^L\ + \h'^Li+uhLm (joules) (89)
where L\ and Lj are the coefficients of self-induction of the two circuits, and
Lm called the coefficient of mutual inductance of the two circuits.
is
All three coefficients are measured in henrys.
84. The coefficient of mutual inductance is also deflned from the
relations:

that is, Lm determines the voltage ei induced in the circuit (1) when the current
»a in circuit (2) varies with the time, and vice versa.
85. coefficient of mutual inductance of two long coaxial
The
single-layer coils of the same length I and cross-section A, is
im = 1.257ra,n2M10-8, (henrys), (91)
where ni and m
are the numbers of turns per centimeter length of the two
coils respectively; I and A are measured in centimeters.
86. For two long coaxial coils wound in several layers the coefficient
of mutual inductance is
Lm='iniin2ndi(hri'~(\+~+^,) (henrys) (92)
\ ri oriv
and if an iron core is present
Lm = ^ni"-7i2nduhri^[l + (.Hr-l)a^+p +^^] (henrys) (93)

For explanation of notation see Par. 72 above. See also the references
in Par. 74.
87. The coefficient of mutual inductance of two parallel line
circuits (Fig. 11a) is given by

Lm -0.4605 logio(^—") (miUihenrys per km.) (94)

where ai and 6i are the distances from one of the wires of circuit 1 to the

• Maxwell, J. C. " Treatise on Electricity and Magnetism," Vol. II, p. 324.

74
 ELECTRIC AND MAGNETIC CIRCUITS Sec. 2-5

conductors of the other circuit, and 02 and 62

are the corresponding distances of the other
wire of circuit 1 from the conductors of the
other circuit. For interference between
transmission and telephone lines due to
mutual inductance see Sec. 21. Transposition
of telephone lines is also explained in Sec. 21.
Circuit 2 88. Actual measurement must be em-
ployed in most cases to determine the coeffi-
Fig. Ho. cient of mutual inductance. See Sec. 3.

HYSTERESIS AND EDDY CURRENTS

89. The hysteresis loop. When a sample of iron or steel is subjected
to an alternating magnetization, the relation between (B and 3C (Par. 49) is
different for increasing and decreasing values of the magnetic intensity (Fig.
12). This phenomenon may be thought of as due to some kind of friction
between the molecules of the magnetic material. Each time the current
wave completes a cycle, the magnetic flux wave must also complete a cycle
and each molecular magnet be turned through one revolution. This loss
appears as heat. The figure AefBcdA in Fig. 12 is called the hysteresis loop.
90. Retentivity. If the coil shown in Fig. 5 be excited with alternating
current, the ampere-turns and consequently the m.m.f. will, at any instant,
be proportional to the instantaneous value of the exciting current. Plotting
a (B-JC or a * — 5 curve (Fig. 12) for one cycle, the closed loop, cdAe/B, is
obtained. The first time the iron is magnetized the virgin or neutral curve,
0.4, will be produced: but it cannot be produced in the reverse direction,
AO, because when the m.m.f. drops to zero there will always be some mag-
netism (+0e or —Oc) left. This is called residual magnetism and in
order to reduce this to zero, an m.m.f. { — Of or -fOd) of opposite polarity
must be applied. This m.m.f. is called the coercive force.
91. Wave distortion. In Fig. 12 the instantaneous values of the ex-
_

citing current I (which is directly proportional to the m.m.f.), and the

corresponding values of the flux and voltage E (or e) are plotted against
</>

time as abscissae, side by side with the hysteresis loop, (a) If the voltage
applied to the coil is sinusoidal {E, to the left), the current wave will be
distorted and displaced from the corresponding sinusoidal flux wave. The
latter wave is in quadrature with the voltage wave. (6) If the current
through the coil is sinusoidal (I, to the right), the flux is distorted into a
flat-top wave, and the induced voltage wave e is peaked.

Fig. 12. —Periodic waves of current, flux and e.m.f. ; hysteresis loop.

92. Components of exciting ciurrent. The alternating current which

flows in the exciting coil (Fig. 12) may be considered to consist of two com-
ponents, one exciting magnetism in the iron, and the other supplying the
hysteresis loss. For practical purposes both components may be replaced
by equivalent sine- waves, and finally by vectors (Fig. 13). have We
Ir =1 cos 9 = power component of the current;
Ph = IE cos 6 = IrE = hysteresis loss in watts,
Im^I sin 9 = magnetizing current,
75
Sec. 2-93 ELECTRIC AND MAGNETIC CIRCUITS

wherein / is the total exciting current and d the angle of time-phase displace-
ment.
The energy lost per cycle can be represented by the area, AfBd, of the
loop; see Par. 94 below.
93. Hysteretic angle. Without hysteresis, E/<
the current / would be in phase quadrature with
E. For this reason the angle a=90 — is called
the angle of hysteretic advance of phase.
Ir IrE watts loss —
Sxn a =-=-=„ =
„.
-. (95)
I IE apparent watts
In practice, the measured loss usually includes
eddy currents (Par. 98) so thatthe name "hys-
teretic" is somewhat of a misnomer.
94. The energy lost per hysteresis cycle
(Fig. 12) is proportional to the area of the loop, Oy
+ <&
Energy = cF^ aCAOJ (joules) (96)

~^ Fig. 13. — Components

wherein V is the volume of the iron, (B and 3C of exciting current; hys-
being the coordinates of the loop instead of * and teretic angle,
ff as shown in Fig. 12; and c a constant depend-
ing upon the scale used. For details see the author's "Magnetic Circuit,"
Art. 16.
96. Steinmetz's formula. According to exhaustive experiments by
Dr. C. P. Steinmetz, the heat energy released per cycle per cubic centimeter
of iron is approximately
TF = 77Bi«mai (ergs) (97)
The exponent of (B varies between 1.4 and 1.8 but is generally taken as
1.6. Values of i; are given in Sec. 4 (see index).
96. Power loss per unit weight. The most convenient way to express
the hysteresis loss is

Ph = kh (watts per unit weight) (98)

lOOV 1000 /
wherein / the frequency in cycles per second; <S> the maximum flux density
is
in lines or maxwells per square centimeter, and kh a constant; see Sec. 4.
97. Two-term formula. Another empirical formula for the hysteresis
loss is
Pk=fiv'B+v"B') (watts per unit weight) (99)

where »;' and ij" are empirical coefficients. This formula

is more accurate at medium and high'flux densities than
the preceding one.
.^: 98. Eddy-current losses are I-R losses (Par. 27) due
3 to secondary currents (Foucault currents) established in
those parts of the circuit which are interlinked with alter-
nating or pulsating flux. Referring to Fig. 14, a bar-
shaped conductor is just entering a non-uniform field.
The advancing side, A, is cutting more lines than the
trailing side, B, so that there is a difference in potential
B between these two sides and electricity will flow as shown
by the arrows. According to the formula e^g, eq. (24),
the loss is proportional to the cube of the thickness t, be-
cause both e and g are proportional to t. Hence the
Via. 14. loss per unit volume of conductor is proportional to the
Eddy currents. square of the thickness. It is assumed that the length is
much greater than the width, and that the third dimen-
sion is constant.
Referring to Fig. 15, which shows a cross-section of a transformer core, the
primary current, /, produces the alternating flux, 4>, which by its change
generates an e.m.f., e, in the core; this e.m.f. then sets up the secondary

76
 ELECTRIC AND MAGNETIC CIRCUITS Sec. 2-99

current, i. Now, if the core be divided into two (6), four (c), or n parts,
the e.m.f. in each circuit will be e/2, k/4, e/u and the conductance g/2, g/A,
gin respectively. Thus, the loss per
lamination will be (l/w3)-th part and
the total loss (l/n2)-th part of the loss in
the solid core.
99. Effect of lamination. From the
two examples given above it is seen that
the eddy currents can be greatly reduced
by laminating the circuit, i.e., by making
it up of thin sheets each insulated from the
others. The same purpose is accomplished
Fig. 15.— Section of trans-
by using stranded conductors or bundles
former core.
of wires. The eddy-current loss in a
laminated iron core is

p, = ft,^'/--"l°^^ (watts per unit weight) (100)

wherein i is the thickness of the laminations in mils; / the frequency in cycles

per second, and kt a factor including the specific weight and resistivity of
the material.
A formula for the loss in conductors of circular section, such as wire, is
(irr/(Bmax)'
P. = - (watts per cu. cm.) (101)
4p 10i»
wherein r is the radius of the wire in centimeters; / the frequency in cycles per
second (Bmai is the maximum flux density in lines per square centimeter
;

and p the specific resistance in ohms per centimeter cube.

A formula for the loss in sheets is
P« = — ^5-%?,T-
op Vj"
(watts per cu. cm.) (102)

wherein i is the thickness in centimeters; /the frequency in cycles per second

Bmax is the maximum flux density in lines per square centimeter, and p the
specific resistance.
The specific resistance of various materials is given in Sec. 4 (see index).
100. Keal or ohmic resistance is the resistance offered by the conductor
to the passage of electricity. Although the specific resistance is the same for
either alternating or continuous current, the total resistance of a wire is
greater for alternating than for continuous current. This is due to the fact
that in a conductor which is continuously cut by flux, there are generated
e.m.fs. these e.m.fs. are greater at the centre than at the circumference
;

so that the potential difference tends to establish currents which oppose the
main current at the centre and assist it at the circumference. The result is,
that the main current is forced to the outside thus reducing the effective area
of the conductor. This phenomenon is called skin effect (Par. 101).
101. A theoretical formula for the calculation of skin effect in a
solid conductor of circular cross-section is*

<'»>
-4'+f2(M5?)'-Tlo(if )'+H <-""»>•
wherein r is the resistance offered to an alternating current; R that offered
to a continuous current; /the frequency in cycles per second, /i the relative
permeability of the conductor and I the length of the conductor in centimeters.
It will be noted that \/R is proportional to the area of cross-section of the
conductor; therefore, the skin effect depends upon the area of cross-section
of the conductor and the frequency of the current. These should be kept as
small as possible, although skin effect seldom cuts any great figure where
moderate sized conductors are used to carry current at ordinary frequencies.
It is in iron or other miagnetic materials, where skin effect becomes really
important. It niust be considered in rail returns for alternating-current
systems. Skin effect tables are given in Sec. 4 (see index). For a detailed
• Maxwell, J. C. "A Treatise on Electricity and Magnetism," Vol. II,
Art. 690; footnote by J. J. Thomson.
77
 Sec. 2-102 ELECTRIC AND MAGNETIC CIRCUITS

treatment of resistance to alternating currents and eddy current losses in

metallic conductors see Loms Cohen, " Formulse and Tables for the Calcu-
lation of Alternating-current Problems," Chap. I. Numerous tables and
formulse will be found there, relating to the resistance to alternating currents
and eddy current losses in solid, hollow and concentric cylindrical conductors,
flat conductors, coils and conductors in slots of laminated iron armatures.
102. Effective resistance and reactance. When an alternating-current
circuit has appreciable hysteresis, eddy currents and skin effect, it can be
replaced by an equivalent circuit, without these losses, by using equivalent
resistances and equivalent reactances (Par. 164) in place of the real ones.
These equivalent or effective quantities are so chosen that the energy rela-
tions are the same in the equivalent circuit as in the actual one. In a scries
circuit let the true power lost in ohmic resistance, hysteresis, and eddy
currents be P, and the reactive (wattless) volt-amperes P'. Then the effec-
tive resistance and reactance are determined from the relations
{h-e// = P; i^Xe/f^P'. (104)
In a parallel circuit, with a given voltage, the equivalent conductance and
susceptance (Par. 169) are calculated from the relations
O e'^gcf/^P; e'^bc//=P'. (105)
Such equivalent electric quantities which replace the core loss are used in
the analytical theory of transformers and induction motors.
103. Core loss. In practical calculations of electrical machinery the
total core loss is of interest rather than the hyteresis and the eddy currents
separately. For such computations empirical curves are used, obtained
from tests on various grades of steel and iron (see Sec. 4).
104. The separation of hysteresis from eddy currents. For a
given sample of laminations, the total core loss P, at a constant flux density
and at variable frequency /, can be represented in the form
P = af-j-bp (106)
where af represents the hysteresis loss and bp the eddy or Foucault-current
loss,a and 6 being two constants. If we write this equation for two known
frequencies, two simultaneous equations are obtained from which a and b
are determined.
105. Determination of constants. It is convenient to divide the fore-
going equation by /, because in the form

j=a + bf (107)

it represents the equation of a straight line between (P//) and /. Having

plotted the known values of (P//) against / as absciss®, the most probable
straight line is drawn through the points thus obtained. The intersection
of this line with the axis of ordinates gives a; b is calculated from the pre-
ceding equation. Knowing a and 6, the separate losses are calculated at any
desired frequency from the expressions af and bf- respectively.

THE DIELECTRIC CIRCUIT

106. Dielectric flux. When a source of continuous voltage E (Fig. 16)
is applied at the terminals of a condenser AB, a quantity of electricity Q
flows through the connecting wires and the same quantity of electricity
may be said to be displaced through the dielectric between the conden.ser
terminals, because electricity behaves like an incompressible fluid. This
displaced electricity in a dielectric is called the dielectric flux and is measured
in the same units as a quantity of electricity in a conducting circuit; that
is, in coulombs or in microcoulombs.

107. The dielectric flux density and the potential gradient. The
flux density D or the dielectric flux per unit area is D
= Q/A when the flux
distribution is uniform, or D = dQ/dA when the flux distribution is non-
uniform. In these expressions Q is the dielectric flux and A is the area
perpendicular to the electrostatic lines of force. Flux density is measured
in microcoulombs per square centimeter or per square inch.
The voltage E applied at the terminals of the condenser acts upon the
whole thickness I of the dielectric, and the dielectric stress (r is characterifed
as the voltage per unit thickness (unit length) of the dielectric in the direction

78
 ELECTRIC AND MAGNETIC CIRCUITS See. 2-108

of the lines of force. Thus, in a uniform &e\d,G==E/l, and in a non-uniform

field, The dielectric stress G is also called the voltage gradient
G = dE/dl.
or the electric force. It is measured in volts per inch, kilovolts per mm..
or in other such convenient units. In a homogeneous dielectric, the flux
density D at any point is proportional
to the voltage gradient at that point,
and the ratio of the two characterizes
the material; or, = kG, where k is D
called the absolute permittivity of
the dielectric. See Par. 113 and 134.
Key
108. Electrostatic capacity (or
permittance). The displacement Q
of through a dielectric is
electricity

Ball.
Eroportional to the voltage E applied
etween the terminals (Fig. IG) as long
1 Galv. as the safe limit of insulation is not
exceeded; or
Q = CE (108)

Condenser Q where the coefficient of proportionality

C is called the electrostatic capacity or
a;
permittance of the condenser. When
E is in volts and Q in coulombs, C is
in farads. If Q is in microcoulombs,
C is in microfarads.
When the applied voltage is vari-
Fig. 16. —condenser.
Circuit containing a able, the preceding equation is writ-
ten in the form

i«=^ = C^. '

(109)
at dl
where _Q and E^ are differentiated with respect to time
called the t, and ie is
charging or displacement current. Either this equation or the relation
Q = CE may be considered as the fundamental one defining capacity C.
109. Elastance. The same proportionality between the applied voltage
and the displacement of electricity is sometimes written in the form
E = SQ, (110)
where S = 1/C is called the elastance of the condenser. When E is in volts
and Q in coulombs, <S is measured in units which the author has termed
"darafs" (farad spelled backward). When Q is in microcoulombs, S is in
"megadarafs."
110. Condensers in series and in parallel. When condensers are
connected in parallel, the equivalent capacity is equal to the sum of all the
capacities of the component condensers, or
Ceq^'^C. (Ill)
When two or more condensers are connected in series, the equivalent
capacity is determined from the relation

(112)

Analogously, for a series connection of elastances (Par. 109)

Se<i = XS; (113)
and for parallel connection of elastances
(114)
Seq S
111. For example, two permittances Ci = 0.2 mf. and C2 = 0.3 mf.
let
be connected in parallel with each other, and in series with a third condenser
for which Ci = 0.4 mf. To find the total capacity of the combination we note
that the combined capacity of the two condensers in parallel is Ci+C2 = 0.5
mf., or the elastance of the combination is two megadarafs. The elastance
of the third condenser is 1/C3 =
2.5 megadarafs, so that the total elastance
of the combination is 2+2.5 =
4.5 megadarafs. Consequently the equivalent
capacity is 1/4.5 = 0.222 mf. This example shows the convenience of using
elastances when condensers are connected in series.

79
Sec. 2-112 ELECTRIC AND MAGNETIC CIRCUITS

112. The specific inductive capacity of a dielectric (A;) is the ratio be-
tween the capacity'of a condenser made entirely of this dielectric and of an
identical condenser using air for dielectric. It is also termed the dielectric
constant. Another name for specific inductive capacity is relative per-
mittivity. For numerical values for various dielectrics see Sec. 6.
113. Capacity (permittance) between parallel plates. When a
condenser consists of two parallel plates the distance between which is small
compared to the dimensions of the plates, the lines of electrostatic displace-
ment are nearly straight lines normal to the adjacent surfaces of the plates.
The capacity of such a condenser is
(k \ A
j-W (abstatfarads) (115)

where A is the area of one of the plates in sq. cm., I the normal distance
between them, in cm. and A:/4x the permittivity of the dielectric; A is the
dielectric constant, which for air is unity. If C is to be in microfarads, then
in the preceding formula in place of k/4Tr use

2-( .,)=0.08842XfcX10-« (mf. per centimeter-cube) (116)

where the velocity of light, or the factor required to change from electro-
v is
static to electromagnetic units.
If instead of taking k/4ir as the permittivity, a term ka called the absolute
permittivity is introduced, then
C — ka-j (microfarads) (117)

And for air, instead of unity (the relative permittivity), the absolute per-
mittivity is
Ka = 0.08842X10-' (mf. per centimeter-cube) (118)
and for any other substance the absolute permittivity would be 0.08842 X
I0"'fc, where k is the specific inductive capacity or the relative permittivity
of the dielectric; see Par. 112. See also the author's "Electric Circuit,
Article 51, for further elaboration of this theory of absolute versus relative
permittivities. At present the accepted method of calculation is based oe
the use of formula (llo) and (116).
114. The elastance of a dielectric between two parallel plates a
short distance apart is S=a (l/A) where the coefficient <r (signia) is called
the elastivity of the dielectric. If S is in megadarafs (1 daraf is the recip-
_

rocal of 1 farad) and the dimensions in centimeters, <r is in megadarafs per

centimeter cube. Elastance is the reciprocal of permittance, or S = l/C,
and, likewise, elastivity is the reciprocal of permittivity, or <r = 'iir/k
Therefore

For air, in practical units,

0- = 11.31 X10« mgd. per centimeter cube.
(120)
Example; to calculate the capacity of a plate condenser (Fig. 16) built ac-
cording to the following specifications: The metal plates are 50 cm. by 70
cm. each, placed at a normal distance of 0.3 cm. The dielectric consists of
three consecutive layers of insulation, which are 0.12 cm., 0.07 cm. and 0.11
cm. thick. The relative permittivities of the materials are 2, 3 and 5 respect-
ively. Since elastances are added in series (Par. 110), the total elastance
of the condenser is

S = [11.3X10«/(50X70)]t0.12/2-f-0.07/3+0.11/5]
= 0.34 X 10' mgd.
Hence the capacity C = S-' = 2.94X 10-« mf.
lis. Capacity of concentric cables. For a single-conductor cable
with a grounded metal sheath (Fig. 17) the capacity
_ 0.03882 A: , .
., ^ 1

logio(h/a)
(121)
0. 024 13A:
(mf. per km.) I
logio(6/a)

80
 ELECTRIC AND MAGNETIC CIRCUITS See. 2-116

where k is the relative permittivity of the dielectric (Par. 112). The same
formula applies for the capacity or permittance between any two concentric
cylinders, provided that their axial length is considerable as compared to
their radii so that the effect of the ends may be neglected.
116. Graded insulation. When the insulation between two concentric
cylinders consists of several concentric layers (Fig. 17), the elastance of the
cable is:
S = C-i = 25.75[Jfci-i \ogio(hi/a)+ki-^ logio(b!/6i)
+ A;3"' logio(63/62)-|-etc.] (megadarafs per mile) (122)

^-^ch "l^ct^
Fig. 17. —Concentric cable. Fig. 18. —Concentric cable and lead sheath.
where ki, ki ., . are the relative permittivities of the layers (Par. 112).
The capacity in microfarads per mile is the reciprocal of this expression.
The capacity of a cable is directly proportional to its length, while the elas-
tance is inversely proportional to the length.
117. For a single-phase concentric cable with a grounded sheath
(Fig. 18), the capacity between two conductors, Cab, and that between the
outer conductor and the sheathing, Ccd,
is calculated according to the formulae
given above. Then, if the voltage be-
tween the two conductors is Eab and the
voltage between the outer conductor and
the sheathing is Ecd, the charging current
at a frequency of / cycles per second is
/ = 2irf{EabCab+EcdCcd) 10-« (amp.) ,(123)
I \ I / '^ ^"^ ^^^ ^"^ ^""^ expressed in micro-
farads.
^^^J__.--^ .

^ * ^ 118. Twin-conductor cable with

grounded sheath. In this case the
sheath may be replaced by a pair of con-
Fig. 19. —
Twin conductor cable ductors located outside, as shown in
showing electrical image due to the Fig. 19. The spacing, b, of these im-
grounded sheath. aginary conductors being given by the
relation*
ba = di (124)
and the capacity of a single conductor is
0.03882/fc
(mf. per mile). (125)
Iogior2a(d^ — a-)-|

L r(.d^ + a^) J
The capacity per mile of the circuit (two miles of conductor) is one-half

•Leo Lichtenstein. Elek. Zeit. Vol. XXV, pp. 106 and 124 (1904).
6 81
Sec. 2-119 ELECTRIC AND MAGNETIC CIRCUITS

of the preceding value. The transverse dimensions may be either in inches

or in centimeters because only their ratio enters in the formula.
119. A three-conductor cable may be treated in a similar way (Fig. 20)-
The sheath replaced by three equally spaced conductors of the same diam-
i.s

eterand spaced according to the relation ba = d'^. The capacity o£ a single

conductor is
0.07764A;
,
^Za^d^-a^^'^^ (mf. per mile) (12C)

where the transverse dimensions are in inches or in centimeters.

120. The capacity of a single-phase transmission line per wire, or
the permittance between one of the wires and the plane of symmetry is
_ 0.03882 , ,
... ,,„_.^
logio(o/a)
where a isthe radius of the wire, and 6 the spacing between the centres.
The capacity between the two conductors is equal to one-half of that given
by the formula above. For values of charging current at standard frequencies
see tables in Sec. 11.

^
Eurth

Fig. 20. —Three-conductor

showing electrical images due to the
cable; Fia. 21. —Overhead conductor,
grounded sheath.

121. The capacity of a single overhead conductor with ground

return (Fig. 21) is
„ 0.03882 , ,
... ,,„^^
logio(2/i/a)
122. When a single-phase line with metallic return is suspended
sufficiently near tne ground its capacity is somewhat increased. Let
the wires be suspended at the heights h\ and ^2 above the ground; then cal-
culate the capacity according to formula in Par. 120, using the corrected
spacing (see the author's "Electric Circuit," Art. 61)

fc.°' , i (129)
Vl-f- (0.256) VM/ij
When the heights of suspension h\ and hi are greater than 3.5 times the
spacing 6, the difference between 6 and the corrected spacing he is less than
1 per cent. The correction in formula (117) is still smaller, because
logarithms of numbers vary more slowly than the numbers themselves.
In formulae (128) and (129) a perfectly conducting ground is assumed.
With dry non-conducting earth the increase in capacity is somewhat less.
128. Capacity of a three-phase line with symmetrical spacing.
The concept of the capacity of a three-phase line is not definite without
further qualifications. In practice a three-phase line is calculated by re-
ducing it to an equivalent single-phase line consisting of one of the conductors
of the three-phase line and a ground return. This equivalent single-phase
line carries oue-third of the total power transmitted by the three-phase line

82
 ELECTRIC AND MAGNETIC CIRCUITS SeC. 2-124

at a voltage f^/V^ corresponding to the star voltage of the three-phase line.

For such an equivalent line the capacity is expressed by the formula given
in Par. 120 above, where a is the radius of each wire and 6 the spacing be-
tween the wires. This expression for capacity means that the charging cur-
rent per wire calculated from the formula I = 2ir/CJ5/V 3 checks with that
actually observed in each wire of a three-phase line when a pure sine-wave
voltage E is applied between the wires. For values of charging current see
tables in Sec. 11.
124. With an unsymmetrical spacing let the actual distances between
the three pairs of wires be 6i, 62, and 63. The capacity can be calculated
from the above given formula using the equivalent spacing
be, = -^blbibz, (1301

equal to the geometric mean of the actual spacings. For a more detailed
treatment of capacity of three-phase lines with unsymmetrical spacing,
unsymmetrical voltages and the effect of the ground, see the author's "Elec-
tric Circuit," Art. 65. For other formulae for the capacity of linear con-
ductors and cables see Cohen, L., "Formulae and Tables for the Calcu-
lation of Alternating Current Problems," Chap. 3. See also Fowle, F. F.,
" The Calculation of Capacity Coefficients for Parallel Suspended Wires,"
El. World, Vol. 58 (1911), pp. 386, 443, and 493.
12B. A
Leyden jar (Fig. 22) may be considered as
_»J(U_ !<-»• J a combination of plate condensers. Thus, using the
general formula Par. 113, its capacity,
A Tr^+2Trrl
^ = K— /1ol^
C =K (microfarads) (131)

where the dimensions are in centimeters and k =

0.08842 X10-« A;; see Par. 112.
126. Permittance of irregular paths. In some
I cases it is necessary to calculate the capacity of a
condenser the dielectric of which is limited by irregu-
FlQ. 22. —
Leyden jar. lar boundaries. The problem is solved either by e^t-
periment or by calculations. In performing the ex-
periment the dielectric is sometimes conveniently replaced by a piece of
metal of identical shape and with identical terminals. Let the resistance
of the metal paths be R, the unknown capacity C, the absolute permittivity
of the dielectric A;a (Par. 112) and the resistivity of the metal p (Par. 20).
Then
C = ^^P (132)

In order to calculate the permittance without any experiment, various

assumptions are made as to the most probable paths of the electrostatic
lines of force, and of the various assumptions one ia selected which gives the
maximum permittance. For details see the author's " Electric Circuit,
Arts. 54—55.
127. The energy stored in a condenser. The potential energy stored
in a condenser is
CE* Q2 EQ
W= —^^=^r-^=-^, in joules (watt-seconds) (133)

where the voltage E is in volts, the electrostatic flux (Par. 106) or charge
Q in coulombs, and the capacity C in farads. If C is in microfarads and Q
in microcoulombs, isW in microjoules.
128. The density of electrostatic energy, or the energy stored per unit
volume of the dielectric, is

where W
is expressed in microjoules per centimeter cube, ha is the absolute
permittivity of the dielectric in microcoulombs per centimeter cube, and O
is the voltage gradient in volts per centimeter length of path; is the di- D
electric flux density (Par. 107) in microcoulombs per square centimeter.
The total energy of as electrostatic field is found by multiplying W by
83
Sec. 2-129 ELECTRIC AND MAGNETIC CIRCUITS

an element of volume dv and integrating within the desired limits. For an

interesting comparison of practical possibilities as to the amount of energy
stored in the dielectric form per unit volume, compared with other forms ol
energy, see Steinmetz, C. P., General Electric Review, 1913, p. 536.
129. A system of charged bodies (Fig. 23). The total charges on
the individual conductors are expressed by the equations
gi=CiDi+Ci2(!)i — !)2)+Ci3(i'i — !;3)+ etc., \ (135)
q2 = C2V2 Cn(v2 — Vl) +C23(V2 — V3)
+ CtC, / +
where vi, n, V3, etc., are the potentials of these conductors above the ground.
The coefficients Ci, Ci, Cs, etc., are called the partial capacities of the con-
ductors; Ci2, Cm, etc., are called mutual capaci-
ties. Their computation is possible in a few
simple ca.ses only, but having determined them
experimentally, it is possible to calculate from the
preceding equations the resultant or equivalent
capacity of the system under various operating
conditions.
130. Maxwell's equations of a charged sys-
tem. The same equation may be written in
Maxwell's form
qi = Knvi + KuVi + Kuvz + etc. , I (136)
g2= Kni>i + K2iVi + K^3V^ + etc., j
where the coefficients Kn, K22, etc., are called the
capacities of the individual conductors, and the
negative quantities Kn, K23, etc., are called coeffi-
cients of mutual induction. Fig. 23. —System of
131. Coefficients in Maxwell's equations. charged bodies.
The following relations hold between the coeffi-
cients K
and C:
itu = Ci +Ci2+Ci3+etc.
^22 = 02+021+023 etc. + (137)
Ki2= — C12; A'2i= — C21, etc.
132. The electrostatic energy stored in the field is
W = iKiivi^ + i A'22D2^ + etc. +ii'i2i'i!'2 + Xi3!)ii)3 + K23V2V3 + ctc. (138)
W is expressed in joules (watt-seconds) if the potentials are in volts and the
capacities in farads.
133. The dielectric strength of insulating materials, or the ruptur.-
ing voltage gradient, is the maximum voltage per unit thickness which a
dielectric can stand in a uniform field, before it breaks down electrically.
The dielectric strength is usually measured in kilovolts per millimeter or
per inch. correct way is to refer the dielectric strength to a uni-
The only
form for instance, between large parallel plates placed at a short dis-
field,
tance apart. If the striking voltage is determined between two spheres or
electrodes of some other shape, the fact should be distinctly stated. In
designing insulation a factor of safety is a.ssumed depending upon the con-
ditions of operation. For numerical values of the rupturing voltage gradi-
ents of various materials see Sec. 4.
134. The critical dielectric flux density is the density at which the
material breaks down. It is determined from the relation
Z)mai = 0.08842A;6'„„xX10-2, (139)
where D^ax is the critical den.sity in microcoulombs per square centimeters
Gmax is the rupturing voltage g:radient in kilovolts per millimeter, and
fc is the relative permittivity of the material (Par. 112).

135. Electrostatic corona. When the electrostatic flux density in the

air exceeds a certain value, a pale violet light appears near the adjacent
metal surfaces; this silent discharge is called the electrostatic corona. In
the regions where the corona appears, the air is electrically broken down, and
ionized so that it becomes a conductor of electricity. When the voltage is

raised still higher a brush discharge takes place, until the whole thickiiess of
the dielectric is broken down and a disruptive discharge, or spark, jumps
from one electrode to the other.
The formation of corona leads to power loss which may be serious in some
84
 ELECTRIC AND MAGNETIC CIRCUITS SeC. 2-136

cases (see Sec. 11). Moreover, corona facilitates the formation of nitric
acid near the conductors, and may lead to corrosion. When corona is allowed
to play on insulation other than a,ii, this insulation may in
time be charred
and deteriorated. For these reasons it is of importance to know the critical
voltages of corona formation and the power loss under various conditions
of surfaces, barometric pressure, humidity, etc. The problem is still in a
research state. For numerical data in application to transmission lines see
Sec. 11; in connection with the design of other high-tension apparatus. Sec. 10.
136. Experiments on corona. A
large amount of experimental and
theoretical information concerning corona and other allied topics will be found
in the various recent volumes of the Trans. A. I. E. E. See in particular
the 'valuable papers by F. W. Peek, Jr., H. J. Ryan, and J. B. Whitehead,
with the accompanying discussion.
137. Dielectric hysteresis and conductance. When an alternating
voltage is applied at the terminals of a condenser, the dielectric is subjected
to periodic stresses and displacements. If the material were perfectly elastic,
no energy would be lost during one complete cycle, because the energy stored
during the periods of increase in voltage would be given up to the circuit
when the voltage decreased. In reality, the electric elasticity of solid and
liquid dielectrics is not perfect, so that the applied voltage has to overcome
acme kind of molecular friction, in addition to the elastic forces. The work
done against friction is converted into heat, and is lost, as far as the circuit
is concerned. This phenomenon is similar to magnetic hysteresis (Par. 89),
and is therefore called dielectric hysteresis. The energy lost per cycle is
proportional to the square of the applied voltage, because both the displace-
ment and the stress are proportional to the voltage.
An imperfect condenser does not give out on discharge the full amount of
energy put into it. After having been discharged and stood some time,
an additional discharge may be obtained; this is known as absorption in .

the dielectric.
An imperfect condenser, that is, one which shows a loss of power from one
cause or another, can be replaced for purposes of calculation by a perfect
condenser with an ohmic conductance shunted around it. This conductance,
or "leakance," as some authors call it, is selected of such a value that the
I^R loss in it is equal to the loss of power from all causes in the given imperfect
condenser. The actual current through the imperfect condenser is considered
—
then as consisting of two components the leading reactive component _

through the ideal condenser, and the loss component, in phase with the volt-
age, through the shunted conductance. In this way, imperfect condensers
can be treated graphically or analytically, according to the ordinary laws of
the electric circuit.
TRANSIENT CURRENTS AND VOLTAGES
138. Transient electric phenomena are such as occur between two
permanent conditions; for instance, when a load suddenly changed, an
is
appreciable time elapses before the generators and the line adapt themselves
to the new conditions, and the currents and the voltages during the inter-
mediate time are called transient. Some electric phenomena are transient
in time (for instance, the short-circuiting of a large alternator), others are
transient in space (the distribution of alternating current in solid conduc-
tors), and some are transient both in time and in space (surges and traveling
waves in long transmission lines).
139. Theory of transient phenomena. The subject is too large and
advanced to be treated here in detail. An elementary treatment of the
subject will be found in W. S. Franklin's "Electric Waves" and in C. P.
Steinmetz's "Electric Discharges, Waves and Impulses." Numerous
formulae and results will be found in Cohen's "Formulae and Tables for the
Calculation of Alternating-current Problems, "Chaps. 5 and 6. For a more ad-
vanced treatment see J. A. Fleming, " The Propagation of Electric Currents;"
A. E. Kennelly, "The Application of Hyperbolic Functions to Electrical
Engineering Problems, "Chap. 6 and foil.; C. P. Steinmetz, "Transient
Electric Phenomena and Oscillations." Numerous articles 'on the subject
will be found in the recent volumes of the A. I. E. E., Elektrotechnische
Zeitschrift a,nd Archiv fur Elektrotecknik.
140. Closing a circuit containing a resistance r (ohms) and an induct-
ance L (henrys) in series with a continuous e.m.f. When the de-enetgized

85
 Sec. 2-141 ELECTRIC AND MAGNETIC CIRCUITS

circuit is suddenly connected to a source of continuous voltage e, the current

gradually rises to the final value io = e/r according to the law

i = i„a-«"'''/^, (140)
where t is time, and « is the base of natural (or hyperbolic) logarithms.
This expression is known as Helmholtz's law. When the source of e.m.f.
is short-circuited the current in the remaining circuit decreases to zero ac«
cording to a similar law
= jV*'"/^. i (141)
141. Periodic e.m.f. When
a de-energized circuit containing r and L
is suddenly connected at the instant t = 0, to a source of alternating
voltage e = Em sin (27r/t-f a), the current in the circuit varies according to
the law
»-^
z
sin {2Tft + a-4>)-~
z
sin (a-0)«-'''/^ (142)

In this equation z = \/r^ + (2vfL) ^ is the impedance of the circuit and is <t>

the phase displacement between the current and the voltage, determined by
tan = 2irfL/r. The angle a is the phase displacement between the voltage
<l>

e and the reference wave which passes through zero at the time t = 0\f is
the frequency. The first term in the expression for i is the current corre-
sponding to the permanent condition, the second term is a transient which
rapidly approaches zero with the time. (See also Eq. 14().)
142. Closing a circuit containing: a resistance r (ohms) and a capacity
C (farads) in series. The charging current is theoretically expressed by
i = i^-'/('<^). (143)
where the current at the first instant. This equation is not applicable
io is
to the beginning of the charge because it .presupposes a sudden jump of the
current from zero to io. In reality, the unavoidable inductance of the circuit
smoothes down the initial change in current.
When a condenser, charged at a voltage e„, is discharged through resist-
ance r, the discharge current at the first instant is theoretically equal to
to = So/t, and then varies according to the law

i^i^-i/^rC) (144)
The voltage across the condenser terminals decreases according to a similar

When a de-energized circuit containing r and C is suddenly connected at

the instant < = to a source of alternating voltage e = Em sin(2ir/t + a), the
current in the circuit will vary according to the law

t = —
z
sin(2x/<-f a-)-0) -— z
sin (a-t-^)*"'/^""^ (146)

In this equation 2= \/r2-{-[l/(27r/C)]2 is theimpedance of the circuit, and <j>

is the phase displacement between the current and the voltage, determined
by cot = 2TrfCr. The angle a is the phase displacement between the voltage
ij>

« and the reference wave which pa.s8e8 through zero at the time < = 0; /is
the frequency. The first term in the expression for i is the current corre-
sponding to the permanent condition, the second term is a transient which
rapidly approaches zero with the time. Compare Par. 141.
143. Single-energy and double-energy transients. The two pre-
ceding cases are examples of single-energy transients, because the energy
is stored in one form only (electromagnetic or electrostatic), and the energy
change consists in an increase or a decrease of the stored energy. In the
case of inductance the energy is that of the magnetic field and in the case of
capacity it is the energy of the electrostatic field. When both inductance
_

and capacity are present, the energy of the circuit is stored in two forms,
and there is a possibility of periodic transformation of the magnetic energy
into the dielectric energy, and vice versa, which constitutes electric oscilla-
tions, surges, and waves. There is also a possibility of a triple-energy
transient, when for instance a synchronous motor is hunting at the end of a
long transmission line which possesses inductance and capacity. In the last

86
 ELECTRIC AND MAGNETIC CIRCUITS SeC. 2-144

i case the total energy of the system is stored not only in the magnetic and the
dielectric forms, but in mechanical form as well.
144. The general differential equation of a circuit containing a
resistance r ohms, inductance L henrys and capacity C farads in
aeries, is
^dH , di . 1 . de ,, _^

where e is the voltage applied to the circmt, and t is time.

When the impressed e.m.f. e is constant (de/dt = 0), two conditions
may arise: r^>-lL/C and r-<4L/C. The intermediate or critical case
r2 = 4L/C is of academic interest only.
146. Non-oscillatory case. In the first case (r2>4L/C) the current
in the circuit is non-oscillatory. It rises_ from zero, reaches a maximum,
and again
falls to zero when the condenser is fully charged; the current never
reverses. The voltage across the condenser gradually rises from zero to its
full value, equal to the applied e.m.f., but never exceeding the latter. During
the discharge both the current and the voltage across the condenser gradually
decrease to zero according to a logarithmic (exponential) law. In practice,
these conditions are usually harmless, and therefore desirable in cases where
oscillations must be suppressed. This is usually done by increasing the
resistance of the circuit until the condition r*>4Z//C is fulfilled.
146. Oscillatory case. In the second case, when r^< 4L/C, the charge
and also the discharge are oscillatory. The oscillations are of decreasing
amplitude, because of the damping caused by the energy consumption in
the resistance. When the condenser is charging, the current is
t=— « sm—ft, (148)

and the voltage across the condenser terminals is

ei =e/ 1 - r'"'/2^(cos^< +^sin ^-t) }

. (149)

For condenser discharge

and
. = e.-^'/2^{cos^. + ;-sin^^.}. (151)

In these expressions q = \/(4L/C) —r^; e is the applied voltage, and eo is the

voltage across the condenser at the beginning of the discharge; c is the base
of natural logarithms.
147. The frequency of oscillation and the logarithmic decrement.
The frequency of oscillations in the preceding case is
/= . , (cycles per sec.) (152)

When the resistancenegligible, that is, r' small compared

is with 4L/C, the
frequency of oscillations is approximately equal to

/o = ^. (153)

Logarithmic decrement. Successive half waves of oscillations de-

crease the more in amplitude, the greater the resistance. The ratio of
the amplitudes of successive half waves, or the decrement of the oscilla-
tion, is t"'' ''
where <i = 1/(2/) is the duration of one-half cycle.

148.Continuous high-frequency oscillations are conveniently pro-

duced by use of a direct-current arc (Duddell). In the Poulsen arc,
the anode is copper and the cathode carbon, while the arc is formed in an
atmosphere ofhydrogen, which appears to increase considerably the in-
tensity of the oscillations. Oscillations have been produced of frequencies
ranging as high as one million per second and of considerable power; they are
87
Sec. 2-149 ELECTRIC AND MAGNETIC CIRCUITS

Successfully used for wireless telegraphy. See Povilsen, V., "System for
Producing Continuous Electric Oscillations," Trans. Int. Elec. Congress, St.
Louis, 1904, Vol. II, p. 963. Also Austin, L. W., "The Production of High-
frequency Oscillations from the Electric Arc," Bulletin of the Bureau of
Standards, Vol. Ill (1907), p. 325.
149. Stored energy. When a considerable amount of energy is liberated
at some point on a transmission line, for instance due to an indirect lightning
stroke, a wave starts along the line carrying this energy to the ends of the
line. Part of it enters the apparatus at the ends, part is reflected and the
rest is converted into heat. Generally speaking, the total energy stored in
the line, or in some part of it, at an instant is
W = ^Li^ iCe^, +
(joules) (154)
where L is the inductance of the lino in henrys, i an instantaneous current, C
the capacity of the line in farads, and e an instantaneous voltage. The term
iLi^ represents the electromagnetic energy, the term iCe'' the electrostatic
energy. At certain instants the current is equal to zero, at others the voltage
is zero, so that the two energies must be equal. Therefore
e_mox /i_
^ (ohms) (155)
imax ' * (7
Thus, knowing the maximum voltage emax, the largest instantaneous current
imax can be calculated, and vice versa. For instance, in the case of a lightning
stroke, the maximum voltage is limited by the disruptive strength of the
insulation to instantaneous voltages, and the maximum current disturbance
may be calculated from the preceding equation.
160. Surge impedance. With concentrated inductance and
capacity, the frequency of oscillations is (Par. 147)
1
/" = -
;^- (156)
2wVLC
With uniformly distributed inductance and capacity, the frequency Is
1
=
/.'
WW
The expression y/L/C is called the natural impedance or the surge
(157>

impedance of the line, and its reciprocal the natural admittance or the
surge admittance. For further information consult the references in Par.
139 above.
ALTEBNATINQ-CURRENT CIRCUITS
161. Sine-waves. In this treatment of alternating-current circuits, a
sine-wave is arbitrarily assumed. For non-sinusoidal currents and volt-
ages see Par. 190 and follow-
ing. Beginning with non- "^
inductive circuits, i.e., cir-
cuits which contain only
resistance, the current at
any instant is proportional
to the instantaneous value f :

of the impressed e.m.f. Plot-

_^J^
ting the instantaneous values
of the e.m.f. and the current,
it is seen. Fig. 24, that the
waves pass through zero and
reach their maximum values
at the same instant. They
are said to be in phase.
162. Instantaneous
values. Lot the amplitude
or the instantaneous maxi-
mum value of the voltage be FiQ. 24.- -Simple sine-waves; non-inductive
Emax, then the instantaneous circuit.
value is
Emax sin 2)r/« (158)
where / the frequency in cycles per second, and I is time in seconds. The
is
angle 2Trfl is in radians If the time of one complete cycle is T (Fig. 24),
/-l/r.
88
I
ELECTRIC AND MAGNETIC CIRCUITS Sec. 2-153

163. Reactive e.m.f. In a circuit which contains inductance only

j
(Par. 67) the current wave lags by 90 electrical degrees, or a quarter of a
J applied e.m.f.
cycle, beliind the Numerically
Ez'=2wfLI (159)
where Ex and / are the root-mean-square or the effective values (160) of
the voltage and the current respectively, L is the inductance in henrys,
and / is the frequency in cycles per second. A similar relation holds true for
the amplitudes of voltage and current, or for the average values.
164. Inductive reactance. For the sake of abbreviation, the expression
2irfL is denoted by x and is called inductive reactance, so that

x = 2irfL =
^ (ohms) (160)

If L in henrys and / in cycles per second, x is in ohms, being equal to the

is
ratio of the reactive voltage to the current. If the voltage is expressed as
in Par. 162, the instantaneous cutrent is

i = - -^— cos 2ir/?, (161)

X
in other words, the current wave lags 90 deg. in phase behind the voltage
wave when the circuit contains inductance only.
166. E.m.f. components. In a circuit which contains resistance
and inductance in series, one portion of the impressed e.m.f. may be
„ considered as consumed in
^^-TP^,-- ^--^' resistance drop and another .,

/^^-?-^$\ I /i^W i7>

1 the counter-e.m.f. of in-
ill

//[ ^/TVvM / /l\\^ ductive reactance. The flux

W
' '

// \J<^ w\J IV^Ci'^tA J

interlinked with the circuit is
// r^^/^y\
^^>J/^ \\ l/^>?*\\k /\ ^° .phase with the current
—(4 ( I Lj /y
f

N. \ \
'

y i
which produces it. The e.m.f.
W\\ \V^^3^J jr jI
//
V >\ ^isy^ / generated in the reactance is
proportional to the rate of
//
I
'Vxi^-'^ change of the flux, and since
\\ -p I
\ \ yy '

^~^^j—^</^
I

I _*;0V i^V^ I
tlie rate of change of the flux
V^;"^^ ' rSi<c ig greatest when the value
'^ passes through zero, the
_
Fia. 25. —E.m.f. and current waves in a
_

e.m.f. is in time-quadrature
with the flux and therefore
circuit containing resistance and reactance in
series. also in time-quadrature with
the current (Fig. 25).
156. Kesultant e.m.f. The current is always in phase with the e.m.f.
which is consumed in resistance, and the impressed e.m.f. is the resultant of
the instantaneous values of the components consumed in resistance and in
the inductive reactance. Referring to Fig. 25, Er is consumed in resistance,
Ex is consumed in overcoming the counter-e.m.f. of inductive reactance,
and E is the resultant or impressed e.m.f.
157. Phase angle. The current is in phase with Er but lags behind
the impressed e.m.f. E by the phase angle determined from the relation

tan0=?^^=*. (162)
r r
the instantaneous applied voltage
If is expressed as in Par. 152, the in-
stantaneous current is
i = Inxax sin(2T/i - 0) (163)
where both 2ir/< and are expressed either in radians or in degrees.
<i> For
the numerical relation between E and I see Par. 165 below.
158. Capacity reactance or condensance. In a circuit which contains
electrostatic capacity or permittance only, Par. 108, the current wave
leads the applied voltage by 90 electrical degrees, or is in leading quadrature
with it. Numerically
Ec = xJ (164)
where

*'"2^ (ohms) (165)

 Sec. 2-159 ELECTRIC AND MAGNETIC CIRCUITS

is calledcapacity reactance, or condensive reactance. When inductive

reactance x (Par. 164) and condensive reactance Xc enter in the same circuit,
xc is considered negative. When C is in farads, Xc is in ohms. See Par. 241*
169. E.m.f. components. In a circuit containing resistance and
condensive reactance in series, the applied e.m.f. may be divided into
two components; one con-
sumed in resistance drop and E
the other in the condensive /^^^\^^\ /TS. ^
1

reactance. The current /yfTE \v\\ //t'^*P\ I I

taken by the condensive re- // p\^~^\ \\ />-~sJV-L ) I

actance is proportional to the // y^^^^'iy \\ //r^ y\r\\ /

rate of change of the e.m.f., I
which is impressed across its TT
h'^^^ II / z: \ \ \ /*
H /
y (
\. V~\j ^/fl ,

terminals, therefore the \\ V f--y y lyA vv /'

counter-e.m.f. of the con-
I j
\.\ ^ // .
| VV^-^oCx^
densive reactance is in time-
\\,.^^^ Er^^^/
'rfiNX^ / I I
quadrature with the current. ^^-A^~l^^^'^ "*1^;*^C^!/ '
I

Referring to Fig. 26, I is the ^^i^ "'

1

^E^"*^^^
total current in phase with Er
which is the e.m.f. consumed
in resistance; Ec is the volt-
Fig. 26. —
E.m.f.'and current waves in a
circuit containing resistance and capacity
age necessary to balance the reactance in series,
counter-e.m.f. of the con-
densive reactance, and E is the total e.m.f. impressed upon the circuit.
It will be seen that in this case the current is leading.
If the instantaneous applied voltage is expressed as in (162), the instanta-
neous current is
t = Imcx sin (2ir/« -f- 0) (1 66)
In this expression, the phase angle between the current and the voltage
is determined from the relation

(^^^>
*-*=2-^r=7-
Terminology. The following terminology used in application of
160.
sine-wave alternating-current circuits is recapitulated here for the sake
of convenience. An instantaneous value of alternating current or voltage
(Fig. 24) is connected with the maximum value or the amplitude by
the relation given in Par. 162. The mean effective value, also called the
root-mean-square value, or simply the effective value of an alternating
current or voltage is defined in Par. 199. For a sine-wave quantity the
effective value is equal to the amplitude divided by \/2; or

E.,, =—^!- = 0.7071 J?™ax. (168)

The mean or average value of a sinusoidal alternating current or voltage

is equal to the maximum value divided by ir/2, or

Eav, =—- = 0.6366iS;„a,. (169)

The ratio between the effective and the average value is called the form
factor (Par. 207) and is equal to 1.11 for sine-waves.
161. Periodic time. The interval of time T in Fig. 24. corresponds to
one complete cycle. The interval of time 7'/2 corresponding to one-half
wave is called an alternation, and for every cycle there arc two alternations.
The frequency or the periodicity of an alternating current may be expressed
either in cycles per second or in alternations per minute. However, the
latter method is not common.
The phase displacement between two currents or two voltages,
162.
or between a current and a voltage, is commonly measured in electrical
degrees. One electrical degree is l/360th part of a complete cycle.
163. Vector representation. .Alternating currents and voltages which
vary according to the sine or ccsine law can be represented graphically by
directed straight lines called vectors (Fig. 27). The length of a vector
represents, to some arbitrary scale, the effective value of the alternating

90
 ELECTRIC AND MAGNETIC CIRCUITS See. 2-164

luantity, while the position of the vector with respect to a selected reference
/ector gives the phase displacement. Counter-clockwise direction of rotation
s always considered positive, so that for instance in the diagram (6) the volt-
ige leads the current by 90 deg. By means of vectors the relative phase
aosition and value of either currents or e.m.fs. can be represented in the
janie manner as forces in mechanics.
164. Vector diagrams for simple series circuits. Referring to Fig.
27, diagrams are shown for circuits containing (a) resistance; (6) inductive
reactance; (c) condensive re-
actance; (d) resistance and
inductive reactance; (e) re-
sistance and condensive re-
actance; (/) resistance, in-
ductive reactance and con-
densive reactance.
166. Ohm's law for
alternating-current cir-
cuits. The impedance (in
ohms) is the ratio of an
alternating voltage .B across
a part of a circuit to the
current / through the circuit.
Fig. 27. —Vector diagram of current
e.m.f.; series circuits.
and Denoting the^impedance by «,
E = zl, (170)
where E and I are the efifec-
tive values. This equation expresses only the numerical relations; it must
be remembered that E and I are not in phase with one another.
166. Impedance consisting of resistance and reactance in series.
In a circuit containing an ohmic resistance r in series with an inductive
reactance x (Par. 166) the impedance is numerically
z = V'r=+x2, (171)
so that numerically,

/= -
. =. (172)
Vr^ + x^
The phase angle, by which the current lags behind the voltage, is found
froni the relation

tan (A =— , or cos <6 =— (173)

r z
167. Impedance consisting of resistance and condensance in series.
In a circuit containing an ohmic resistance r in series with a condensive
reactance Xc (Par. 169), similar relations hold, in which Xe is substituted
for X. The current leads the voltage and the angle 4> is to be considered as
negative.
168. Impedance consisting of resistance, reactance and condens-
ance in series. If a circuit contain both inductive and condensive reactance
(Fig. 27/), the impressed e.m.f. is
E = VEr^ + (Ex-Ecy = V(Ir)-+(.Ix-Ixc)'^. (174)
Dividing E by I, the impedance is

z = -s/r + (.x-Xc)K (ohms) (175)

where
= 2-irfL = oiL
X (see Par. 164) (176)
^ 1 ^J^
^'~ (see Par. 168) (177)
2ir/C "coC
169. Current components parallel circuits of resistance and react-
;

ance. The current, like the e.m.f., can be split into two components,
one in phase and the other in quadrature with the e.m.f. It is convenient
to employ the e.m.f. diagram with series circuits and the current diagram
with parallel circuits. A current diagram is presented in Fig. 28. It pre-
supposes a non-inductive resistance r connected in parallel with a pure
inductive reactance x. The total current

7 = V'/r"-+/x2 (amp.) (178)

91
Sec. 2-170 ELECTRIC AND MAGNETIC CIRCUITS

If E is the voltage across the circuit, then

(amp.)

I^=E~-j--=Eb

I = V(EoV + (Eb)i ='E- = E

In these expressions
: = conductance
 ELECTRIC AND MAGNETIC CIRCUITS Sec. 2-176

resistance and a reactance connected in parallel. The two combinations are

called equivalent when a given impressed alternating voltage produces the
same total current through both, in magnitude and in phase. In other
words, both combinations must have the same impedance e (or admittance y),
and the same phase angle 0. The two resistances and the two reactances
are connected by the relations
„ 1
r,rp = z-=~
. 1

and also (194)

y^ V
176. Calculation of series-parallel circuits. The foregoing relations
are useful in determining the voltage and current relations obtaining in com-
plex series-parallel circuits. For
example, in the .circuit shown
in Fig. 29 the resistance ri in
I— WVA—
'TRRRT — serieswith reactance xi is re-
^s placed by a conductance gi =
with a suscept-
ri/zi^ in parallel
=
ance 6i xi/zi-, where
«i2 = ri2+xi2. (195)
A similar substitution is made
Fig. 29. — Series-parallel combination. for the branch 2, then the
branches 1 and 2 are replaced
by one equivalent branch of
conductance !74=ffi+(72 in parallel with the susceptance 64 = 61 + 62. Now
the branch g\, 64, is replaced by an equivalent series combination consisting
of a resistance ri = gi/y\^ in series with a reactance 0:4 = 64/^4^ where
!/42 = (742 + 645. (196)
The original series-parallel combination is thus reduced to a simple series
^^^rcuit, and we finally have

^T!nowing Vtq and Xeq the total current may be found for a given voltage or vice
versa, from the relations given in Par. 166.

Fig. 30. — Circle diagram for series Fig. 31. — Circle diagram for parallel
circuits. circuits.
177. Circle diagram; series circuits. Drs. F. Bedell and A. C. Crehore
developed a circle diagram which shows the interrelation of the various
constants in an alternating-current circuit when one or more quantities are
varied.

93
Sec. 2-178 ELECTRIC AND MAGNETIC CIRCUITS

,Con8idering the series circuit shown in Fig. 30, let it be required to study
the current when the resistance and reactance are varied, the e.m.f. being
kept constant. With £ as a diameter draw the circle. Obc, then Obc is the
e.m.f. or impedance triangle and 6 is the angle of phase displacement between
I and E. Dividing the current, /, into imaginary components, E/r is laid off
along OC in phase with E, and E/x is laid off along OA in quadrature with E.
Drawing the line AC, and the circles, OB A and OBC, the line, OB, represents
the current, I, both as to value and phase position. If x is constant and r
variable, the point, B, will travel along the circle, OB A, while if r is con-
stant and X variable, the point, B, will travel along the circle, OBC.
178. Circle diagram; parallel circuits. Referring to the parallel
circuit in Fig. 31, let it be required to study the e.m.f. when the conductance
and susceptance are varied, the current remaining constant. With / as
diameter draw the circle Obc, then Obc is the current or admittance triangle
and 6 is the angle of phase displacement between E and I. Dividing the
e.m.f. into components, I/b is laid off along OA in quadrature with /; then
drawing the line, AC, and the circles, OB A and OBC, the line, OB, represents
the e.m.f., E, both as to value and phase position. The circle, OBA, is the
locus of the point, B, when b is constant and (/variable, while the circle, OBC,
is the locus of the point, B, when g is constant and b variable.

o-r-'TJ5WJ0WrWV\Ar-J-
Gener- i.

Fia. 32. —Condensance in parallel Fio. 33. —Load connected to

with inductive impedance. inductive lino.

179.Phase compensation. Condensive reactance connected in

shunt with an inductive impedance can be so adjusted as to bring the
total current more or less in phase with the impressed e.m.f. Referring to
Fig. 32, Xc and the impedance z. are in parallel, where

z.' = r^+x.K
(jgg)
Taking the admittances,
-;(72 = 0;
i,'
bi=—z«'
-andbj"
Xc
~. (199)

In order that I be in phase with E, bi + bt must be equal to zero, or

x, = ~. (200)
Xt
Thus, it is seen that the value of Xe depends upon the resistance, r, as
well as upon x,:

i2.^E-''Ebt:ii = E-J(J^y+t'^y = E^/g^i + bi^ (201)

(202)

ISO. Leading current through an inductive line will raise the e.m.f.
at the receiving end of the circuit. Referring to Fig. 33, let E be the voltage
at the generator end of a circuit, e the voltage at the receiver end, and i the
line current. Let the load be of such a nature that the current is leading
withfrespect to the voltage e. Adding to e the ohmic drop ir in the line
(Fi^ 34a) in phase with i, and the reactive drop ix in leading quadrature
with i, the impressed voltage E is obtained. It will be seen that e; but E<
with a lagging current, E>e
(Fig. 346).
nl. Series resonance. In a constant-potential circuit which contains
Inductive reactance and also condensive reactance in series, it is possible
94
 ELECTRIC AND MAGNETIC CIRCUITS SeC. 2-182

to obtain an enormous rise in e.m.f. by adjusting the reactances or the

frequency. Thus, according to Par. 168,
E = Iz = iVr^ + (x. ~xc)-, (volts) (203)-
The e.m.f. across the condensive reactance is
e = Ixc,
so that

(204)
E Vr*+(.x,-XcP

Fio. 34a. —leading

Effect inductance with
of Fro. 34b. — Effect of inductance with
current. lagging current.

Now, z (the total impedance) may be less than Xe, and in this case e (the
drop across the condenser terminals) will be greater than E (the total impressed
If the frequency is
IHta&.f.).
/=, (cycles per second) (205)
2'Vlc

I iBhall

whic
have
X, = Xe,
Eich condition gives the highest rise in voltage,
ance of the circuit) is assumed to be zero.
If moreover
(206)
r (the resist-

(207)

ed we have an extreme case of voltage resonance.

'his is purely an ideal case, but in any event

E
- when/=-
- = xc
e , . 1
-= (208)

wherein L the coefficient of self-induction in henrys and C the capacity iu

is
farads of the apparatus connected in series. Sometimes the constants of
the circuit are such that a resonance of one of the higher harmonics of the
voltage takes place.
182. Parallel resonance. When an inductive reactance and a condensive
reactance are joined together in parallel, they can be so adjusted or the fre-
quency can be so chosen that current resonance will take place.
Let the total conductance of the combination be g, the inductive sus-
ceptance b, and the condensive susceptance 6c. Then, the total current
7=£3/ = Vff-+(6.-6c)2 (209)
The current through the condensive susceptance is

ic = Ebc, (210)

(21*)

I
Sec. 2-183 ELECTRIC AND MAGNETIC CIRCUITS
But the total admittance y may be smaller than be, and in this case the total
line current / is less than one of its components tc similar relation may A
be proved for ti«. When the frequency is

/= ;=z> (cycles per second) (212)

2irVLC
it follows that
b, = bc, (213)
and
I = Eg, u=-ic. (214)
The line current is comparatively small, but there is a large interchange
of current between the inductance and the capacity, in parallel.
Resonance can occur at only one frequency. Sometimes, in the case
of a complex wave, it occurs at the frequency of one of the component
harmonics instead of the fundamental frequency. In such case, either for
volta?e or current (series or parallel
resonance), the magn tude of the reso-
nant harmonic component is much exag-
gerated, as compared with its normal
magnitude in a non-resonant circuit.
The condition of resonance, except in
tuned circuits where it is specially de-
sired (as in radio-telegraphy), is one to
be avoided.
183. Consonance. Resonance in
primary circuit of a transformer,
the
caused by the proper combination of
inductance and capacity in the second-
—
ary circuit, is called consonance.
181. Alternating-
. . currents and
Fig. 35.— Complex quantities; axes voltages treated by means of com-
of reals and imaginaries. pjex (imaginary) quantities. If e
and e' (Fig. 35) are the projections or
the components of a vector E along two perpendicular axes, then the vector
E may be represented symbolically as
E = e+je', (21.5)

where
i = V-l, (216)
and the dot under E signifies that the magnitude as well as the direction
of E is meant.
185. Addition and subtraction of vectors. Let two vectors of volt-
age be represented as
Ei='e,+je'u (217)
E2 = ei+je't. (218)
Then the sum or the difference of these two vectors is
El = El + Ej = (ei±e-z) +j(e', ± e'2). (219)
186. Rotation of a Vector. Multiplying a vector by j turns it by
90 deg. in the positive direction (counter-clockwise). Thus,
jE =j(e +je') = - e' +ie (220)

because y^ 1 =—
Multiplying a vector by —> rotates the vector by 90 deg.
in the negative direction
.

that is, clockwise. —

A vector E may be also represented symbolically (Fig. 35) as
E = E(coB e+j sin 0) (221)
where E without the dot, on the right hand side of the equation, stands
for the magnitude only.
The operator
V J<t> = cos <i,+j sin <(,, (222)
where t is natural logarithms, turns a vector
the base of by the angle * '

in the positive direction. Thus,

.B (cos « 4- J sin 0)=£(cos e+j sin 9) (cos <l>+j sin «)«=£[co8 (e + <t>) +
j sin {B + <l>). (223)

96
 ELECTRIC AND MAGNETIC CIRCUITS SeC. 2-187.

I The operator
(-;> =co8 <t>
-j sin 4> (224)
•
turns a vector by the angle 4> in the negative direction, that is, clockwise.
187. Impedance and admittance operators. The impedance
operator
Z = r+}X (225)

converts the vector of a current into that of a potential difference across an

impedance (consisting of a resistance r in series with a reactance x). The
admittance operator
Y = g-jb (226)
converts the vector of a voltage appied across the terminals of a conduct-
ance g in parallel with a susceptance 6, into the vector of the total current
through this combination. When b stands for capacity susceptance, as in a
transmission line (Par. 236), Y = g-\-jb. When a current I = i+ji' flows
through the impedance Z — r-\-jx, the required voltage is

E = ZI = {r+jx)(.i+ji'). (227)
or, separating the real and the imaginary quantities,
E='(ir-i'x)+j(,i'r + ix). (228)
In other words, S
a vector such that its horizontal projection e (Fig. 3.5)
is

is equal to (.it — i'x), and the vertical projection is (t'r + tx).

The angle 8 which E fotms with the horizontal axis is determined by

t^^g = p:±^
— tx)
(ir
(229)

188. Networks of conductors. The method given in Par. 29 to 35 is

generalized in the case of alternating e.m.fs.- by writing Kirchhoff'a equations
for the vectors of the currents and of the voltages. With the notation used
above, we have
S/ = 0; 2£=27Z. (230)
Equating the vertical and the horizontal projections of the vectors to zero
separately (Fig. 35), and using expression (228), equations (230) become
2;!; = 0; 2i' = 0; 1

2;(tr-i'a;) = Se; \ (231)

xii'r +
ix) = Ze'. J

If there are n unknown currents or voltages, 2n independent equations of the

form (231)may be written, and from these equations 2n projections of n
unknown vectors can be determined. The problem is thus similar to that
with direct currents, and the references given in Par. 36 may be consulted for
simphfications which may be taken advantage of in practical cases. *
189. The expressions for power and power factor. The average
power expressed through the projections of the vectors is

P = ei+e'i'=EI cos (p, (232)

where e and e' are the projections of the voltage E (Fig. 35), and i and i' are
those of the current /. Note that the power is not a vector quantity.
The power factor is found from the relation
cos </>=cos (9e-9i), (233)
where
9, = tan-i e'/e and S,- = tan"* i'/i. (234)
Or else, the angle <f> is found directly from the relation
tan fli = [(e'/e) -(t7i)l/[l + (e' »•'/«)] (235)
It tan is positive, the current is lagging; otherwise
<l>

spect to the e.m.f. See also Par. 196.

it is leading — with re-

*See also Campbell, G. A. "Cisoidal Oscillations;" Trans. A. I. E. E., Vol.

XXX, 1911, pp. 873 to 913.

7 97
Sec. 2-190 ELECTRIC AND MAGNETIC CIRCUITS

NON-SINUSOIDAL OB COMPLEX WAVES

190. Examples of complex waves. The curves shown in Fig. 3i
illustrate the effect of theinductance and the capacity in a circuit to whicl
is applied an alternating e.m.f., differing from the simple sine-wave. Thi
curves were taken simultaneously with an oscillograph. E is the impressei
e.m.f.; I. the current taken by an inductance coil, and Ic that taken by i

condenser. Fig. 37 shows the circuit.

191. Wave of reactive e.m.f. due to inductive reactance. Assumini
the reluctance of the iron core ii
the inductance coil to be constant
which is approximately true belov
the saturation point, the value o
 ELECTRIC AND MAGNETIC CIRCUITS See. 2-196

where e is an instantaneous value of the voltage in volts, i is the eorre-

U spending instantaneous current in amperes and h — h = T is the interval of
t! time, in seconds, for which the energy is to be determined. The average
It
j
power deUvered during the same interval is
^1 r«2
. eidt (watts) (240)
—(
h:-
12

sine-waves. When
196. Power factor, the current and the voltage
vary according to the sine law, the power P = IE cos 4>, where E and /
are the effective values of the voltage and the current respectively, and
is the phase angle between the two, cos <p being known as the power factor
of the circuit. See also Par. 189.
197. Power factor, complex waves. When e and i are irregular curves,
the average power is found as the average ordinate of a curve, the ordinates
of which are proportional to the product ei. If e and i are resolved into their
harmonics, each harmonic contributes its own share of power as if it
were acting alone, so that the average power is
P = EiIi cos <j>i+E3l3 cos 03 etc., + (241)
where 7i, Is, etc., and Ei,Ez, etc.,are the effective values of the harmonic
currents and voltages respectively, and the angles <j> are the respective phase
displacements.
198. The energy component and the reactive component of volt-
age or current. In a simple harmonic circuit with the voltage E, current
7, and the phase displacement between the two, E cos <^ is called the energy
(j>

component of the voltage and E sin <^ the reactive component of the voltage.
Analogously, I cos is the energy component of the current and I sin ^ is
<t>

the reactive component of the current. Similar components are used in

circuits with non-sinusoidal currents and voltages, provided that these are
first replaced by equivalent sine-waves.

199. Effective value of any wave. The effective value of a variable

current or voltage is defined as that continuous value which gives the same
total i^ loss. Or, if I be the effective value of a variable current i,
'T
Ih-T^ iVdt

from which
I I (joules)

(242)

7= Ht (amp.)

This may be expressed by saying that the effective value of a current or voltage
isequal to the square root of the mean square (r.m.s.) of the variable values. Hot-
wire instruments and electrodynamometer-type instruments indicate directly
the effective values of alternating currents and voltages.
200. Effective value of a sine-wave. For sine-waves the effective values
are given in Par 160. In terms of the maximum value, the effective value
is£«// = 0.7071 Emax.
201. Computation of effective value of a complex wave ; first method.
For irregular waves the following four methods are used in order to
obtain the effective value of the ordinates of a curve, y = f{x). Under the
first method, plot a curve the ordinates of which are equal to y-. Deter-
mine the average ordinate of this curve either by a planimeter or by weigh-
ing the paper on which it is drawn, and take the square root of the value
of this ordinate.
202. Second method. According to Simpson's rule,* divide the curve
•
Simpson's Rule is a formula for computing the area comprised between
a given curve, y = f(x) the axis of abscissse and two given ordinates. Divide
,

the distance between the given ordinates into n equal parts, where n is an
even number, and erect the corresponding ordinates. Let these ordinates,

99
Sec. 2-203 electric and magnetic circuits

into equal parta by k + l equidistant ordinates

A; j/„, yi, etc., j/t, where A: is an i

even number. Tlien the effective value is

V'/f = T/wTl 2/<'' + 4(2/i'+y32 + etc.+i^*_l!)+2(j/2= + y4M-e<c + J/j^ .j)+J/^°]*.

(243)
203. Third method. If the irregular wave is given in terms of its
harmonics, then the effective value is
2/,// = 0. 707 1 VAi^+^J^+etc, (244)
where Ai, A3, etc., are the amplitudes of the separate harmonics.
204. Fourth method. Replot the given irregular curve (Fig. 38) in
polar coordinates (Fig. 39), and determine the area Ap, of the polar curve,
with a planimeter, or by plotting on homogeneous paper of known area and
weight, then cutting out and weighing again the areas are then proportional
;

Fio. 38. —Complex wave

tangular coordinates.
in rec- Fia. 39. — Complex wave
38 in polar coordinates.
of Fig.

to the weights. This area must be expressed in units, j/'mo», as taken from
Fig. 38. This is done by multiplying the area, Ap, of the polar curve by
the ratio) "^S^^ .
y„^^ and pmai are measured in terms of the same units.
V pmax /
The mean effective ordinate is

V'//' in terms of j/» (24,-.)

20s. Generalization of fourth method. The latter method has been

generalized by Mr. C. O. Mailloux for determining the effective value of
direct current taken by an electric car or a train during a run. For a
detailed treatment and numerous practical applications see his paper
" Methode de Determination du Courant Constant Produisant le Mfime
Echauffement qu'un Courant Variable," in the Transactions of the Inter-
national Electrical Congress held at Turin (Italy), 1911.
206. The amplitude factor is the ratio of the maximum ordinate to the
mean effective ordinate, thus
V- "= amplitude factor. (24G)

207. The form factor is the ratio of the mean effective ordinate to the
mean ordinate, thus
V'//
'form factor. (247)

including the two given ones, be denoted 1/0, yi, yi, etc., j/„. Then the area of
the curve is
A==ih[yo + 4{y\+y3 + yi + etc. + yn-i)+2{y2 + yi + yt + etc.+Vn-2)+yn],
where h is the distance between any two adjacent ordinates. The greater
the number of strips (n), the more nearly the foregoing fornmla represents
the area of the given curve.

100
 ELECTRIC AND MAGNETIC CIRCUITS See. 2-208

'
The table in Par. 208 gives the form factor and the amplitude factor
for various mathematical curves.
208. Table of Form Factors and Amplitude Factors.
_„ Reciprocal A»„„i;i„j„ Reciprocal
Name. Trace. 7°™
17

factor.
of form
,„„. ,
7P''*"^%f amplitude
factor. »„„„,
factor. factor.

Rectangle 1.00 1.00 1.00

Semi-ellipse 1.04 0.96 1.22 0.82

Semi-circle 1.22 0.82

Semi-ellipse 1.04 0.96 1.22 0.82

Sine 1.111 0.900 1.414 0.707

Triangle
J^. . .15 0.87 1.73 0.58

Inverse sine 2.10 0.48

Inverse circle or
inverse ellipse 3.23 0.31

209. Wave analysis; Fourier's series. In the mathematical treatment

of alternating wave.'^, it is most convenient to work with those having sine
form; therefore, those waves differing from the sine form are getierally resolved
into both a fundamental sine-wave and its harmonics. The general equation of
any alternating wave, as given by Fourier's series, is
y=Yimn(o,t ei) +
Y2am(.2wt + e2)+ +
... -F yn8in(n<o<-|-9„)
. etc., (248)
. +
wherein y is the ordinate of the resultant wave; Yi, Yi, Fn, etc., are . . .

the maximum ordinates of the first, second, nth, etc., harmonics; . .

6i, 62, . dn, the constant angles which determine the relative time-
. .

phase position of the corresponding harmonics, and ai = 2x/ the angular

velocity of the generating vector of the fundamental wave.
210. Wave analysis; Fischer-Hinnen's method. By inspection it
can be said that waves having like loops above and below the time axis
contain only odd harmonics, while waves having unlike loops above and
below the axis contain both even and odd harmonics. A direct method of
wave analysis given by J. Fischer-Hinnen* is based on the following
equations:
A„ = {yi+ys+yii +. j/2n-2 — y2 — yt — yio Vin.i) (249)
and
B„: (.yi+yi+yi+ j/2n-i — ys — yj — yii — j/2„.,) (250)
wherein yi, yi j/„ are ordinates at points along the base of the half
. . .

wave, which is divided into 2m equal parts, and An and B„ are the ordinates
of the nth harmonics lying 90 time-degrees apart. The maximum ordinate
of the nth harmonic is y/ An'^+Bn'^, and its time phase displacement from
the resultant wave is

e, = tan-i(-f^), (251)

• Elek. Zeit., Vol. XXII, p. 396 (1901). Also P. M. IJncoln, Elec. Jour.,
Vol. V, p. 286 (1908).

^ 101
Sec. 2-211 ELECTRIC AND MAGNETIC CIRCUITS

0„ being measured in terms of the nth harmonic. Assuming time measured to

the right and ordinates measured up as positive, and quantities measured
in opposite directions as negative, positive values of $„ indicate that the
nearest intersection of the nth harmonic with the axis is to the right of the
intersection of the resultant wave with the axis, and positive values of Bn
indicate that the nth harmonic is rising at its nearest intersection with the
time axis. The values obtained with the above equations for the tith
harmonic are affected by the harmonics which are multiples thereof, that is
2n, 3«, etc. This correction is practically negligible for all harmonics, except
the first or fundamental, and a correction rarely needs to be carried beyond
the ninth harmonic. Since wave forms in practice almost never contain
even harmonics, they do not enter into the correction, and denoting the
corrected values by prime, we have:
A'n'= A„ — A'^n — A'in — A'^n — {252)
and
B'„=B„+B'3n-B'6n+5'7„- . . . (253)
When applying this to the first harmonic. An is the ordinate of the re-
sultant wave at yo (Fig. 406), and Bn is the ordinate 90 time-degrees there-
from at yi.

Fig. 40a. —Wave analysis. Par. 211. Fio. 40b. Wave analysis, Par. 211.

311. Example of wave analysis. As an example,* assume the wave

given in Fig. 40o, which is split into three harmonics; the first or funda-
mental, the third and the fifth. Fig. 406 shows the method of determining
a given harmonic, in this case the third. The base of the wave is divided
jnto 2n or six equal parts and ordinates erected. Assume the ordinates to
measure as follows:
yi = 676; 2/2 = 660; j/3 = 940; j/4 = 1004; 2/5 = 554; yt = 0. (254)
then,
1004-660 ,,,,
^, = J(j/4-2/2)=-
, ,, ,
5 "114.7, (255)

and
Ba = 1(2/1+2/6 •2/>) = 676 + 554-940 '90.7. (256)

The maximum ordinate is

V'(J14.7)»+(96.7)« -150 (257)

and the phase angle is

e, = tan-'(
gg^)
- -50 deg.t (258)

manner it is found that At= —92.8, and Bs = 37.4. In this

In a similar
example the wave contains only the third and the fifth harmonics; therefore,
the fundamental is determined as follows:

Ai =2/0- vl 'a -^'6 = 0-114. 7 + 92.8 21.9;

Bi = 2/j +B'i -B'i = 940 + 96.7 - 37.4 = 999.3;
9i = tan-i(21.9/999.3) = l deg. 15 min. (approx.)

• Elec. Jour., Vol. V, p. 386 (1908).

t Fifty deg. in the terms of the third harmonic, or 60/3 deg. in terms of
the resultant

102
 ELECTRIC AND MAGNETIC CIRCUITS SeC. 2-212
I

1 aia. Wave analysis tables are available (Published by John Wiley and
Sons, inc.,) by means of which an irregular wave may be easily analyzed
j

i
,

' into its harmonics by taking a sufficient number of ordinates. For the
use of these tables see the author's " Experimental Electrical Engineering,"
I

Volume II, Chapter 31; John Wiley and Sons, New York, 1911.
POLYPHASE SYSTEMS
213. A polyphase system is an alternating-current circuit or network
to which are applied two or more e.m.fs. of the same frequency, but dis-
I placed in phase by a fixed amount relatively to one another.

{^l\
Sec. 2-217 ELECTRIC AND MAGNETIC CIRCUITS
 ELECTRIC AND MAGNETIC CIRCUITS SeC. 2-218

The relation between the star currents I, and the mesh currents J™ (Fig.
456) is

/. = 2J„ sin . (260)

218. Three-phase Y
and A connections. In a three-phase system
the star connection is also called the Y-connoction (Fig. 46a), and the mesh
is called the delta connection (Fig. 46&). The relations of the currents
and the voltages are (Figs. 47a and 47b).
E =Ev\/3~ =1.732Ey,and I = -^=z = Yjjz2
^^^^^

FiG. 49. —Two-phase e.m.fs. and currents.

19. Two-phase star and ring connections. In a two-phase
Item (Fig. 48) the relations of the currents and the voltages are (Fig. 49)
/- I- I.
E„= V2 =IAUE,; /m = 77? = T^:i^ = 0.7071/, (262)
E,
V^ 1.414
where the subscripts m and s refer to the mesh and the star respectively
(Par. 217)

-J ,.\\:J -

Fig. 50. —Two-phase three-wire system.

Two-phase three-wire system. With a two-phase three-wire
330.
system (Fig. 50) the current in the common or return wire is v'2 times
the_current in each phase' (Fig. 51), and the voltage between the phases is
V 2 times the voltage between each phase and the common return.

105
Sec. 2-221 ELECTRIC AND MAGNETIC CIRCUITS

221. Polyphase power. The total power in a symmetrical n-phase

system is given by the formula
P = nI.E, = nImEm cos
cos . (263)
In an unsymmetrical or unbalanced system the
total power is found
by summing up the power in the separate phases.
222. Three-phase power. In a three-phase system (Fig. 46), the power
P = MyEy cos = 3/^ £?^ COS = lyE^y/Z cos
<f, (watts) (264) <t>

if the currents are in amperes and the voltages in volts.

223. Two-phase power. In a quarter-phase system (Fig. 47) the
power
P = 47^, cos = 4/m^m cos = 2\/2/<^m cos <^ (watts) (265)
224. An equivalent single-phase circuit is a circuit which is used in
computations relating to polyphase transmission lines and machinery.
For three-phase circuits some engineers
use a single-phase circuit with a vol-
tage equal to the Y-voltageof the three-
phase system, and the power equal to
that in one phase. Others use a single-
phase circuit having a voltage equal
to the delta voltage of the three-phase
circuit, and transmitting the power
equal to the total power in the three
phases. Both methods lead to the
same result, provided that the assump-
tions are consistently carried out.
225. Unbalanced polyphase cir-
cuits are treated as separate single-
phase circuits and then combined into
one. Assuming a three-phase system
with a line voltage triangle as shown
in Fig. 52 and an unbalanced load, E\,
El and Ez, are given. (They form the
Constructing semicir-
triangle abc.)
cles on E\, El, and Ei as diameters, Flo. 51. — E.m.fs. and currents in
two-phase three-wire system.
the e.m.f. triangle for each branch is
constructed (Par. 165). We have
El Ei
(266)

Fia. 52. —Unbalanced three-phase system.

The currents, t'l, tj and
iz, are in phase with the ir drops in their respective
branches. These can be conveniently combined by prolonging the ir lines
until they intersect, and laying off the currents, i, from the intersection.
The main currents, JTi, It and />, are found by taking the vector sum of the
branch currents, ii and iu ii and iz, iz and t'l, respectively.

106
 ELECTRIC AND MAGNETIC CIRCUITS See. 2-226

226. Unbalanced star-connected system. Let, in Fig. 44a, all the star
voltages f!s be different from each other, and let the admittances of the
branches between the two neutral points be Fi, Yi, etc., also all different.
Let Po be the potential difference between the two neutral points, the vector
flo being measured in the same direction as the phase voltages Jp$. Then
the currents in the individual phases are:
h = Y^(E.-Eo) 1
^^'''^
h=Y2m-Eo),et<:. i
where
^o =
^f (268)

First, f!o is computed from eq. (268) and then the currents determined from
eq. (267). All the quantities in eq. (267) and (268) are understood to be
vectors in complex notation (Pars. 184 to 187). When there is a common
return conductor of appreciable impedance, the foregoing expressions are
applicable, if the given n-phase system be considered as an (n+1) -phase
still
system, the last phase consisting of the return conductor for which ^, = 0.
227. Three-phase, unbalanced star-connected system. Some of
the special cases of the foregoing formulae are as follows: (a) the load admit-
tances are balanced, the applied voltages unsymmetrical, no common re-
turn conductor:
.Po=j2.F (269)
1 (6) same, with a return conductor of admittance Yo:

(c) When the load admittances are unequal, the general equations (267)
and (268) must be vised, whether the voltages are balanced or not.
228. Resolution of an unbalanced three-phase system into two
balanced systems. It is sometimes convenient to represent a given
system of three unequal delta voltages as a result of superposition of two
balanced systems of voltages of opposite phase sequence. This is expressed
symbolically by the vectorial equations:

E2 = Aa+Ba-^ I . (271)
Ei^Aa-i+Ba j

In these equations ^i, Eit -Ps are the given unbalanced voltages, and 4 and
B are the component vectors which together make vector Ei. The factor
o = €j2ir/3 turns a vector in the positive direction (counter-clockwise) by 120
degrees (Par. 186). It will thus be seen that the balanced 4-system has
its vectors numbered counter-clockwise, while the vectors in the B-system
are numbered clockwise. Only two of the three equations are independent
because
Ei Ei+E} =
+
^^
^^k229. Determination of the balanced components. When .^i, E2,
(272)

^^Bd Ei are given, we have from eq. (271)

^^^P' , _Ei^—Ei<£2 1

m
^^^wnen
is^'
the principle of superposition is applicable, that is in circuits without
satiu-ation, the currents may be determined for the systems A and B separ-
ately, using the simple relationships (Par. 218) which hold for a balanced
system, and then added to obtain the actual currents. For details, applica-
tions, and an extension to n phases, see C. L. Fortescue, Trans. A. I. E. E.,
1918, Vol. 37, p. 1027; J. Slepain, Electrical World, 1920, Vol. 75, p. 313.
230. Higher haxmonics in polyphase systems. In a balanced n-
phase system the time angle between two consecutive star voltages is 2ir/n.
If the voltage wave has a g-th harmonic, the angle between the phases of
these harmonics will be 2ir3/n. When q = n, 3n, 5n, etc., the g-th harmonics

107
Sec. 2-230 electric and magnetic circuits
in the voltages are in phase with each other. When the neutral points
all
of the system are isolated, such harmonics give rise to the so-called oscillat-
ing neutral. With the grounded neutrals, currents of the corresponding ,

frequency flow through all the phases and return through the ground. In \

the three-phase system the harmonic voltages in phase with one another are
the 3rd, the 9th, the 15th, etc.
231a. Harmonics in mesh voltages. Harmonics of the order n, 3n, 5n,
etc., even if present in the star voltages, cannot appear in the mesh voltages.
Thus, in a balanced three-phase system, harmonics of the following order are
absent in delta voltages: 3rd, 9th, 15th, etc., although they may exist in star
voltages and in the line currents, and may give rise to inductive interference
and to other troubles.
2316. Harmonics in mesh and star currents. In a mesh or ring (Fig.
446) the harmonic currents of the order q = », 3h, 5n, etc. (Par. 230) are in
phase with one another and may cause large circulating currents, even though
*
they are absent in the line currents.
232. For further treatment of the current and voltage relations
with unbalanced loads and unsymmetrical voltages sec the last few
chapters, in Dr. Steinmetz's "Alternating-current phenomena"; also the
author's "Experimental Electrical Engineering," Vol. II, Chapter 25, and
his'Ueber mehrphasige Stromsysteme bei ungleichmiissiger Belastung"
(Enke, Stuttgart, 1900). For the "V" and "T" connections of trans-
formers, and for six-phase connections, see Sec. 6, on tranisformers. Also see
Sec. 11, on Power Transmission, for further treatment of the calculation of
polyphase systems, and Sec. 12, on Distribution Systems.
UNIFORMLY DISTRIBUTED RESISTANCE, REACTANCE, CAPAC-
ITY AND LEAKAGE
233. Uniformly distributed properties. In a transmission line the
resistance, the reactance, and the capacity are uniformly distributed.
Besides, there may be appreciable leakage to the ground or between the
wires, which leakage for the purposes of computation may also be assumed
to be uniformly distributed. Under such conditions the current along the
line at any certain instant is different indifferent places; in other words, the
current is a function not only of time t but also of the distance s from the
receiver end.
234. Continuous impressed e.m.f. For a direct-current line
possessing a resistance of r ohms per unit length and a leakage conductance
of mhos per unit length, the current and the voltage relations at a distance
« from the receiver end are expressed by the differential equations,
d^i d'^e
^^^^rgi, and ^-^-,
= roe. (274)
The solution of these equations is of the form
i = j4i«-™-|-Aj«'«, (275)
« = fl^«-m.-t-Bj«m.; (276)

where m = v ro, and A\, Ai, Bi and B?, are the constants of Integration which
are determined by the electrical conditions at some one point of the line.
235. Solution of continuous-current case. The solution of the fore-
going differential equations is preferably expressed through hyperbolic
functions, t >n the form
i = Ci Cosh ms+C2 Sinh ms; (277)
e = £)i Cos h ms+Dt Sinh ma; (278)
* For a detailed treatment see V. Karapetoff, "Harmonics in Symmetrical
Jlf-phase Systems," Electrical World, 1918, Vol. 71, p. 660.
t For a simple theory of hyperbolic functions see Seaver's "Mathematical
Handbook," Sec. Ill; also somewhat more advanced, "Hyperbolic Func-
tions," by McMahon. The best tables of hyperbolic functions of real
hyperbolic angles are probably those by Becker and van Orstrand, published
by the Smithsonian Institution. Tables of hyperbolic functions of com-
plex angles over a limited range will be found in' the above-mentioned book
by McMahon, and also in the General Electric Review, Supplement, May,
1910, and in the Harvard Engineering Jourrial, Vol. X, No. 4 and Vol. II,
No. 2. See also A. E. Kennelly, "Tables and Chart Atlas of Complex
Hyperbolic and Circular Functions," Harvard Univ. Press, 1914,
108
 ELECTRIC AND MAGNETIC CIRCUITS Sec. 2-236

f where C\, Ci, Di, and Di are the constants of integration which depend upon
the given conditions at some one point on the line. For example, if the
'*
I
receiver current I2 and the receiver voltage Ei are given, the constants have
"
j
the following values:
'1
Ci = Ir, C2=Ei'^-; Di = Ei;Di = Ii~- (279)
! m g
'

Thus, knowing i and e at the receiver end, their values may be calculated for
the sending end or for any point on the line. For further details see the first
;
i few chapters of A. E. Kennelly's "The Application of Hyperbolic Functions
I
to Electrical Engineering Problems."
j
Another form of solution, employing the exponential method instead
! of the hyperbolic, will be found in the Transactions of the A. I. E. E.* for
; 1911, where the problem discussed is one of telegraphic transmission over
; long aerial-wire circuits by means of the closed-circuit Morse system widely
i used in America.
236. Alternating impressed e.m.f. Let a sine-wave alternating voltage
I
be applied to an equivalent single-phase line (Par. 224) with uniformly dis-
tributed characteristics. Let the resistance and the inductive reactance of
the line be r ohms and x ohms per unit length, respectively, so that the series
;
impedance is Z = r+jx ohms per unit length. Let the condensivesusceptance
'

and the leakage conductance be b and g mhos, per unit length respectively,
so that the shunted admittance is Y='Q—jb mhos per unit length. The cur-
rent and the voltage relations at a distance s from the receiver end of the
j
line are expressed by the differential equations
d^j d"'E
-T^2=M27, and --- = il/2£
i

I
(280)
^
I
ds ds^ '

where M ^y/YZ. In these expressions 7, E and M

are complex quantities,
(Par. 184), and the magnitude and the phase of the current and the voltage
vary from point to point, remaining at the same time sine fc.actions. In
other words, the current and the voltage are sine functions of time t, and such
functions of s as to satisfy the above-given equations. The parameter M
characterizes the line and is independent of either t or s. The solution of
these equations is of the form

m I^A^i-^^ + A^t^^'
E^B^t-^^+B/^^'
where the constants of integration Ai, Ai, Bi and Bz are complex quantities
(281)

(282)

These constants are determined by the electrical conditions at some one point
of the line, for instance, when the current and the voltage at one point are
given in magnitude and in relative phase position.
237. Solution of alternating-current case. The solution of the fore-
going differential equations is preferably expressed through hyperbolic
functions (Par. 236) of the complex angle Ms. Namely,
I = Ci Coah MS + C2 Sinh Ms; (283)
E = bi Cosh Ms+ Di Sinh Ms; (284)
where the complex quantities Ci, Cj, Di, and Di are the constants of integra-
tion which depend upon the given conditions at some one point of the line.
For example, if the receiver voltage Ei and the receiver current Ji are
given in magnitude and in phase (at s = 0) the constants of integration have
the following values:

Ci = n; C2 = Ei jj;Di
Y
= Er,Dt = Ii —
M (285)
Thus, knowing / and E at the receiver end, their values may be calculated
for the sending end or at any other point on the line.
238. The general relationship between the currents and the voltages
.at the two ends of a line of the length I is:

h = j2Cosh Ml-^Ei{Y/M) Binh Ml (286)

El = Ei Cosh Ml + JiiM/Y) Sinh Ml (287)
• Fowle, F. F. "Telegraph Transmission; " Trans. A. I. E. E., 1911, Vol.
XXX, Part II, p. 1683.

109
Sec. 2-239 ELECTRIC AND MAGNETIC CIRCUITS

If any twoof the four quantities Eu Ei, h, and /s are given, the other twi'
may be determined from these two simultaneous equations.
239. Methods of computation. Numerical computations connectct,
with eq. (280) and (287) may be performed in accordance with one of thr
following methods:
(1) Tables and charts of hyperbolic functions of complex variables uri
available, but the intervals are too large, and the interpolation is botl
tedious and inaccurate.
(2) Tables of hyperbolic and circular functions of real angles are available
with much smaller intervals between consecutive values, making the inter-!
polation in most cases unnecessary. When using such tables the follow-
ing relationships are taken advantage of:
Sinh (a+jb) = Sinh o Cos b+j Cosh a Sin b (288)
Cosh (a+jb) = Cosh a Cos b+j Sinh o Sin b (289)
(3) The hyperbolic functions of the complex angle Ml are expanded into
the infinite series,
SinhMl -=Ml + k(Ml)> + ^la{Ml)^+ etc. (290)
Coah Ml =l + i{MD^+2\(.Ml)*+ etc. (291),
For the longest transmission lines in use or projected, the second term is
small as compared to the first, and the third is altogether negligible. r

(4) Graphical approximate solutions, simplified formulae, sets of curves,

etc., have been proposed at different times for various problems connectedi
with eq. (286) and (287). They refer only to specific applications, such as
power transmission, telephone transmission, radio antenna oscillations, etc.;
240. References to other literature. For further details and applica-
tion of the foregoing equations to power-transmission lines and to the prop-
agation of currents in telephone and telegraph lines see C. P. Steinmetz,
"Theory and Calculation of Transient Electric Phenomena and Oscillations;"
J. A. Fleming, "The Propagation of Electric Currents in Telephone and
Telegraph Conductors;" F. E. Pernot, "Electrical Phenomena in Parallel
Conductors (Wiley).
CAPACITY IN ALTERNATINQ-CUEEENT CIRCUITS
241. In addition to the general information contained in Par. 158-176
the following more specific formulae are useful in practice.
242. Capacity susceptance. When an alternating-current circuit
contains capacity only, the relationship between the current and the volt-
age (Par. 168) may be also represented as
Ic = bcEc (292)

6c«=l/x« = 2ir/C (293)

The quantity he is called the capacity susceptance, and is measured in mhos
when / is in cycles per sec. and C is in farads.
243. Capacity and inductance in parallel. When a capacity C and a
pure inductance L are connected in parallel, the equivalent susceptance is

^ = ^'-^' = 2;|l-''^^^ (294)

and the total current through the combination is

I==bE - (295)
When b,>hc the current lags behind the voltage by 90 dog.; when b,<bc
the current leads the voltage by 90 deg. See Par. 182.
244. Capacity in parallel with a conductance. With the notation in
Pars. 242 and 19, the admittance (Par. 169) of the combination, in mhos, is

V = Vff^ + fcT' = y/{l/r,y+{2itfC)i (296)

Thus, an imperfect or leaky condenser may be replaced by a perfect con-
denser with a conductance in parallel, according to formula (296). When
r is in ohms, C must be in farads, and not in microfarads.
245. Capacity in series with a resistance. The impedance of the
combination, in ohms, is
z= V'r.5 + (1/?T/C)2 (297)

110
 i ELECTRIC AND MAGNETIC CIRCUITS See. 2-246

n 246. Equivalent series and parallel combinations of capacity and

resistance. The equations given in Par. 176 hold true, provided that
tf ;he values of capacity susceptance, admittance and impedance are used
iliis given in Pars. 243 to 245.
The equivalent values are also sometimes
called the effective values of resistance, conductance, reactance and suscept-
"
I

tfiance respectively, although the term equivalent is preferable.

i' 247. Combinations of capacity, inductance and resistance. When
the effect of the capacity predominates, the value of its susceptance (when
'

f in parallel with the inductance) is corrected for the effect of the inductance
' (Par. 243) and the combination is treated as a resistance and a capacity
•only. Similarly, a correction is made in the value of capacity reactance
when an inductive reactance is in series with it. When the effect of the
inductance predominates, corrections are made for the capacity effect in the
formulas for the inductive reactances or susceptance. See Par. 168.

BIBLIOGRAPHY
General reference literature,
i
248.
—
Arnold, E. "Die Gleichstrommaschine;" 2 Volumes, Berlin, Julius

i
Springer,1920.
—
Arnold, E. "Die Wechselstromtechnik; 5 Volumes, Berlin, Julius
'

'
Springer,
— " Elements Electromagnetic Theory; " New York, The
1910-1912.
B.4.RNETT, S. J. of

and Crehobe, A. — "Alternating Currents;" New York,

:
Macniillan Company, 1903.
i
Bedell, F.,
McGraw-Hill Book Co., Inc., 1909.
j

Ben'ISchke, —
a. "Die Wissenschaftlichen Grundlagen der Elektro-
technik; " Berlin, Julius Springer, 1907.
I

—
C.vMPBELL, A. "The Electron Theory;" Cambridge, University Press,
England, 1913.
—
Child, C. D. "Electric Arcs;" New York, D. Van Nostrand Company,
1913.
—
Christie, C. V. "Electrical Engineering;" New York, McGraw-Hill
Book Company, Inc., 1917.
—
Cohen, L. "Formulae and Tables for the Calculation of Alternating-cur-
rent Problems;" New York, McGraw-Hill Book Company, Inc., 1913.
Cramp, W. and S.mith, C. F.—" Vectors and Vector Diagrams;" New
York, Longmans, Green & Company, 1909.
—
Drysdale, C. V. "The Foundations of Alternating-current Theory;".
London, Edward Arnold, 1910.
—
Dwight, H. B. "Transmission Line Formulas;" New York, D. Van
—
Nostrand Company, 1913.
EwiNG, J. A. " The Magnetic Induction in Iron and Other Metals; " Lon-
don, Electrician Printing & Pub. Co., Ltd., 1900.
—
Fleming, J. A. "The Propagation of Electric Currents;" New York,
D. Van Nostrand Company, 1911. —
Foster, G. C. and Porter, A. W. " Joubert's Elementary Treatise on
Electricity and Magnetism;" London; Longmans, Green & Company, New
York, 1909.
Franklin, W. S. — "Electric Waves;" New York, The Macmillan Com-
pany, 1909.
Franklin, W. —
and Williamson, R. B. " The Elements of Alternating
S.,
Currents;" New York, The Macmillan Company, 1904.
—
Franklin, W. S. and Esty, W. "The Elements of Electrical Engineer-
ing;" New York, The Macmillan Company, 1914.
Gerard, E.—" Electricity and Magnetism;" New York, McGraw-Hill
Book Company, Inc., 1897.
He.vviside, O.—" Electromagnetic Theory," 2 Volumes; London, Elec-
trician Printing & Publishing Co., Ltd.,
— 1899.
Herzog, AND Feldmann, C. p. " Die Berechnung Elektrischer Leit-
J.,
ungsnetze in Theorie und Praxis;" Berlin, Julius Springer, 1905.
—
Jeans, J. H. "Mathematical Theory of Electricity and Magnetism;"
Cambridge, University Press, England, 1908.
—
Jones, H. C. "The Electrical Nature of Matter and Radioactivity;"
New York, D. Van Nostrand Co., 1911.
—
Karapetopp, V. " The Electric Circuit; " New York, McGraw-Hill Book
Co., Inc., 1912.

Ill
 Sec. 2-246 electric and magnetic circuits
KXrapetoff, V. —"The Magnetic Circuit;" New York, McGraw-Hill
Book Co., Inc., 1911.
—
Kennelly, a. E. "The Application of Hyperbolic Functions to Elec-
Engineering Problems;" London, University Press, 1912.
trical
—
La Coub and Bragstad. "Alternating Currents;" New York, Long-
mans, Green & Company, 1913.
——
Lamb, C. G. "Alternating Currents;" London, Edward Arnold, 1906.
Lodge, O. "Modern Views of Electricity;" London, The Macmillan!
Company, 1907.
Mascart, M. E. and Joubert, J. A.
—
"A Treatise on Electricity and
Magnetism," 2 Volumes; London, Thos. De La Rue & Co., 1888.
—
Maxwell, J. Clerk. "A Treatise on Electricity and Magnetism," 2
> —
Volumes; London, Clarendon Press, 1904.
NiPHER, F. E. "Electricity and Magnetism;" St. Louis, Mo., J. L.
Boland Book & Stationery Company, 1895.
—
Oruch, E. "Kapazitat und Induktivitftt; " Berlin, C. Vieweg, 1909.
—
Patterson, G. W. "Revolving Vectors;" New York, The Macmillan
Pender, H. — "Principles
Co., 1912.
Electrical Engineering;" New York, Mc-
of
Graw-Hill Book Co.,
Rasch, E. — "The Electric Arc;" New York, D. Van Nostrand Co., 1913.
1910-11.
Inc.,

ROESSLER, G. — "Die Fernleitung von Wechselstromen; " Berlin, Julius

—"The Theory Alternating Currents;" Cambridge Univ.
Springer, 1905.
Russell, A. of

Steinmetz, C. P. — "Theoretical Elements

Press, 1914.
Engineering;"
of Electrical
New York, McGraw-Hill
— Theory
Book Company, 1909. Inc.,
Steinmetz, C. P. "and Calculation Alternating-current Phe-
of
nomena;" New York, McGraw-Hill Book Company, Inc., 1908.
Steinmetz, C. P.—^"Theory and Calculation of Transient Electric Phe-
nomena and Oscillations;" New York, McGraw-Hill Book Co., Inc., 1911.
—
Thomalen, a. " Electrical Engineering;" New York, Longmans, Green
& Co., 1910.
— " Elements
Thomson, J. J. of the Mathematical Theory of Electricity
and Magnetism;" New' York, D. Van Nostrand Co., 1904.
Thomson, J. J.— "Notes on Recent Researches in Electricity and Mag-
netism;" London, Clarendon Press, 1893.
—
Webster, A. G. " Theory of Electricity and Magnetism; " London, Mao-
taillan & Company, 1897.

112
 SECTION 3

MEASUREMENTS AND MEASURING

APPARATUS
BY F. MALCOLM FARMER, M.E.
Chief Engineer, Electrical Testing Laboratories; Fellow, American Inatitutt
of Electrical Engineers; Member American Society of Mechanical
Engineers

GEORGE K. BURGESS, SC.D.,

Chief of Metallurgical Division U. S. Bureau of Standards, Chairman Pyrome-
ter Com. Nat. Res. Council; Member Board of Editors Physical Review;
Fellow Am. Phys. Soc; Member Fr. Phys. Soc, A. I. M. M. E.,
A. S. T. M., Brit. Iron and Steel Inst., Wash. Acad.
Sci. and Wash. Phil. Soc.

PAUL D. FOOTE, Ph.D.

Chief of Pyrometer Section U. S. Bureau of Standards; Sec. Pyrometer Com.
Nat. Res. Council; Editor Jour. Optical Soc. of Am.; Fellow Am. Phys.
Soc, Member Fr. Phys. Soc, Optical Soc. of Am. Wash.
^ Acad. Sci. and Wash. Phil. Soc

REGINALD J. S. PIGOTT
ks Manager, Crosby Steam Gage and Valve Co.; Member American Insti-
tute of Electrical Engineers; Member A. S. M. E., Member S. A. E.,
Chairman, Fluid Meter Committee, A. S. M. E.

AND WILLIAM J. DRISKO

Professor of Physics, Massachusetts Institute of Technology
CONTENTS
{Numbers refer to Paragraphs)
ELECTRIC AND MAQNETIC MEASUBEMENTS
General 1 Curve-drawing Instruments 235
Galvanometers and Detectors 8 Inductance Measurements 240
Continuous E.m.f. Measurements 42 Capacitance Measurements 254
Alternating E.m.f. Measurements 63 Wave-form Measurements 267
Continuous-current Measurements 82 Frequency Measurements 278
Alternating-current Measurements 97 Slip Measurements 283
Resistance Measurements 110 Magnetic Measurements 292
Power Measurements 149 Bibliography 322
Energy Measurements 186

MECHANICAL POWER MEASUREMENTS

Torque Measurements 323 Speed Measurements 333
THERMOMETRY, PYROMETRY AND HEAT CONDUCTIVITY
Thermometry 336 Heat Conductivity 385
Pyrometry 341 Bibliography 386
FUEL AND GAS ANALYSIS, 387
WATER, GAS AND STEAM METERS
AIR FLOW MEASUREMENTS
Water Meters 403 Gas Meters and Air Meters 417
PRECISION OF MEASUREMENTS, 430

8 113
 SECTION 3

MEASUREMENTS AND MEASURING APPARATUS

ELECTRIC AND MAGNETIC MEASUREMENTS
> BY F. MALCOLM FARMER, M.E.
GENERAL
1. The measurement of any given quantity is the comparison of
that quantity with another quantity of the same kind which has been chosen
as a unit. The unit may be a purely arbitrary quantity with no rational
significance, such as the foot and the pound, or it may have a very definite
meaning, as the centimeter and the gram. The units used in electrical
measurements belong to the latter class because they are based on the centi-
meter-gram-second or C.G.S. system. The C.G.S. system (Sec. 1)
is the fundamental system upon which all physical measurements have been
based, on the theory that all physical phenomena are the result of matter
and motion, that is, space (centimeters), mass (grams) and time- (seconds).
2. Measurements classified —
according to precision. Electrical
measurements may be divided, in a very general way, into three classes,
(a) High-precision measurements, such as those made at the various
national standardizing laboratories in connection with the establishment
and maintenance of standards. Every precaution is observed to obtain
the highest possible degree of accuracy. Expense is a secondary considera-
tion, (b) Commercial laboratory measurements, where the object
is to secure results which are reliable and accurate, but only to the degree
justified by commercial and engineering requirements. The cost must be
a minimum, (c) Commercial measurements are those involved in the
production, distribution and sale of energy. The scope of the subject in
this section is limited to the last two classes.
3. A standard is a concrete representation of a unit. The fundamental
C.G.S. units are difficult to represent and early in the development of the art
the need for a system of units which could be used in electrical measurements
was recognized, and resulted in the establishment of the "practical" units
(see Sec. 1). These units are derived from the fundamental C.G.S. units
and can be represented by definite, concrete and reproducible standards. _
The distinction drayyn between primary and secondary standards is
largely a matter of viewpoint. In general, however, primary standards may
be considered as those which represent directly by definition the unit involved,
such as the mercury ohm, the silver voltameter and the saturated cadmium
cell, made according to certain specifications. Secondary standards are the
more practicable working standards which are standardized by comparison
with primary standards and used as the basis of all ordinary measurements.
They include, for example, the manganin standard resistances and the ordi-
nary Weston-typo standard cell. Primary standards are, in general, main-
tained only by the government custodians of the standards in the various
countries; whereas secondary or working standards, based on these primary
standards, serve as the fundamental basis of practical measurements in engi-
neering and commercial fields.
4. The precision obtainable in an electrical measurement depends
upon the various factors which enter into the determination; among these
are the correctness of the principle employed and the method used, accuracy
of the standards, number and magnitude of possible error.s, correctness of
calculations and so forth. In precision measurements, as classified above,
a precision of one part in 100,000 in certain classes of measurements is regu-
larly attained. In commercial measurements, the cost of such a high degree
114
 MEASURING APPARATUS SeC. 3-5

of precision is not justified. The limits, however, are being gradually raised
as the art develops and greater refinements are introduced. The table
given in Par. 5 indicates the precision which may be reasonably expected
in various classes of measurements made by average observers, under ordi-
nary conditions, and with standard commercial instruments.
6. Table of Average Precision to be Expected in Various Classes of
Commercial Measurements
Probable
Class of Measurements and Method precision,
per cent.
(Deflections of two-third scale assumed in indicating instruments)
Current
Potentiometer, high-grade types 03 .

Portable ammeter, continuous-current 0.4

Portable ammeter, alternating-current 0.5-1.0*
Switchblard ammeter, continuous-current 1.5
Switchboard ammeter, alternating-current 1.0-2.5*
Recording instruments 1.5 -3.0
Potential ^
Potentiometer, high-grade type . 02
Portable voltmeter, continuous-current 0. 25
Portable voltmeter, alternating-current 0.5-1.5*
Switchboard voltmeter, continous-current 1.0
Switchboard voltmeter, alternating-current 1.0-2.5*
Recording instruments 1.5 —3.0
High potentials (in testing of insulators, etc.) 5.0
Power
Portable wattmeters 1.0
Laboratory wattmeters (non-portable or semi-portable) 0.25
Switchboard wattmeters 2.0
Recording instruments 2.0 -4.0
Energy (watt-hour meters)
Continuous-current 2.5
Alternating-current, single-phase, no transformers 2.0
Alternating-current, single-phase with transformers 2.5
Alternating-current, polyphase with transformers 3.0
Frequency
Portable instruments 0.5
Switchboard instruments 1.5
Power-factor
Portable instruments (ammeter, voltmeter, wattmeter) 2.0
Switchboard instruments (above 90 per cent.) 1.0
Switchboard instruments (below 90 per cent.) 2.0 -4.0
Resistance
Medium: 1.0 to 10,000 ohms with high-grade Wheatstone
bridge 0.1
Less than 1 ohm or more than 10,000 ohms with high-
grade Wheatstone bridge 0.2-1.0
With portable bridges 0.5-2.0
Low: By fall-of-potential method 0.5
With Thomson double bridge , 0. 05
High: (Insulation) 5.0
Conductivity . 25
Magnetic measurements 2.5
6. Classes of errors. There are two general classes of errors in any
kind of measurements, a, systematic and b, accidental. The former class
affects each result in a series of similar observations in the samt manner,
as for example, an error in the standard used. The latter class includes those
over which the observer has no control, such as observational errors in reading
an indicating instrument. Accidental errors, unlike systematic errors, are
as likely to be positive as negative and therefore tend to eliminate themselves

* Depends upon capacity and whether used with instrument transformers.

115
 Sec. 3-7 MEASURING APPARATUS
from the mean value as the number of readings ia increased. Where the
necessary degree of reliability is not obtained in a single measurement, a
number of observations are made, from which the most probable true value
may be obtained, together with its probable error. These latter quantities
may bo derived in different degrees of precision by various mathematical
methods involving the theory of probabilities and the method of least squares.
In all ordinary electrical measurements it will usually be sufficiently correct
to assume that the true value is equal to the average of the various values
obtained (eliminating systematic errors) plus or minus the average error.
The average error is the average of the differences between the average value
and each individual value. It should be noted, however, that according to
the theory of probability, the precision of the result does not increase directly
> but only as the square root of the number of observations made (see Par. 430
to 439).
7. Certain general precautions which should be observed in electrical
measurements, and certain sources of error which should be avoided, are
indicated in the following paragraphs.
(a) The probable limit of accuracy of the standards, instruments
and methods should be known.
(b) As a general proposition, in other than rough determinations, one
measurement should not be relied upon. Several readings should be
taken, and the conditions should be altered, wherever possible, in order to
avoid accidental errors.
(c) Indicating instruments should be of such a range that the quantity
under measurement will produce a reasonably large deflection on the'scale.
The percentage observational error decreases in direct proportion as the
magnitude of the deflection increases.
(d) The possible presence of external or stray magnetic fields, both
direct and alternating, should always be borne in mind. Such fields may be
produced by current in neighboring conductors, or by various classes of
electrical machinery and apparatus, structural iron and steel in buildings, etc.
These fields introduce errors by combining with the fields of portable indi-
catinginstruments, galvanometers and other instruments utilizing a magnetic
field, and, in the case of alternating fields, by inducing small e.m.fs. in the
loops formed in bridges, potentiometers, etc.
(e) In measurements involving high resistances and galvanometers,
such as bridges and potentiometers, possible "leakage" or shunt circuits
should be eliminated. This is done by providing a "guard" circuit the
principle of which is to keep all points to which the current might flow
improperly, at the same potential as the highest in the apparatus. See
further discussion under potentiometers (Par. 49 to 62).
(f) Temperature changes in various parts of bridge, potentiometer and
similar circuits should be avoided because of thermo e.m.fs. produced at
the junction of dissimilar metals. Such effects are often produced if the
observer's hand comes in contact with the metal parts of the galvanometer
key, switches, etc.
(g) Instruments with covers made of glass and hard rubber should not be
rubbed, especially with a dry dust cloth. The induced electrostatic
charge on the mo\'ing element is often sufficient to change the deflection
materially.
(h) At potentials of 500 volts and above, the electrostatic attraction
between moving and fixed parts may become serious. This is prevented by
keeping the two parts at the same electrostatic potential. When ground-
ing is permissible, this can be done by connecting the circuit to earth at the
point where the instrument is connected, care being taken that the moving
coil end of the instrument is on the ground side. In very high potential work
this electrostatic attraction becomes very troublesome, so that the instru-
ments must be connected in circuit at a grounded part of the line, or else
be thoroughly insulated from proimd and the moving element connected to
the case or to an electrostatic shield around the instriiment.
QALVANOMETERS AND DETECTORS
8. Qalvanometers are used extensively in all classes of electrical meas-
urements. Strictly speaking, the term applies to many other instruments for
measunng current, such as voltmeters and ammeters, but it is ordinarily
understood to apply to those instruments which are used to measure very
small electrical quantities.
116
 MEASURING APPARATUS See. 3-9

9. Classes of galvanometers. There are two general classes: (1)

moTing magnetic needle (2) moving coil. In the former class, a small
;

md (usually) permanent magnet is suspended at the centre of a coil of wire

ihrough which flows the current to be measured, producing a deflection. In
moving coil galvanometers, a coil of relatively fine wire is suspended at the
centre of a permanent or electromagnetic field; the current to be measured
Bows through this coil, producing a deflection. Moving-magnet instru-
ments are most prominently represented by the tangent galvanometer and
the Kelvin galvanometer; moving-coil instruments by D'Arsonval and
electrodynamometer type galvanometers.
10. Direct-current types of galvanometers are represented by the
following: Tangent galvanometers, sine galvanometers, the Kelvin type,
D'Arsonval type, ballistic type, differential galvanometers, electrodyna-
mometers and electrometers. These are described briefly in the following
paragraphs. The first two, though obsolete, are of great historical im-
portance.
11. Tangent galvanometers. In this instrument the magnetic needle
issuspended or pivoted above the centre of a circular scale, over which
moves the pointer attached to the magnet. The coil carrying the current is
in a plane perpendicular to that of the scale, so that the direction of the field
which it produces is in the plane of the magnet, the earth's magnetic field
being the directing force. The current is approximateI>; / = 5rH tan a/rn
(amp.), where r = radius of coil in centimeters; H= horizontal component
of earth's field in gausses; n. = number of turns in coil; and a = angle of
deflection.
12. The
sine galvanometer is similar to the tangent galvanometer, the
essential difference being that the coil is moved as the needle deflects, so
that they are finally in the same plane and sin a replaces tan a in the formula.
13. Kelvin galvanometer (astatic type) . In this instrument there are
two magnetic needles or sets of needles, of slightly different strengths, at
opposite ends of a light quartz rod and oppositely directed. Each is at the
centre of a pair of coils through which flows the current to be measured, these
pairs being oppositely wound so that the moment exerted on the two needles
IS in the same direction. Thus the moving system is almost, but not quite,
astatic. The controlling force is the earth's field modified as desired by means
of a movable permanent magnet. This galvanometer must be calibrated
against a standard. It is one of the most sensitive types of galvanometers
known, instruments with a current sensibility of the order of 1 X lO"'^ am-
peres having been built and used in research work.
The Broca' galvanometer is a modern form of the Kelvin galvanometer.
The magnets are two steel wires suspended vertically close together and
with consequent poles at the center, making a moving system which has very
small inertia and is highly astatic.
14. Moving coil or D'Arsonval galvanometers consist of a coil of
fine wire suspended between the poles of a permanent horse-shoe magnet.
The coil is usually suspended by a phosphor-bronze or steel wire, or flat
strip, which not only conducts the current to the coil but provides the con-
trolling force. Current is conducted from the coil by a helix of fine wire at
the bottom. The strength of the field in the region occupied by the coil is
increased by mounting a soft iron core in the central apace enclosed by the
coil, the pole pieces being shaped to give a uniform field throughout the apace
in which the coil moves. While the D'Arsonval galvanometer cannot readily
be used to make absolute measurements, but requires calibration, its many
advantages have made this the most generally used type of galvanometer
in the electrical laboratory. It is practically independent of the earth's
field or other external fields; its period can be made short, which, with its
dead-beat qualities, makes it a much faster instrument than other types; it
is comparatively rugged, simple to use and one instrument can be employed
for a wide range of work.
The Einthoven string galvanometer is of the moving-coil type, but the
coil is a single wire suspended between the poles of a powerful electro-
magnet. Its deflection is measured with a microscope.
15. Ballistic galvanometers are used to measure quantity of electricity
i
coulombs) such, for example, as the discharge from a condenser or the in-
;

duced charge in a secondary circuit. Ballistic galvanometers may be of the

moving-magnet or the D'Arsonval type. In order that the instrument may
be perfectly ballistic the quantity to be measured must be completely dis-
117
Sec. 3-16 MEASURING APPARATUS I

charged through it before the suspended system has moved appreciablyi

The period, or time of vibration, must therefore be long comiiared with th«
time of discharge. This is accomplished by increasing the inertia of the;
moving system.
16. Deflection of ballistic galvanometers. The magnitude of the
first deflection is a measure of the quantity discharged into the instrument.
In an instrument in which there is no damping (Par. 26) such as the moving-
magnet type, the quantity may be calculated directly from the constants
of the instrument. Thus
Q= 2Ht
-, sin
TrCr
7= —
(J)
- / i s
(coulomb) i /,.
(1)

or for small angles, 5 deg. or less,

^ Ht sin a
Q= -^
irtr
/• i i_\
(coulomb) /on
(2)

where Q = quantity of electricity in coulombs, ff = field strength in gausses,

6 = constant computed from the coils, = period in seconds, a = angle of
t

deflection.
17. Ballistic galvanometer constant. In practice, ballistic galvan-
ometers are usually standardized and the formula becomes very simple:
Q = kd where d = deflection and A: = quantity per unit deflection or galva-
nometer constant. The constant is determined with a standard condenser
or mutual inductance. The deflection obtained upon suddenly discharging
a charged condenser through the galvanometer is d = Q — CE\ and hence
k = CE/d, where Q = quantity of electricity in coulombs, £? = potentialto which
the condenser had been charged in volts, and C = capacity of condenser in
farads. When a mutual inductance is used, the deflection is d = Q = MI/R
and k = MI/dR, where Q = quantity of electricity in coulombs, M
= coefficient
of mutual inductance in henrys, / = steady or Ohm's law value of current in
primary of mutual inductance in amperes, and /J = resistance of secondary
circuit (including the mutual inductance) in ohms.
18. A differential galvanometer is one provided with two independent
coils or sets of coils by means of which two currents may be compared
simultaneously. This method provides a means of measuring a current with-
out making the circuit common with that of the comparison standard. In
D'Arsonval instruments, the two coils are wound side by side on the same
frame and are connected in opposition, so that when the two currents being
compared are adjusted for zero deflection, their ratio is usually unity. The
actual ratio can be determined experimentally.
19. Electrometers. In the electrometer, a piece of thin aluminium ia
suspended by a metallic suspension over four quadrants of sheet metal which
are insulated from each other and from the frame or support. Opposite
quadrants are connected to each other and the two sets are connected respec-
tively to the two sides of the circuit to be measured. If a charge from a
condenser is placed on the moving vane, one end will be repelled and the
opposite end attracted, producing a deflection which will be a measure of
the potential applied to the stationary quadrants. This instrument is ex-
tremely sensitive, and while it is one of the earliest types of electrical measur-
ing instruments it is still used extensively in research work, especially where
the available energy is extremely small, as in measurements of radiant
•

energy.
20. Qalvanometers as detectors. The majority of galvanometers are
used as detectors only, that is, in zero-deflection methods where the kind of scale
or proportionality of deflections does not enter into the determination. In
such cases a very short, straight scale is sufficient and space may be econor
mizcd by placing the galvanometer on the wall above the table, with the
scale directly underneath. The beam of light is properly directed by
suitable prisms and mirrors.
21. Reflecting galvanometers may be read with a telescope and scale,
or with a lamp and scale. In the former, the scale is reflected from the
plane mirror (attached to the moving system) to the telescope through which
movements are observed. In the latter, an image of a narrow beam of liglit
(issuing from a narrow slit in a vessel enclosing a lamp, or from a portion of
ao ipcandescent lamp filament) is thrown on to the scale by the mirror. In
118
 MEASURING APPARATUS Sec. 3-22

order to get a sharp image, either the mirror is made concave (with a 1-
m. focus if the scale is the usual distance of 1 m. away), or a lens is used.
Fig. 1 shows the general arrf ngement.
22. Galvanometer scales. When readings are to be taken, care should
be exercised that they are proportional to the angular deflections. On a
straight scale the deflection in millimetres is
d = Ata.n2a (3)
where A — distance from mirror to scale in millimetres and a = angle through
which the moving coil turns. If the angle is small, d is proportional to a.
The error becomes about 0.5 per cent, at a = 5 deg. Obviously a curved
scale will eliminate this er-
ror, and by properly adjust-
ing the curvature the read-
ings may be made propor- ^
tional to the angle or to any o, ^^^
desired function of the angle. V^-9--{)— -j

23. The sensitivity of a h I L

galvanometer is expressed
in one of several ways, the
numerical expression of
—
which is called the galva- Fig. I. Lamp and scale. Telescope and
nometer constant. In in- scale,
struments of the D'Arsonval
type, the sensitivity depends upon the moment of inertia of the moving
system, the torsional moment of the suspension, the field strength, and the
number of turns and the area of the coil.
24. Different forms of galvanometer constants. The various con-
stants are usually defined as follows:
(a) The ampere constant is the current in microamperes (millionths
of an ampere) which will produce 1 mm. deflection on a scale 1 m.
distant.
(b) The megohm constant is the number of megohms in series with the
galvanometer through which one volt will produce 1 mm. deflection on a
scale 1 m. distant.
(c) The volt constant is the potential in microvolts (millionths of a
volt), across the galvanometer terminals which will produce a deflection of
1 mm. on a scale 1 m. distant. Or it may be expressed as the deflection in
millimeters which will be produced by one microvolt.
(d) The coulomb constant refers to ballistic galvanometers (Par. 17)
and is the quantity in microcoulombs (millionths of a coulomb) which will
produce 1 mm. deflection on a scale 1 m. distant.
25. High current sensitivity is desirable for high-resistance measure-
ments, such as insulation resistance. High voltage sensitivity is desir-
able for measurements involving small potentials, such as low-resistance
bridges, potentiometers, etc. High coulomb sensitivity is desirable in
magnetic tests.
26. Damping. This term is applied to those forces which collectively
bring the moving system to rest after it has been set in motion. In order
to shorten the period and facilitate readings, damping sometimes is intention-
ally produced mechanically with air vanes, or more generally by electrical
means. The latter means include: (a) use of a metal frame on which the
moving coil is wound and in which eddy currents are produced; (b) use of a
closed loop of copper wire attached to the coil and in which eddy currents
are produced; (c) use of the generator action of the swinging CQJl when its
circuit is closed. The latter is the more convenient method for general pur-
poses, because the damping can be readily changed by means of resistances
in series or in parallel with the galvanometer.
27. Critical damping is that condition of damping where the moving
system comes to zero position, or equilibrium, but does not pass through it,
in the shortest time after deflection. A galvanometer is aperiodic when it
is critically damped. It is dead beat when the coil deflects to its final
po.sition or reading witlout oscill.itirn.
28. The period of a galvanometer is the time in seconds required for
one complete oscillation, or the time between two successive passages through
the zero or mid-position.

119
Sec. 3-29 MEASURING APPARATUS
29. Oalvanoxneter shunts are combinations of resistances so arranged
and so connected to the galvanometer that the constant of the latter may be
quickly changed. Ordinary resistance boxes may be used as shunts for gal-
vanometers when the resistance of the galvanometer circuit is not too small. (

In the latter case the box is connected as shown in P^ig. 2, i

thus increasing the resistance Rg of the galvanometer cir-

cuit. The readings of the galvanometer must be multi-
plied by a factor

R. (*^i

^ wherein Rg is the resistance of the galvanometer circuit

and R, is that of the shunt. In special galvanometers
Fig. 2.— Galva- shunts,
nometer shunt. Ra Tig Rg Rg
iJ.= 9^' 99' 999' 9999' etc. (5)

then ft = 10, 100, 1,000, 10,000 respectively. ''

30. The Ayrton or universal shunt is so arranged that

can be used it i

with any galvanometer. When, in Fig. 3, the movable contact x is at 6,

I'g'=Irab/(rab + rg), where /'b = current through galvanometer, / = current-
from battery, ro6 = resistance between o and 6, and r^ = resistance of galva-
nometer. If the contact x is moved to c.

/"„ =/ (amp.)
'"O (6)

It willbe noted that rg is not in this equation; hence if the galvanometer

constant is obtained with the shunt all in (x at b), the shunt ratio at any
other position of x is tac/rah and is independent
of the galvanometer resistance.
31. Alternating-current types of galvanom-
eters include the following: Electrodynamom-
eters, or, as they are more commonly known,
dynamometers; vibration galvanometers, ther-
mogalvanometers, electrostatic galvanometers, al- 1.,. ...... .»,».»». 1
ternating-current detectors, barretters and bolom- o|-^W^AA^AAA/)j^^AA^r;j.
eters.
32. Dynamometer-type instruments are
used extensively in measurements of alternating
currents becau.se they measure mean effective
values and can be calibrated on direct current.
They can be used for a wide range of measure- FiQ.vanometer
3. Universal gal-
shunt.
—
ments of current, e.m.f. and power, from ex-
tremely small values to very large ones.
33. The operative principle of the dynamometer is the elcctrody-
namic action between a movable coil (or coils) suspended between two or
more fixed coils, all of which are energized. The Aowland electrodyna-
mometer* is typical of this class of instruments. It consists simply of two
fixed coils mounted close together, between wliich is suspended a small
coil of very fine wire. Each fixed coil consists of two separate windings of
different current capacities brought out to separate terminals. For e.m.f.
measurements the moving coil and the fine wire fixed coils are connected in
series; for current measurements, the moving coil is connected across a non-
inductive shunt in the current circuit; for power measurements, the moving
coil is connected across the circuit to be measured while the proper fixed
coil is connected in series with it.

34. Dynamometers are made astatic, or independent of external fields,

by having two sets of moving coils, oppositely wound, one above the other,
with a common suspension. There may be one or more pairs of fixed coils.
In heavy-current instruments, the fixed coils are wound with cable composed
of many fine strands laid up in braided form. This reduces the eddy currents
which otherwise would be set up and which would influence the moving coil.
"
• Rowland, H. A. "Electrical Measurements by Alternating Currents;
Leeds and Northrup Catalogue No. 74, 1911; p. 294.

120
 MEASURING APPARATUS Sec. 3-35

36. Vibration galvanoineters* can be used only with alternating cur-

rents. There are two typea, the coil and the soft-iron magnet. In the
former, themoving element is a single wire or narrow coil of very fine wire
suspended between the poles of a permanent magnet. An exceedingly
small mirror is attached at the centre of the wire or coil. When the natural
period of this moving system coincides with that of the current to be measured
it will resonate and be sensitive to extremely small currents, the indication
being the width of the spot of light on the screen or scale. The instrument
is "tuned" or adjusted to resonance by changing the effective length of the
suspension or its tension. The Einthoven galvanometer (Par. 14) makes a
;
very sensitive vibration instrument.
In the soft-iron magnet type, a very small piece of soft iron is suspended
by a silk fibre between the poles of a permanent horse-shoe magnet. Ad-
jacent is a coil carrying the alternating current to be measured, which pro-
duces a field perpendicular to that of the permanent magnet. The tempo-
rarily magnetized needle vibrates in synchronism with the period of the alter-
nating current and with an amplitude proportional to the strength of the
current. The effective period of the moving system is ad-
justed to resonance, by shunting more or less of the per-
manent field by means of a movable keeper across the
limbs of the magnet. Obviously these instruments can be
used only for detector purposes, that is, in zero-method
T
measurements, such as inductance andcapacitymeasurements Q
with a Wheatstone bridge. t They are extremely sensitive, be-
ing capable of detecting currents of the order of 1 X 10"' amp.
and are applicable to frequencies up to 1,000 cycles per sec.
M
36. Thermo-galvanometers utilize the heating effect of
an electric current and are independent of frequency. They
can be constructed with practically no inductance or elec-
trostatic capacity, and are therefore used extensively in
high-frequency measurements. One of several forms is the
Duddell type. Fig. 4, in which a moving coil, suspended be-
tween the poles of a permanent magnet as in D'Arsonval
galvanometers, includes a bismuth-antimony thermocouple
placed immediately near an electric heater through which
passes the current to be measured. The instrument can
be used for a wide range of measurements by changing the 1]56

heater. It can be used on frequencies up to the order of

100,000 cycles per sec. flMtV
37. Electrostatic galvanometers utilize the force of re- Fio. 4.
pulsion between two bodies carrying electrostatic charges Dudell ther-
of the same polarity. One or more very thin m€tal vanes mo-galva-
are suspended by a fine wire between two or more stationary nometer.
vanes, so shaped (circular discs with opposite quadrants
cut away) that when excited, the movable vanes swing outward from the
fixed vanes between which they are interleaved. These instruments require
no appreciable current and can be calibrated on direct current, thus pos-
sessing characteristics which make them valuable for measuring e.m.fs.
where the current capacity is very small or nil.
38. Alternating-current detectors. Other methods of determining the
condition of balance in zero-method alternating-current measurements are
shown in Figs. 5 and 6. The former indicates the scheme of a synchronous
commutator, t A commutator, C, and two slip-rings, r and r', are mounted
on the shaft of a small synchronous motor. The bars in the commutator are
narrow, and equal in number to the poles of the motor and equally spaced.
Two brushes, a, o', connected to the galvanometer are so spaced as to bridge
two bars simultaneously. These brushes are mounted on a disc which can
be rotated about the shaft. The bars are connected alternately to the two

* Wenner, F. "Characteristics and Applications of Vibration Galvan-

ometers;" Trans. A. I. E. E.. 1912, Vol. XXXI, p. 1243
t Rosa, E. B. and Grover, F. W. "Measurement of Inductance by Ander-
son's Method Using Alternating Current and a Vibration Galvanometer;"
Bureau of Standards Bulletin, Vol. I, 1905, p. 291.
t See also Frederick Bedell, "Use of Synchronous Commutators in Alter-
nating-current Measurements;" Jour. Franklin Institute, Oct., 1913, p. 385.

121
Sec. 3-39 MEASURING APPARATUS
rings which in turn are connected through the brushes, 6, 6', to the alternating
current being measured. It is apparent that the connections to the gal-i
vanometer are reversed every half cycle, so that the indication is a steady one,'
the value of which may be made anything from zero to a maximum by shift-i
ing the angular position of the brushes. Thus the most sensitive position
can be readily found, irrespective of the phase relation between the current
in the circuit being measured and the motor armature. The variation in
contact resistance at high speeds, and possible presence of thermo e.m.fs.,
may cause trouble where the resistances or potentials are very low, ais in
low-resistance bridge measurements. *

Synchronous commutator.

39. k synchronous reversing key which overcomes the latter diflSculty

is indicated in Fig. 6. A cam, C, mounted on the shaft of a small synchronous
motor is so designed that it moves the lever, I, up and down in such a manner
that the pair of contacts, a and a', at the end of tiie lever make alternate con-
tact with the pairs of stationary contacts, c and c', once per cycle. The num-
ber of projections on the cam of course will correspond with the number of
pairs of poles on the motor. The contacts are arranged as shown diagram-
matically at the right of Fig. 6, from which it will be seen that the connections
to the galvanometer are reversed every half cycle, so that a steady deflection
is obtained in the direct-current galvanometer. All the contacts are sup-

^^^f^Su^

Synchronous reversing key.

ported on a solid disc which can be rotated around the shaft, and hence re-
versal can bo made at any point on the wave as in the case of the synchronous
commutator. The contacts are all made of platinum, the cam is hardened
steel and the lever I is kept in contact with the cam at all times by means of
a .spring. The roller r is necessary to insure contact at the low portion of
the cam.

•Sharp, C. H. and Crawford, W. W. "Some Recent Developments in

Exact Alternating-current Measurements;" Trans. A. I. E. E., 1910, Vol.
XXIX, p. 1518.

122
 i
MEASURING APPARATUS See. 3-40

40. A barretor* is a bridge arrangement (Par. 143) in which the change in

•esistance with the passage of current of a high temperature coefficient wire
3 utilized to measure currents of telephone magnitude and frequency.
41. A bolometer is an instrument devised by Prof. S. P. Langley with
which extremely small temperature changes (order of 0.0001 deg. fahr.)
may be measured. A very thin strip of platinum or other metal is expo.sed
to the radiation from a suitable source heated by the current to be measured.
This strip forms the arm of a balanced Wheatstone bridge and the change in
resistance corresponding to the change in temperature is indicated by the
galvanometer deflection.
CONTINUOUS-E.M.F. MEASUREMENTS
!
Standards of e.m.f. The legal unit of e.m.f. in the United States
42.
'is the international volt adopted by Act of Congress in 1894; in practice
i
the prefix is generally omitted. This unit is the e.m.f. which, when applied
to a conductor having a resistance of one international ohm, will produce a
current of one international ampere. The Act also states that the volt
"is represented sufficiently well for practical use by 1000/14,34ths of the
e.m.f. between the poles or electrodes of the voltaic cell known as Clark's cell
at a temperature of 15_ deg. cent, and prepared in the manner described in
the accompanying specification." The Clark cell has since been superseded
by the Weston cell as the standard of e.m.f. The value of the latter as
adopted by the Bureau of Standards, Jan. 1, 1911 is 1.0183 at 20 deg. cent.,
which is now the standard of e.m.f. in this country.
43. The Clark cell was the first form of voltaic cell to meet the require-
ments of a reliable standard of e.m.f., namely, reproducibility and reasonable
permanence. The elements are: positive electrode, metallic mercury;
negative electrode, amalgamated zinc; electrolyte, saturated solution of zinc
sulphate and mercurous sulphate. Its e.m.f. in terms of fundamental or
c.g.s. units was originally taken as 1.434 international volts at 15 deg. cent.,
the value having been made legal in 1894 as stated above. Later and more
careful determinations have shown, however, that 1.4328 is a more correct
figure. The e.m.f. of the Clark cell changes with temperature in accordance
with the formula:
S = 1. 4328[1- 0.00077 (t° 15)1 C- (7)
where J? = international volts at any temperature, t deg. cent.
44. Objections to Clark cell. As the electrical art developed and more
precise working standards became necessary, the defects in the Clark cell
were noted. The most conspicuous of these are large temperature coefficient,
large temperature lag and difficulty in obtaining the temperature. This cell
has therefore been superseded by the Weston cells, which are practically free
from these objections.
45. Weston cells. t There are two forms of Weston cells, the saturated
cell and the unBatiira,ted cell. The elements are: positive electrode,
metallic mercury; negative electrode, amalgamated cadmium; electrolyte,
solution of cadmium sulphate and mercurous sulphate.
46. Weston normal cell. In this cell the electrolyte is saturated.
This form is the official standard because it is more permanent and can be
reproduced with greater accuracy than when the electrolyte is unsaturated.
When carefully made according to the official specifications, cells will agree
with each other within a few parts in 100.000. The e.m.f. changes slightly
with temperature according to the following formula:
£=1.0183[1 -0.000041 «° C.-20)] (8)
where E = international volts at any tempernture, t deg. cent.
47. The unsaturated Weston cell, on the other hand, has practically
no temperature coefficient (0.00001 per deg. cent.). Although it is not so
reliable as a fundamental standard as the Weston normal cell, and each cell
has to be standardized, it is, nevertheless, more convenient for general use.
This is the form furni.shed by the Weston Electrical Instrument Co. The
makers recommend that these cells be not subjected to temperatures below
* Cohen and Shepard, "Telephone Transmission Measurements," Jottr.
Inst. E. E., 1907, Vol. XXXIV, p. 503.
t See Circular No. 29, Bureau of Standards, 1910.

123
Sec. 3-48 MEASURING APPARATUS
4 deg. cent, or above 40 deg. cent., and that no current greater than 0.0001 ij

amp. be passed through them. 1

48. Comparisons of continuous electromotive forces with a stand-

ard cell. Electromotive forces may be compared witli a standard cell by'
1

several methods. The more typical methods are based on the following'
principles. i

(a) In the substitution method, the current flowing through a high.;

resistance (not less than 15,000 ohms) is measured with a high-sensibility
galvanometer, first with the standard cell in the circuit and then with the
unknown e.m.f. substituted for the standard cell. The resistance being the
same in the two cases, the deflections are proportional to the e.m.fs. E = cd'/d,
where £ = unknown e.m.f., e = standard cell e.m.f., ti = defiection with
standard cell and d' = deflection with unknown e.m.f.
(b) The equal deflection method is a modification of the above, in
which the deflections are kept the same in the two cases by clianging the
resistance. Then E = er'/r, where r = total resistance of the circuit, including ,

the galvanometer, with the standard cell in the circuit and r' = total resistance
with the unknown e.m.f. This method is better tlian (a) because it is a
constant deflection method and the result depends on the known values of
two resistances, rather than observed deflections.
(c) In Wheatstone's modificaition of the equal deflection method, the
galvanometer resistance does not have to be known. The deflection, d, is
noted when the unknown e.m.f., E, and a known high resistance are in circuit.
Additional resistance, r', is added and the deflection, d', again noted. Simi-
larly with the standard cell of potential difference, e; the resistance is
adjusted until the same deflection, d, is obtained and then an amount of
resistance, r, is added until the deflection d' is again obtained. The unknown
e.m.f. is E= er'/r.
(d) In the condenser discharge method a condenser is charged, first
from the unknown e.m.f.,then from the standard cell, and discharged in
each instance through a ballistic galvanometer. The deflections will be
proportional to the e.m.fs., hence E = ed'/d as in (a). Obviously, if the un-
known e.m.f. is much smaller or much larger than the standard cell, the
deflection can be made about equal to that of the standard cell by using a
larger or a smaller condenser. In that case the ratio of the capacities should
be known, and then E = ed'C'/dC, where C = capacity of condenser used with
the unknown e.m.f. and C = capacity of condenser used with the standard
cell. This method has the advantage that practically no current is re-
quired, which is advantageous in making measurements of voltaic cells of
very small capacity ox, rapid polarization.
(e) The principle of the opposition or potentiometer method is that
of opposing the e.m.f. of the standard cell against an equal difference of
potential which bears a known proportion to the unknown e.m.f. This
method is the most accurate and tsy far the most generally used, because it
is both a zero-deflection and a zero-current method, the result depending
only on the ratio of two resistances which can be very accurately determined.
Potentiometers are instruments employing this principle (Par. 49).
49. Description of Leeds and Northrup potentiometer, low resist-
ance type. Fig. 7 shows the arrangements of the circuits. The figures for
the second decimal place and beyond are obtained from a slide wire at the end
of the circuit, CB, along which a contact moves. A special dial is also pro-
vided for the standard cell (at the left) and separate contacts arc provided
for the standard-cell e.m.f. and the unknown e.m.f., so that no settings have
to be disturbed when checking the secondary current in the potentiometer
circuit. The essential part of the instrument consists of 15 fjve-ohm coils,
AC, connected in series with the extended wire, CB, the resistance of which
from to 1,100 scale divisions is 5.5 ohms. Thus when the current from
the battery, B, is adjusted by the rheostat, R, to 0.02 amp., the fall of poten-
tial across each 5-ohm coil in AC is 0.1 volt and across CB, 0.11 volt. Since
the latter is divided into 1,100 parts, the e.m.f. may be measured to 0.0001
volt. At point 5 in AC,& wire is permanently attached connecting to one
point of the double switch, U. When this switcli is thrown to the left, the
standard cell is connected through the galvanometer to point 5 and the
sliding contact T which moves over the dial at the left consisting of 19 resist-
ance coils. Between a and A is a resistance which is adjusted to such a
value that with 0.02 amp. flowing, the potential drop between 6 and a is

124
 MEASURING APPARATUS Sec. 3-50

1.0175 with 0.0001 volt additional drop across each dial coil, giving a maxi-
mum of 1.0194. This range will include the usual differences between dif-
ferent Weston standard cells. To adjust the current to 0.02 amp., throw the
switch U to the position indicated by the dotted lines, set the contact T
to correspond to the e.m.f.
of the standard cell and regu- R
late i? until the galvanometer MWVVWamWAV -o
shows no deflection. The i„,_ 'I'r
unknown e.m.f. is then meas-
ured by throwing the switch
U to the position indicated
by the full lines and adjust-
ing the contacts M and M'
until no deflection is noted.
After a balance has been ob-
tained, the current may be
checked by simply shifting
U to the first position and
pressing the contact key.
60. Paul potentiometer,
low resistance type. Fig. 8
is the connection diagram.
It is similar to the instru-
ment described in Par. 49 in
that the lower part of the
reading is obtained from an Fig. 7. —
Leeds & Northrup potentiometer.
extended slide-wire on one
end, and a standard-cell switch is provided at the other end. The rheostats for
adjusting the battery current are within the instrument {R and r). The slide
wire is laid straight, with divisions equal to about J in. (0.4 cm.), which
correspond to 0.001 volt divided into 5 subdivisions. A special switch,
S, is so arranged that the various circuits 1, 2, 3, etc., may be quickly con-
nected to the potentiometer circuit. The resistance of the standard type is
10 ohms per volt, with a range from 0.0002 volt to 1.8 volt. It is also made
with ranges as low as 0.000004 volt to 0.036 volt for thermoelectric work.

X-l

Fig. 8. —Paul potentiometer.

II. WolfiE potentiometer, high resistance type. Fig. 9 shows the
diagram of connections in the latest model. The total resistance is 20,000
ohms and there is no slide wire, all resistances being comprised in the form
of 5 dials, having steps of 1,000, 100, 10, 1 and 0.1 ohm respectively. These
read 0.1, 0.01, 0.001, 0.0001 and 0.00001 volt respectively. Instead of ob-
taining a balance by moving along the main circuit the contacts connected
to "X," as in the slide wire form, the final balance is obtained by adding or
subtracting resistance in the main circuit between these two contacts; the

125
 Sec. 3-52 MEASURING APPARATUS
three low dials are so arranged that a corresponding change is automatically
made in the external part of the main circuit and the total resistance is kept
constant. A separate dial is provided for the standard-cell adjustment,
together with a separate resistance which can be altered to accommodate
different cells without affecting the measuring circuits. The total range of
the instrument is 1.9 volts.

Fig. 9. —Wolff potentiometer.

B2. Care and use of potentiometers. The following notes apply to
the use of potentiometers in ordinary work.
(a) The accessories should be suitable for the particular type of in-
strument, that is, high or low resistance, and for the class of measurement
to be made. The galvanometer should be sufficiently sensitive to give a per-
ceptible deflection when there is an unbalance equal to the smallest scale
division in the potentiometer curcuit. A low-resistance galvanometer, of
the order of 100 ohms, should be used with a low-resistance potentiometer,
and a high-resistance galvanometer of 500 to 1,000 or more ohms, wiin a
high-resistance potentiometer. Similarly, the resistance of the volt box
(Par. 53) for low-resistance potentiometers should be as low as the permis-
sible power loss in the resistance coils will permit. This is usually about
5,000 ohms for 150 volts. For high-resistance instruments, the resistance is
1,000 ohms or more per volt.
(b) The first trials for balance should always be made with a resistance
in series with the galvanometer. This is usually provided in the instrument,
with facilities for readily cutting it out of circuit when an accurate balance is
being obtained. The resistance protects the galvanometer and also the
standard cell from the effects of excessive currents.
(c) Trouble is sometimes experienced, especially in damp weather, due to
current "leaking to ground from the potentiometer circuits in a manner
'

which produces a false deflection. This can be obviated by providing a

"guard circuit." In one scheme of this kind all of the apparatus is placed
on small, hard-rubber pillars each of which in turn rests on a small metal
Clate. These are connected together and to the positive "x" binding-post
y fine bare wire. Thus all points to which current might "leak" over the
surface are kept at the highest external potential to which the potentiometer
is connected. When the surfaces become noticeably moist, conditions can
be improved by carefully wiping with a cloth moistened with grain alcohol.
(d) Calibration and checking. The essential requirement is that the
ratio of the resistance of each step to that resistance between the standard
cell terminals shall be the same as the ratio of the corresponding potentials.
For example, if the standard cell e.m.f. is 1.0183 volts and the resistance
between its terminals is 101.83 ohms, the resistance of the various steps
should be adjusted to 10 ohms per 0.1 volt. If the standard cell resistance
is 102.848 ohms the potentiometer is still accurate if the resistance throughout
the circuit is adjusted to 10.1 ohms per 0.1 volt.
 MEASURING APPARATUS Sec. 3-53

S3. Volt boxes.' When the potential to be measured is greater than the
range of the potentiometer (usually 1.5 volts) a volt box is used. It consi.sts
of a number of resistance coils connected in series, with taps brought out to
binding posts. Fig. 10 shows the diagrammatic arrangement, in two forms.
In (^4), the potentiometer is connected to the posts marked " -|- " and "
— "
.

When the potential to be measured is between 1.5 and 15 volts, it is connected

to the " + " and " 15" posts, between which the resistance is just ten times
that between " -(- " and " — ." Hence only one-tenth of the unknown
Eotential is applied to the potentiometer, the readings of which must therefore
e multiplied by 10. Similarly, when the potential is between 15 and 150
" -[- " and "150" posts, and the ratio becomes
volts, it is connected to the
100. In (B), Fig. 10, the potential to be measured is always connected to
one pair of posts, designated "+ " and " — ," and the potentiometer connec-
tions are shifted to obtain the desired ratio. Theoretically the former
method is the better because the resistance in parallel with the potentiometer
is constant and the sensibility is therefore constant. In the latter case,
the sensibility varies, being a minimum with the lowest ratio, or when the
maximum amount of resistance is in parallel with the potentiometer. On the

To": Xo"a;"e.m.f.

U)
To Potentiometer To Poteutiometer
Fig. 10. —Volt boxes.
other hand, the unknown e.m.f. is always connected to a high resistance, and
hence there is no danger of burning out the volt box; this occasionally happens
with the first form, {A), due to accidental connection with the wrong
terminals.
64. Deflection potentiometers. Precision measurements obviously
can be made only with very steady sources of e.m.f. If the e.m.f. is not
steady, and a higher precision than that obtainable with secondary standards
(voltmeters) is desired, a deflection potentiometer may be employed. In
this instrument the greater part of the e.m.f. is measured by balancing
against the potentiometer current in the regular manner, and the remainder
is obtained from the indication of the calibrated galvanometer, which is
preferably of the portable type. The Brooks deflection potentiometer*
IS of this type.
65. Voltmeters for continuous e.m.fs. Indicating instruments
called voltmeters are used in ordinary commercial measurements. They
are, essentially, low-sensibility galvanometers pro-
vided with scales over which moves a pointer attached
to the moving system. The scale is calibrated in
volts by comparison with an indicating instrument of
higher sensibility, or by means of a potentiometer.
Practically all direct-current voltmeters employ the
principle of D'Arsonval galvanometers as shown in
Fig. 11. They consist essentially of a light rectan-
gular coil of fine copper wire wound upon an alu- Fig. 11.
minium frame, pivoted in jeweled bearings and ca- Weston d.c. volt-
—
Diagram,
pable of rotating in the annular space between the soft- meter.
iron core and the pole-pieces of the permanent mag-
net. The aluminium frame, being a closed secondary circuit, acts as a
brake or damper when the coil is deflected; the instrument is thus made
"dead beat. The pole-pieces are so shaped that the magnetic field
strength is uniform throughout the space in which the coil moves. The
field strength varies widely in different makes of instrument, ranging from
200 to 3,000 lines per square centimeter in the air gap and 1,000 to 6,000

* Bureau of Standards Bulletin; Vol. II, p. 225; Vol. IV, p. 275: Vol. VIII.
pp. 395 and 419.

127
Sec. 3-56 MEASURING APPARATUS j

lines per square centimeter in the steel. A light tubular pointer attaohedi
to the coil moves over a calibrated scale. The current is introduced!
into the coil by two spiral -springs which also provide the controllings
force. Since the field strength and the gradient of the controlling forces
are uniform, the deflection is strictly proportional to the current pas.«ing
through the coil, and the scale divisions are uniform. A large amount of i

resistance is connected in series with the moving coil in order to make the
current small. Thus the same instrument can be made suitable for a vmiIc
range of voltages by changing the amount of series resistance. This re-
sistance is made of wire having a low temperature coefficient in order to
neutralize as much as possible the effect of the large coefficient of the copper
in the coil.
66. Voltmeter characteristics (continuous current). The usual
resistance of portable voltmeters of this type varies from 50 to 150 ohms
per volt and the current sensibility from 7 to 20 milliamperes at fuU-scnle
deflection. The resistance of the moving coils is about 75 ohms. Tlie
torque varies from 2 to 6 millimeter-grams at maximum current, with a
ratio of torque to weight (in grams) of 1 to 5. The temperature
coefficient is usually negligible, b^ng of the order of 0.01 to 0.02 per cent.
per deg. cent, at full scale.
67. Laboratory standard voltmeters (continuous current). So-
called laboratory standard voltmeters are similar to portable instruments
except that they are larger, have a longer pointer, a longer and more oi)on
scale and are made with greater care. They are only semi-portable and are
intended primarily for standardizing purposes.
68. Switchboard voltmeters (continuous current) are usually of the
D'Arsonval type. The construction is the same as that of portable instru-
ments, except that they are more substantial and rugged, especially as
regards the moving system, in order to withstand the harder conditions oi
continuous service and excessive fluctuations. They are mounted in iron
cases to protect them as much as possible from the normal stray fields due
to the bus bars.
69. Effect of stray fields. The general effect of stray fields on the stand-
ard types of portable and switchboard instruments is shown in the table in
Par. 60. These errors are usually only temporary and disappear with tht
stray field. When the field is very strong, as under short-circuit conditions!
in a neighboring conductor, demagnetization of the instrument magnets:
may result in a permanent error. Shields are likely to be of little value undei|
such conditions because the iron becomes saturated.
60. Effect of Stray Magnetic Fields on Continuous-current VoIt-|
meters and Millivoltmeters
Error at two-thirds full-scale deflection, per cent.
Stray field,
lines per sq. cm.*
Shielded Unshielded

5 0.5 to 1.0 2
10 0.75 to 1.75 3.5 to 5.5
15 1.0 to 3 . 6 to 7.5
.

20 1.25 to 3.25 7.5 to 10

61. The measurement of very small continuous potentials may be

efifectedby some of the methods outlined in Par. 48.
A potentiometer is most convenient, high resistance for high resistance sources
such as small galvanic cells and low resistance for low resistance sources such at
thermocouples.
62. Ground detectors. Those of the direct-current type are usuall>
special forms of voltmeters. In one form, there are two coils, differentially
WQund on the moving system. One end of each coil is connected to ground
and the two free ends are connected respectively to the two sides of the
* The field produced at a distance of 30 cm. (12 in.) from a conductor carryii
Ing 3,000 amp. is about 20 lines per square centimeter.

128
 MEASURING APPARA T US Sec. 3-63

*"• When there is no ground or fault on the system, the pointer stands
i
irstem
the centre of the scale, in normal equilibrium.
«i '

t
When a ground or fault
"« ccurs, current flows through the coil connected
to the ungrounded side,
» Toducing a deflection. In another form of detector a standard voltmeter,
^ rithout the series resistance, is connected to the centre of a resistance shunted
«'
cross the line, with the remaining terminal connected to ground.
k'
^ ALTERNATING-E.M.F. MEASUREMENTS
10
63. Measurements of alternating e.m.f.
1
In alternating e. m. is.
« here are three values to be considered; the maximum, the average and the
'root-mean-square" or mean effective value (Sec. 2). The last value is
;he one usually required, being the value of the
equivalent continuous e.m.f.
al

?ince the standard of e.m.f. is the standard cell, the measurement

'
of altemat-
IS

ie
ng potentials involves, like continuous potentials, comparison with the stand-
ird cell. The comparison may be more or less a direct one, as in precision
e

8 measurements, or it may be indirect by means of secondary standards

J which in turn have been standardized by direct comparison.
64. Precision measurements of alternating e.m.f. Obviously an
alternating e.m.f. cannot be compared directly with the standard cell, the
.e.m.f. of which is unidirectional and constant. The comparison is made
J
therefore by a substitution or "transfer" method. galvanometer of the A
; electrodynamometer type, or an electrostatic galvanometer, is connected to
; the alternating potential to be measured and the deflection noted. It is
then connected to an adjustable continuous potential which is manipulated
until exactly the same deflection is obtained. The continuous potential is
'
then compared with the standard cell by means of a potentiometer, in the
usual manner.
i A double-throw double-pole switch is usually arranged so
'

that the transfer from alternating current to continuous current can be

quickly ma(Je, without allowing the deflection to change appreciably, thp
!

continuous potential having been previously adjusted to about the proper

value. Two readings, direct and reversed, are taken on continuous currerit
at the same reading as the alternating deflection; the aVerage of these two is
taken as the true value, thus eliminating the effect of stray magnetic or
i

electrostatic fields.
'

It is obvious that, on account of this indirect method,

alternating-e.m.f. measurements cannot be made with the degree of
i

precision obtainable in measurements of continuous e.m.fs.

;

! 66. Secondary standards. The dynamometer type instruments which

are used as secondary standards of alternating current are adapted to
measurements by constructing the windings of a large number of
j

I
e.m.f.
i
heavy wires. See Par. 99.
turns of fine wires, instead of a few turns of
I 66. Classification of alternating-current voltmeters. The volt-
meters in general use may be divided into five types, as follows: dyna-
mometer, soft-iron vane, induction, hot-wire and electrostatic.
67. Dynamometer type voltmeters (alternating current) depend upon
the reaction between a fixed and a moving coil connected in series. The

Suspensions

F'
Fig. 12. —Diagram, Weston
dynamometer type volt-
a.c.
Diagram, Kelvin balance.

meter.
movement of the movable coil is a measure of the current flowing through the
and therefore proportional to the e.m.f. impressed at the terminals. In
coils
one form (Weston model 18), a single coil moves within two parallel fixed

129
Sec. 3-68 MEASURING APPARATUS
coils as shown in Fig. 12, where F, F' are the fixed coils and M
is the movii
coil, to which a pointer P is attached. The deflection is approximately pr
portional to the square of the current. The scale is compressed at the upp
end instead of extended becao.se the coU moves be.vond the uniform part of tl
field. The Thomson Inclined Coil voltmeter is similar, except that tli
plane of the fixed coils makes an angle of about 45 deg. with the shaft of ti
moving coil for the purpose of making the scale more uniform.
In the Westingnouse type Q, the Kelvin balance principle is use<
This principle is shown in Fig. 13, where there are two coils, MM', attache
to opposite ends of a beam which is supported at the middle and free to mov.
Each coil moves between a pair of fixed coils, F F and F' F', and all of th
coils are connected in series in such a manner that the moments of all th
forces on the movable system, taken about the beam axis, are cumulativi
thus tending to produce rotation. In the Kelvin balance the controUin
or opposing force is a weight moved along a graduated scale attached t
the beam supporting the movable coils; the moment of this weight abou;
the beam axis, when the moving system is balanced, varies as the squar
of the e.m.f. In the Westinghouse instrument the coils are arranged vei |

tically and the controlling force is a spiral spring. The amount of com'
pression of this spring necessary to balance the electromagnetic forces, al
indicated by a pointer moving over a scale, is a measure of the e.m.f. Single.!
coil instruments are direct reading and hence fluctuating e.m.fs. can be mor
easily read on them than on the torsionhead instruments, but the latter ar
astatic and therefore practically independent of stray fields.

68. Soft-iron-vane voltmeters (alternating current) utilize the re

action between a temporarily magnetized piece of soft iron and the magnetiz
ing field. In the Thomson inclined coil instrument of this type th<

Counter Wt--

Flo. 14. — Diagram,voltmeter.

coil a.c.
Thomson inclined ]''l' !
"

! ) ;i^,'-!in,
soft-iron type a.c. voltmeter.
WeStOE

plane of the energizing coil, C (Fig. 14), makes an angle with the shaft, S
which carries a member, i, comprising a rectangular piece of very thin, sofi
iron. This piece of iron is so attached to the shaft that rotation is producec
by the tenden cy of the iron to become parallel with the field established bj
the coil. In Weston instruments of this type (model 155), the reactioi
which produces the deflection takes place between two pieces of soft iroi
bent in the arc of a circle and placed concentrically, one of which, F' (Fig. 15)
is movable, and the other, F, is stationary. When the surrounding coil, M
is energized, the pieces of iron become magnetized in like manner, so that th<
resulting force is one of repulsion. The stationary piece F is made triangula:
in shape, with the pointed end in the direction of rotation, for the purpo8<
of making the scale more uniform. Air damping is obtained by means of i

light aluminium vane, V, in an enclo.sing chamber, C. This type has th(

great advantages of low price, ruggedness, open scale and small weight.

69. Induction-type voltmeters (alternating current) utilise the prin

ciple of induction watt-hour meters (Par. 202), or the rotative tendency of i
free cup of thin metal when placed within a so-called revolving magnetii
field. Actual rotation of the movable clement is prevented by an opposini
spiral spring, so that the deflections become a measure of the current in th(
energizing coils. The Weatinghouse type P voltmeter is an importan

130
 MEASURING APPARATUS Sec. 3-70

sample of this type, for which is claimed a very high ratio of torque to
veight of moving element, rugged and simple con.struction, extremely long
cale and compactness.* The ar-
angement of the circuits is shown in
?ig. 16. The primary winding, P,
which is connected to the line circuit,
nduces a current in the secondary
grinding, S,opposite in phase to the
Drimary current. The secondary cur-
•ent passes through two auxiliary
joils, AA', wound in opposite direc-
;ians on the poles. The field pro-
duced by these coils will be displaced
:tO deg. in time phase from the field
produced by the primary winding and
approximately at right angles thereto
in space, thus producing the necessary
rotating field to cause the cup, C, to
tend to rotate. Incidentally, the in-
herent frequency error of induction
type instruments is largely neutralized
by this combined transformer and in-
duction motor action, the effect of fre-
quency changes being opposite in the
two cases.
70. Hot-wire voltmeterst (alter-
nating-current) utilize the expansion
—
and contraction of a wire carrying a Fig. 16. Diagram, Westinghouse
current proportional to the e.m.f. to be induction-type a.c. voltmeter.
measured. Fig. 17 shows the princi-
])al features of the Hartmann and Braun voltmeter. The current flows
ihrough the platinuni-iridiuni alloy wire, AB, which expands under the
heat produced. This ex-
pansion reduces the tension
on the fine phosphor-
bronze wire, CF, which in
turn allows the silk fibre.
Hi!, attached to the spring,
S, to be pulled to the left.
This fibre passes around a
small pulley on the shaft of
the moving system and
thus produces a deflection
of the pointer. Damping
is effected by the alu-
minium disc, D, moving be-
tween the poles of the per-
manent magnet, M. The
hot wire, AB, is in series
with a large non-inductive
resistance, R, so that the
current is proportional to
the e.m.f.
71. Electrostatic volt-
meters (alternating-cur-
rent) are similar to elec-
trostatic galvanometers
(Par. 37) or electrometers,
Fig. 17. — Diagram, Hartmann & Braun hot- except that they are de-
signed for measuring larger
wire type a.c. voltmeter.
potentials and are provided

* MacGahan, P. "Induction Type Indicating Instruments;" Trans.

A. I. E. E., 1912; Vol. XXXI, p. 1565.

t Pierce, A. W. and Tressler, M. E. "Hot-wire Instruments;" Trans.

A. I. E. E., 1912; Vol. XXXI, p. 1591.

131
Sec. 3-72 MEASURIXG APPARATUS
with scales which make them direct reading. They are made in a great variety
of forms, for both portable and switchboard use, but are used commercially
much more in Europe than in this country. The principle of their operation is
shown in Fig. 18, in w hichmm' is a thin aluminium vane suspended or pivoted'
between two pairs of fixed vanes,//'. The deflection through moderate ranges
is proportional to the square of the potential and is controlled either by a spiral
spring or by gravity. Damping is produced magnetically, by air vanes, or
by immersing the elements in oil. For ordinary commercial voltages a num-
ber of sets of vanes are arranged one above the other in a vertical position,
and connected in parallel, thus multiplying the effect (Fig. 19). For higher
voltages, one set of vanes is sufficient and they are usually placed in a vertical
plane with the moving element mounted on a horizontal shaft. In the
Westinghouse electrostatic voltmeter, the moving system ia not con-
nected to the circuit; Fig. 20 shows the arrangement of the parts. When
potential is applied to A and A', the hollow cylinders C and C
become oppo-
sitely charged by induction. The resultant attraction produces a deflection
because of the shape of the fixed plates, P and P'. The condensers K
and
K' are each formed by two flat plates and are connected in series with A
and A' to increase the range. For lower ranges these condensers are short-
circuited, so that ranges of 30,000, 60,000 and 100,000 volts are available in
the same instrument and on oqe scale. The elements are entirely immersed

Fio. 18. — Dia- Fia. 19. — Dia- Fig. 20.—Diagram, Westinu-

gram, electrostatic- gram, electrostatic- house high-tension volt-
type a. c. voltmeter, type a.c. voltmeter. meter.

in oil which permits a relatively compact construction, increases the torque

because of the greater specific inductive capacity of the oil and provides
damping.
72. Alternating-current awitchboard voltmeters are made in all of
the types described above (Par. 66 to 70), although in this country the
dynamometer, soft-iron vane and induction types are in most general use.
They are similar in general to the portable instruments, due regard being
given to the more severe requirements of switchboard service.
73. Calibration of alternating-current voltmeters. The dyna-
mometer type of voltmeter gives the same indication on continuous current
as on alternating current and may therefore be calibrated with continuous
currents, direct and reversed readings being taken. The inductance in
instruments of commercial ranges is so small that the readings are independent
of standard frequencies.
The soft-iron-vane type of voltmeter should theoretically be used only
on alternating current because hysteresis occurs to some degree in the vane.
Practically, however, the hysteresis is so small that there is very little differ-
ence between the respective indications with increasing and decreasing
potential. Provided with a steady source of e.m.f., under suitable control,
these instruments may be calibrated with continuous current by taking the
average of the "up" ai*l "down" potential readings corresponding to the
various points. Care should be taken that the potential is increased or
decreased only to the desired value and not beyond it. Theoretically, in-
struments of the soft-iron type are not independent of frequency or wave-
form; practically, however, the variation is not measurable throughout
commercial ranges.
 MEASURIXG APPARATUS See. 3-74

I Hot-wire voltmeters are theoretically and practically independent of

I
changes in frequency and wave form, and can therefore be calibrated with
j
continuous current. They are especially suitable for high-frequency
r; measurements.

|. Induction-type voltmeters are affected by changes of frequency.

!' Tliey must therefore be calibrated on alternating current of the frequency

^ for which they have been adjusted, in comparison with some secondary stand-
s ard which can in turn be calibrated with continuous current aa described
1 under precision measurements. Errors which result from ordinary varia-
J
tions in commercial wave forms are negligible.
Electrostatic voltmeters are independent of changes both in frequency
and in wave form, and may therefore be calibrated with continuous current
where the range will permit.
74. The effect of stray fields on alternating-current voltmeters is
very marked in some types of instruments. The error will vary with the
deflection and with the direction of the superposed field. In the case of
unshielded, single-coil dynamometer instruments, the error caiised by a
magnetic stray field of five lines per square centimeter may vary from 25
per cent, at quarter scale to 5 per cent, or 10 per cent, at three-quarters
scale; with a field of 10 lines per square centimeter these figures may become
75 per cent, and 25 per cent., respectively. Soft-iron-vane instruments are
much less affected, a stray field of 10 lines per square centimeter causing
about 10 per cent, error. Hot-wire and electrostatic instruments are not
affected. Shielded dynamometer instruments are available in which the error
with stray fields of 20 lines per square centimeter is only 1 or 2 per cent.
75. Measurement of small alternating e.m.fs. The single-coil
dynamometer type voltmeter is practically the only one available for potentials
of less than 25 volts. Since the deflections in this type of instrument are
proportional to the square of the potential, the lowest value that can be
measured with a 7.5-volt instrument is about 2.5 to 3 volts. By separately
exciting the fixed coils the sensibility will be greatly increased, because
the deflections will then be directly proportional to the potential impressed
on the moving coil. The "unipivot dynamometer type instrument
(Paul) with separate binding posts for fixed and moving coils is intended to
be used in this manner, full scale deflection being obtained with 1 volt.
For the accurate measurement of potentials of the order of 0.25 volt
and less, dynamometer instruments must be of the suspension, reflecting type.
Care should be taken that the excitation is in phase with the potential being
measured and that the current through the instrument remains proportional
to the potential. This current is I = E/\/^^+I^u^, wherein E = impressed
voltage being measured, i2 = resistance of instrument, Z/ = inductance and
u = 27rX frequency. When R is large the inductance is negligible, but when
it becomes small as in very low reading instruments, it may have to be
considered in the measurement. In that case, the instrument can be cali-
brated as an ammeter on continuous current and the alternating e.m.f.
computed with the above formula. For similar reasons, the temperature
coefficient may become significant.
76. Measurement of large alternating e.m.fs. Theoretically, any
alternating potential can be measured with any of the voltmeters described,
if sufficient series resistance is used. In a practical sense, the large energy
consumption and the insulation difficulties limit their use to measurements
of a few thousand volts, and then only for testing purposes. In connection
with commercial generation and transmission, potentials up to about 33,000
volts are almost universally measured in this country by means of step-down
instrument transformers (shunt type) connected to ordinary voltmeters.
The measurement of potentials higher than 33,000 volts is usually required
only in connection with high-voltage tests. The various methods of making
such measurements are as follows:
(a) Ratio of the step-up power transformer, in connection with an
ordinary voltmeter on the low tension side. This method requires an accu-
rate knowledge of the transformer ratio under various conditions of load and
potential, information which is often difficult to obtain.
(b) Step-down instrument transformers (shunt type) with an
ordinary voltmeter. This method requires an accurate knowledge of the
transformer ratio at various potentials, with the voltmeter as the secondary

133
Sec. 3-77 MEASURING APPARATUS
load. The method is simple, convenient and accurate, but the power con-
sumption and the cost of the transformer become prohibitive at high
potentials.
(c) Electrostatic voltmeter. Commercial instruments are available
up to about 200,000 volts. They require no appreciable power and are quite
satisfactory. The principal objections are the high cost of large sizes and the
lack of dead-beat qualities.
(d) Test coil. Where the source of the high potential to be measured
is a testing transformer, an ordinary low-reading voltmeter can be connected
to a few turns of the high tension winding brought out to separate terminals.
These turns should be at the grounded end of the winding. The ratio,
under all conditions, will be that of these turns to the total turns in the high-
tension winding, if the transformer has been well designed. This method is
generally sufficiently accurate and is very convenient.
(e) Spark gaps. The sparking distance between two terminals in
atmospheric air is a standard method of measuring high potentials. The
maximum length of gap which a given potential will break down depends,
in this case, on the maximum value and not upon the virtual or effective
value which is the value obtained in the other methods. The maximum
value, however, is the important one in tests of insulators and insulating
materials. When the wave
form is not a sine curve the
maximum value may deviate
materially from the theoretical
value, which is the virtual
(voltmeter reading) value mul-
tiplied by V^
77. Needle- point and
sphere spark gaps. The 0^35 "^
4
needle-point gap was for many '

years the standard method of

measuring high voltages, but
it is unsatisfactory for very
high potentials because of
variations due to atmospheric
pressure, humidity, proximity
of surrounding objects and
sharpness of the needle-points.
Spheres are now used instead
of needle points for the higher
values. • A gap with carefully .w—S.26A A i* 4^^-
machined and polished spheres
gives very reliable and con- Note:
sistent results due, probably, A Variation of 1 Cm. in Thickness and
to the fact that the gap breaks Width of Wood Parts is Permissible
down before corona forms and
perhaps also to the lesser di-
FlQ. 21. —Sphere spark gap.

electric spark lag.t The A. I. E. E. Standardization Rules (Sec. 24) recom-

mend the use of the sphere gap for voltages above 50 kv. and preferably down
to 30 kv. The needle gap may however be used from 10 kv. to 50 kv.
78. A. I. E. E. standard sparking distances in air, with needle-
point and sphere gaps are given in Sec. 24.
79. Batio of shunt-type instrument transformer. When a very
accurate measurement (within 2 per cent.) of a high potential is to be
made with an instrument transformer of the shunt type, the nominal ratio
cannot be relied upon as being sufficiently correct and the true ratio should
be determined by a direct measurement. In the accurate measurement of
power and energy the phase antrie .should also be known (Par. 179). For
the accurate determination of the ratio of instrument transformers of the
shunt type, the following methods are typical.
(a) Direct measurement of the primary and the secondary voltage

* Farnsworth, S. W. and Fortesjcue, CL. " The Sphere Spark Gap,"

Proe. A. I. E. E., 1913, Vol XXXII, No. 2, p. 301. See P'ig. 21.
t Minton, J. P. " Effect of Dielectric Spark Lag on Spark Gape," Qemral
EUctnc Review (1913), Vol. XVI, p. 614.

134
 MEASURING APPARATUS Sec. 3-79

preferably with two similar voltmeters. Fig. 22 shows diagrammatically

the connections for this method. The voltmeters Vi and Vi are similar, and
the resistance R is adjusted until the two deflections are about alike. The two
voltmeters are then connected in parallel on the secondary of the transformer
and the indication of Vz, corresponding to the previous indication of Fi,
is noted. The ratio is given by:
(?±L.)|,

wherein ft = resistance in with Vi; fi. = resistance of voltmeter Vj;

series
A'l = first reading of Vi; X2 = second reading of Vi.

^ Ground

Fia. 22. —^Connections — ratio of Fig. 23. — —

Connections ratio of
shunt type transformers. shunt type transformers.
(b) Opposition method. The secondary voltage is reversed and con-
nected in opposition to a part of the primary voltage, the ratio being measured
in terms of two resistances. Fig. 23 shows the scheme. The resistance r
is varied until the detector, T, indicates zero or a minimum deflection. The
desired ratio is evidently expressed by (fi r)/r. +
The detector may be either a telephone receiver, a dynamometer instru-
ment, or a synchronous reversing key with direct-current galvanometers
r._39). The telephone receiver is not sensitive at commercial frequencies,

'
Oround =" Ground

Single Phase Detector Three Phase Detector

Fig. 24. — Diagram, Westinghouse a.c.ground detector,
and if harmonics are present the precise balance point for the fundamental
frequency is difficult to locate. When using a dynamometer, the fixed coils
are connected in series with R (not r) and the moving coil in place of T.
When a rectifier is used, it is connected directly in place of T.
(c) Comparison with standard transformer. H. B. Brooks* proposes
* Brooks, H. B. Electrical World, Nov. 1, 1913, p. 898.

135
Sec. 3-80 MEASURING APPARATUS
a simple and convenient method of comparing two transformers by means
of a wattmeter.
80. Alternating-current ground detectors are usually electro-
stfktic instruments. Fig. 24 shows diagrammatically the principle of West- i

inghouse detectors. The stationary vanes are connected through con-

densers to the main lines, and the movable vane is connected to ground.
In the single-phase detector, a charge will be induced on each end of the mov-
able vane, opposite in sign to that on the corresponding stationary vane,
setting up forces of attraction. When the system is free from grounds,
these attractive forces are equal and opposed to each other; hence the mov-
ing system stands at zero. A ground on either phase wire produces an un-
balanced condition and a deflection away from the grounded conductor. In
the three-phase detector, the vanes are sectors of spheres, the movable vane
being mounted on a universal bearing.
81. Oeneral Electric ground detectors operate on a principle similar
to that last described. Four quadrants, or fixed, flat vanes are cross-con-
nected and mounted between them is a moving vane connected to ground.
Opposite sets of fixed vanes are connected to the two sides of the line circuit
and the action is the same as described in Par. 80. The three-phase
detector is similar, consisting of three pairs of fixed quadrants mounted
120 deg. apart on a common base plate, and a flat moving vane with three
corresponding sectors.
CONTINUOUS-CURRENT MEASUREMENTS
82. Absolute measurements of current. The fundamental unit of
current, as derived from the centimeter, gram and second, is defined in
terms of the dimensions of the conductor and the strength of the magnetic
field produced by the current. Absolute measurements of current are there-
fore made with instruments so carefully constructed that the current can
be calculated from their dimensions.
83. Instruments for absolute measurement of current. Absolute
determinations have usually been made with two classes of instruments. In
the first, the deflection of a magnetic needle at the centre of a coil is measured,
and the current is calculated from the dimensions of the coil, the strength of
the earth's field and the torsion of the suspension. The best known example
of this class is the tangent galvanometer (Par. 11). This method involves,
of course, any error in the determination of the earth's field. In the other
class of instruments, the needle is replaced with a suspended coil. When the
length and the radius of both movable and fixed coils are in the ratio of
VS : 1, when the centres coincide and when the dimensions of the fixed coil
are large compared with those of the movable coil, it has been shown by
Gray that the torque exerted by the moving system is expressed by
T=~ (dyne-cm.) (10)

where iV = number of turns in fixed coil, n = number of turns in movable coil,

D = diameter of fixed coil in centimeters, L = length of fixed coil in centimeters,
r = radius of movable coil in centimeters, and / = current (coils in series).
Hence by measuring the torque (weighing it), the current can be determined
directly in C.G.S. units.
84. Practical unit and standard of current. It would be quite
impracticable to make ordinary measurements in terms of the fundamental
unit, by the methods indicated above (Par. 82 and 83). The Act of Congress
of 1894 which legalized certain practical units of electrical measure defined
the practical unit of current, or the international ampere, as one-tenth
of the fundamental C.G.S. unit. This Act also defined the standard unit
of current as the rate of deposition of silver at the cathode of a silver volt-
ameter (Par. 86) constructed and operated under certain prescribed condi-
tions, the ampere being the current which will deposit 0.001118 g. of
silver per sec. in a standard voltameter.
86. Methods of measuring continuous currents. The several
methods of measuring continuous currents may be classified aa follows:
voltaraeter; potentiometer; and ammeters.
86. Voltameter method of current measurement. When a con-
tinuous current is passed through an electrolyte, the latter is decomposed at

186
 MEASURING APPARATUS Sec. 3-87

i rate which is proportional to the current strength, and an apparatus for

asuring current by such means is called a voltameter. In the silver
roltameter, the cathode or negative electrode is always platinum, the anode
or positive electrode is pure silver, and the elec-
trolyte is silver nitrate. Fig. 25 shows the general
form. The anode is usually a silver rod projecting
into a platinum bowl, which rests in turn on a cop-
In cheaper forms, plates of silver and
^ Q« per plate.
platinum are supported in a glass jar. The solution
is usually about 15 per cent, (by weight) silver ni-
trate, and the effective area of the anode is about
50 sq. cm. per ampere. In order to prevent disin-
tegrated silver on the anode from dropping on the
cathode, the anode is surrounded with pure filter
paper or a porous cup made of unglazed porcelain;
S ^=^^y a in other cases, merely a shallow glass dish is placed
fl \-~ V — r)I
beneath the anode.
I .
. Recent investigations at the
f
Bureau of Standards* have shown, however, that
'
the chemical activity of filter paper results in an
'

Fia. 25. —
Silver
voltameter.
excessive deposit of silver and that the porous cup
is much more suitable. The average current in
amperes is computed from the formula

^=000^ ^^-P-)
.
''''

where M = weight
=
grams, t = total time in seconds
of silver deposited in
and 0.001 118 electrochemical equivalent of silver (Sec. 19).
87. The copper voltameter is used to measure very large currents.
The anode is electrolytically pure copper, the cathode is either copper or
platinum, and the electrolyte is a solution of pure copper sulphate in the
proportion of 10 g. of crystals to 40 cu. cm. distilled water. Two anodes may
be used in order to utilize both sides of the cathode (Fig. 26) and the current
capacity may be further increased by connecting additional
plates in parallel. The current density should not exceed 1 amp. R,
per square centimeter of cathode area.
88. In the gas or water voltameter the electrodes are •^f^J'
two plates made of platinum, and the electrolyte is a 10 per
cent, solution of sulphuric acid. In the electrolysis of this solu-
tion, hydrogen gas is formed at the cathode and oxygen gas
at the anode. The total gas formed collects above the liquid,
and is measured volumetrically in a closed graduated tube form-
ing the upper part of the containing vessel.
89. Potentiometer method of measuring continuous
currents. Although the silver voltameter is the legal standard
for the measurement of current, its use is practically limited to
reference measurements or primary standardization. It is _

seldom used in commercial measurements because it is much Fig. 26.

more convenient to measure current in terms of the volt and the Copper
ohm. Even in measurements of the highest precision, current voltameter,
is determined from the fall of potential across a standard resist-
ance (Par. 113), the potential being measured with a potentiometer (Par. 48
(e),49, 60, 61). The potentiometer method is not only more convenient
than the voltameter method, but it is much more rapid and at least equal
in accuracy, because it depends only on the measurements of a difference of
potential and a resistance, both of which can be determined with a very high
degree of precision.
90. Indicating continuous-current instruments which indicate
current directly by the deflection of a pointer over a marked scale
are called
ammeters. Modern continuous-current ammeters are almost universally
simple millivoltmeters of the D'Arsonval type connected to the terminals of
a resistance (shunt) which in turn is connected in series with the main circuit
whose current is to be measured. The deflections of the instrument will be
proportional to the fall of potential across the shunt, and therefore to the cur-
rent flowing through it. A millivoltmeter may be made an ammeter of any
capacity by simply changing the resistance of the shunt.
• Bureau of Standards Bulletin, Vol. IX (1912), No. 2.

137
Sec. 3-91 MEASURINCr APPARATUS

91. D'Arsonval tsrpe of continuous-current ammeter. The prin^

ciple of these instruments has been described under "e.m.f. measurements"
(Par. 66). They are usually designed to have a full scale deflection with 50
to 200 millivolts (thousandths of a volt) at the terminals. The resistance of
the moving coil is much lower (0.5 to 5.0 ohms) than that of voltmeters, in
order to make the millivolt constant high.
92. Continuous-current ammeters of the switchboard type are
intended for continuous operation and the shunt loss should therefore oe low.
They are designed for 50 to 75 millivolts at full scale deflection. High-grade
portable ammeters are designed for 100 to 200 millivolts at full scale deflec-
tion, in order to permit the use of resistance in series with the moving coil,
thus reducing the temperature error, which is more important than the larger
shunt loss.
93. Shunts for continuous-current ammeters. In switchboard
ammeters and the lower grade portable ammeters of 25-amp. ratings and
less, the shunt is within the instrument case. Above 25-amp. ratings, the
shunt is usually separate from the instrument and means of connection are
provided by special flexible leads, which are included in circuit when the
instrument is calibrated, since they form a part of the resistance of the entire
instrument circuit. Obviously, these leads should never be altered
without recalibrating the instrument. In high-grade ammeters the shunts
are separate for all capacities.
94. Construction of ammeter shunts. Ammeter shunts are so
constructed as to have a resistance which will be constant, as nearly as
possible, under all conditions. The resistance metal has a low temperature
coefficient, and the temperature is kept low either by connecting several
strips in paralleland making the current density low, or by making the cur-
rent density high and using short lengths of the resistance metal with heavy
copper terminals designed to dissipate the heat by conduction and radiation.
The former method is most generally used, the strips being silver-soldered
into relatively heavy copper or brass terminals which are connected into the
circuit to be measured. The resistance metal should also have a low thermo
e.m.f. (Sec. 2) in junctions with copper.
96. Reduction of temperature errors in continuous-current
ammeters. Because of the large temperature coefficient of copper, it is ,

very undesirable con-

to ,

nect the moving coil of the C Rm

instrument directly to the o ^TRnT' Vv^^WVWvVWvWW\^» o
v\jv
shunt. Temperature er- ^
rors are reduced to a negli-
gible value by connecting
Pio. 27. —
Temperature compensation in
miUivoltmeters.
sufficient resistance having
a low temperature coeffi-
cient (manganin or similar Ri
metal) directly in series I VM\WV\AAAAV
with the moving coil as
shown in Fig. 27, or by C R^^ iJ,
arranging a compensating
shown in
circuit as Fig. 28,
q—i-HRHyiT
«vvv ^AMM
vvvv»» ^—^MM
vy»»» O \j
^
where C = moving coil, Rm ~
Fia. 28. — Temperature compensation m
. . .

= low-coefficient resistance
wire, and ije = copper re- millivoltmeters.
sistance wire.
96. The calibration of D'Arsonval type ammeters is effected by
adjustment of the resistance of the shunt, the resistance of the millivolt-
meter circuit, or both. Formerly each instrument and shunt were adjusted
together, but it is becoming customary to adjust all of the instruments of
a given type to deflect full scale with the same potential in millivolts at the
terminals. The shunts for these instruments are all similarly adjusted to
give the same potential drop, thus making all shunts and instruments of a
given type interchangeable. The shunts should be adjusted by varyjng
the main-line resistance between the potential taps and not by adjusting
resistance wire connected in series with the instrument leads. In calibrating
switchboard instruments and the lower grade portable instruments, the
potential terminals are attached to the main current terminals and adjust-

138
 MEASURING APPARATUS See. 3-97

ment is effected by reducing the cross-section of the resistance strips which

has been purposely left too large. In instruments of higher grade, the poten-
tial terminals are connected to the resistance strips inside the main terminals;
approximate adjustment is obtained by trial, and after soldering the tap wire
to the resistance strip, final adjustment is obtained by varying the cross-
section, or by cutting back a tongue-shaped piece of the strip whose end
is soldered to the tap wire.

ALTEKNATING-CURRENT MEASUREMENTS
97. Measurements of alternating: currents. There are, in the case
of alternating currents, three values to consider, the maximum, the average
and the mean effective or root-mean-square; the last is the value usually
desired. Alternating currents, like alternating e.m.fs., can only be compared
with the standard by means of a "transfer" instrument, that is, one in which
the effect produced by a current is the same whether the current is continuous
or alternating. Having determined the indication produced by the alter-
nating current to be measured, the value of a continuous current which will
produce the same deflection is obtained in terms of the standard.
^
98. Precision measurements of alternating current are made with
transfer" mstruments (Par. 64) which are usually of the reflecting, suspen-
sion, electrodynamometer class. The principle of these instruments is
described in Par. 32 to 34. P. G. Agnew has developed a tubular water-
cooled electrodynamometer having a capacity of 5,000 amperes and- an accur-
acy of 0.05 per cent. *
99. Secondary standards for alternating-current measurements,
adapted for direct observation, must obviously be capable of calibration
on continuous current. There are several instruments which fulfil this
requirement.
The Siemens electrodynamometer consists of two stationary coils
connected in series, with a moving coil su-spended between them by
a silk
fibre, The deflecting force or moment is opposed by a spiral spring, which
IS twisted by hand (in the so-called torsion head) until
the moving coil is
brought back to the zero position. The amount of this twist, as indicated on
a scale over which moves a pointer attached to the torsion head, is a measure
of the current. The final relation of the fixed and moving coils is therefore
always the same. The current in amperes is / = A; v^
where L = twist of
torsion head in degrees and A = a constant determined by calibration
on con-
tinuous current. The instrument is sensitive to stray fields, from both
direct and alternating current. The presence of such fields can be detected
by passing current through the moving coil only; a deflection under such con-
ditions indicates a stray field. Its effect may be reduced to a negligible
quantity by turning the whole instrument until no deflection is noted.
100. The Kelvin balance (Par. 67) is an electrodynamometer type
ot instrument which astatic and in which the forces of attraction and
is
repulsion are actually weighed as in an ordinarv balance. Kelvin current
balances are troublesome to use unless the current is extremely steady
a
condition which rarely exists with alternating currents; they have
therefore
been practically superseded, in this country at least, by other and
reliable, convenient instruments of the dynamometer
more
type, of which the
Westinghouse precision" ammeter is an example.
The Westinghouse "precision" ammeter is practically a Kelvin
balance, of relatively small dimensions, in a vertical instead of
a horizontal
plane. The electromagnetic forces are opposed by a helical spring which
19 twisted by means of a torsion head as in the Siemens
dynamometer. The
angular movement of the torsion head necessary to keep the mo\-ing
system
in the zero position is a measure of the current. The actual value of the
current is equal to the square root of the deflection, multiplied by
a constant.
101. Types of alternating-current ammeters. The four principal
types ot commercial ammeters are as follows: dynamometer, soft-iron
vane
induction, and hot wire. They are similar to the voltmeters of the same
(fat. 67 to 70 ), except that the windings consist of
types
relatively few turns of
' A^pew, P. G. "A Tubular Electrodynamometer for Heavy Currents."
Keprint No. 184, Bureau of Standards, June 17, 1912.

139
Sec. 3-102 MEASURING APPARATUS
coarae wire instead of a large number of turns of fine wire, the ampere-turnB
being about tiie same in both cases. Hot-wire ammeters with ratings of
more than 1 or 2 amp. are usually small current instruments connected to
non-inductive shunts, as already described in principle (Par. 90).
102. Measurements of larg:e alternating currents. The only type
of ammeter which is generally used in the direct measurement of large
alternating currents is the hot-wire ammeter, because it can be used with
shunts. While shunts are made for capacities of 1,000 amp. and over, the
'

accuracy with shunts of very large capacity depends upon the care taken
in the design to eliminate the eddy-current and skin-effect errors. The most
common method is to use current transformers of the series type, to step
down the current to a small value, usually 5 amp., which is convenient to
measure witii standard instruments.
103. Series-type instrument transformers (also known as current
transformers) serve two purposes; the convenient measurement of large cur-
rents, and the insulation of instruments and apparatus from high-voltage
circuits. They are similar to so-called power transformers, except that the
latter are connected in shunt across the line and the secondary potential
remains substantially constant irrespective of the connected load. Series
transformers are connected in series with the primary line, and the secondary
current remains substantially constant for a wide range of loads. The load
consists of instruments or other devices which are connected directly in series
with the secondary winding.
104. Measurement of ratio of series transformers. The ratio
of series-type instrument transformers may be determined by measuring the
Erimary and secondary currents directly with current-measuring instruments,
ut obviously such
method is much less ac- Trans, ijj P'
curate than null or "zero"
methods. The principle AA/W- -"TTOIP
of the latter is the same
as that, of the potenti-
ometer. A non-inductive
resistance in the second-
ary circuit is adjusted
'^^^ZiCs
until the potential drop
across it is equal to that Fig Connections for measuring ratio of
in a non-inductive re- series type transformers.
sistance in the primary
circuit. The ratio of the two resistances
is equal to the ratio of transformation.
The differences among the various null
methods are largely in the manner of de-
termining the balance and in measuring
the phase angle. Fig. 29 shows the scheme
of a method used at the Bureau of Stand-
ards,' where a reflecting dynamometer is
used as the detecting instrument. R' and
R^ are the resistances in the primary and Fig. 30. —
Connections for
secondary circuits, respectively. The fixed measuring ratio of series type
coil of a dynamometer, D\, is connected transformers.
in series with the primary; then, with the
switch S thrown to the right, R2 is adjusted until zero deflection is obtained.
The component of the potential drop in Ri, which is in phase with that in
R\, is thus equal in magnitude to the drop in R' .Since the phase angle is
always very small, the ratio of Ri to Ri may be taken as the transformer
ratio. The phase angle is then determined by measuring the component of
the Rz drop which is 90 deg. from the Ri drop, by means of another dyna-
mometer, />!, the fixed coils of which are excited by a current displaced 90
deg. in phase from the primary current.
Fig. 30 shows the scheme of a method used at the Electrical Testing
Laboratories. t R\ and Ri are the primary and secondary resistances,

• Bureau of Standards Bulletin, Vol. VII, 1913, No. 3, p. 423.

t Sharp, C.H. and Crawford, W. W., Tram. A. 1. E. E., 1910, Vol. XXIX,
p. 1617.

HO
 MEASURING APPARATUS. Sec. 3-105

espectively, and C is the detector which in this case is a synchronously driven

oversing key (Par. 38) connected to a Paul "unipivot" galvanometer. The
econdary of a mutual inductance, M, is in the detector circuit and the pri-
iiiry of the inductance is in series with the secondary circuit of the trans-
(
inner. After the value of Ri has been found which will make the "in-
ili.i^o" potential drops balance each other, the quadrature drop in Bj is
cihinced by the e.m.f. in the secondary of the variable mutual inductance.'
\iui\ving the value of this inductance, the value of the phase angle may be
•ai('\ilated.

105. Ratio of series-type instrument transformers. Theoretically,

he ratio of transformation should be the same as the ratio of the secondary
"!s to the primary turns, and the secondary current should be in exact
-( opposition to the primary current. Actually neither of these condi-
- exists because of the current required to excite the core and supply the

hi many commercial measurements these errors can be neglected, but

.!i uccurate measurements of current, power and energy, the true ratio
should be known. In power and energy measurements, the phase angle
(an;j;le between the actual vector position of the secondary current and the
theoretical position which ie 180 deg. from the primary current) should also
be known. See Par. 179.
106. Measurements of small alternating currents. The methods
described measuring small alternating e.m.fs. (Par. 76) may be used
for
for similar measurements of current. Portable ammeters of the soft-iron-
vane type are made with ratings as low as 50 or 75 milliamperes at full scale;
the impedance of such instruments is much higher than that of dynamometer
instruments. The dynamometer type, when separately excited, can be used
to measure currents as low as 10 milliamperes, with fair accuracy; one form
made by Paul has a maximum range of 20 milliamperes. For very small
currents, reflecting dynamometers are the most suitable.
107. Measurements of high-frequency alternating currents.
High-frequency currents are best measured by methods involving the heating
effect of the current. In the Fleming thermoelectric ammeter for relatively
l8trge currents the high-frequency current
flows through a number of very fine copper wires
stretched between the two terminals. These
wires are separated in space and each carries
about 2.5 amp., additional wires being added up

Fig. 31. — Diagram, Paul high- Fig. 32.

y
—Diagram, high-frequency
frequency galvanometer. ammeter.
to 30 amp. At the middle of the centre wire is placed a
of total capacity.
thermojunction connected to a sensitive galvanometer, whose indications
are proportional to the mean effective value of the high-frequency current.
For instruments used in Radiotelegraphy see Sec. 21.
Small high-frequency currents are sometimes measured with the ther-
mogalvanometer_ described in Par. 36. In a high-frequency galvanometer
made by Paul, Fig. 31, a thermojunction may be formed with an iron wire,
o, and a eureka wire, 6, looped together in such a way that the high-frequency
current traverses the junction from one side while a sensitive galvanometer is
connected to the other. Similar instruments in which the measured current
does not flow through the joint are stated to be superior because of the absence
of the Peltier effect* (Sec. 2).

* Douse. C. M. The Electrician, London; Aug. 19, 1910; p. 765.

141
 Sec. 3-108 MEASURING APPARATUS
Another practical method of measuring small high-frequency currents is
indicated in Fig. 32, where o and a' are two fine wires of different materials
stretched between two terminals. The wires leading to the galvanometer
are of the same materials, but so connected that a' and b are alike, and a and
b' are alike. Thus there are two thermo-
couples in series. Obviously the connections
should be at the same potential, and this is
adjusted on continuous current with direct
and reversed readings. In a bridge method,
the current is measured by the change in re-
sistance of a carbon lamp (with a very small
filament) in one arm of a bridge. Fig. 33; in-
ductance coils, o and a' prevent the high-
^ frequency current from flowing through the
bridge.
lOS. Measurement of rectifier currents.
T?
iiG. 11
33. w
High
\^ f
frequency
Either of two values of the current from a
rectifier may be required, the average value,
cur r e n t measurements qj. ^jig root-mean-squaro value. In connec-
bridge method. tiQjj vvith storage-lottery charging, the average
value corresponds to the equivalent c.c. value
and a permanent-magnet type of measuring instrument should be used.
On the other hand, the power taken by incandescent lamps varies as the
square of the current, and the equivalent c.c. current should be measured
with instruments which indicate the mean effective value such as hot-wire or
dynamometer ammeters.
109. Measurements of telephone currents. Telephone currents may
be measured with a form of potentiometer* or with a barretter (Par. 40) but
since telephone currents are of constantly varying amplitude and frequency,
measurements made by this and the above methods are usually of little value.
Telephonic intensities are usually compared by ear with a telephone, using
artificial standardized cables. Where quantitative measurements are re-
quired, a high-sensibility oscillograph can be used.t

&ESISTANCE MEASUREMENTS
110. Resistance standards in general. The practical unit of resist-
ance, the ohm, is represented by a column of mercury having certain dimen-
sions (Sec. 1). This standard is obviously difficult to construct, maintain
and use; and, in general, will be found only in the laboratories of the
national custodians of the fundamental electrical standards.
Secondary standards are therefore employed in actual measurements.
These are made with metal of high specific resistance, in the form of wire or
ribbon. Manganin (a copper-nickel-manganese alloy) is most used,
because, when properly treated and aged, it meets the necessary requirements.
These requirements are; permanent electrical and physical characteristics;
low thermo e.m.f. in junctions with copper; small temperature coefficient of
resistance; and relatively high specific resistance. The completed standard
must, in addition, be unaffected by immersion in oil, or by changes in
atmospheric conditions.
111. Classes of resistance standards. In general, resistance standards
may be divided into two classes: standards of resistance, or those used
primarily for the measurement of resistance; and current standards, or
those intended primarily for the measurement of current.
112. General construction of standards of resistance. Standards
of resi.stance have very small current capacity. They are made in two forms,
the Reichsanstalt and the N.B.S. (National Bureau of Standards). J The
former is shown, partially in section, in Fig. 34. The N.B.S. form is shown in
Fig. 35. The distinctive features of the latter form are that it is immersed
in oil and hermetically sealed. This prevents the absorption of moisture by
* Drysdale, C. V. "Alternating-current Potentiometer for Measuring
Telephone Currents," London Electrician, Aug. 1, 1913.
t Gati, B. Report of Second International Conference, European Tele-
phone and Telegraph Administrations; 1910.
X Bureau of Standards Bulletin, Vol. V, 1908, p. 413.

142
 MEASURING APPARATUS Sec. 3-113

shellac and the consequent expansion of the fine wire used in the larger
-tances. * Both forms are intended to be hung from mercury cups by
- of lugs, and suspended in an oil bath in order to measure the tempera-

more accurately. The N.B.S. form is made only in sizes larger than

Fig. 34. —Standard resistance

Reichsanstalt form.
FiQ. 35. -Standard resistanc
N.B.S. form.

113. Current standards are made in two forms, the Reichsanstalt and
bir-cooled. The Reichsanstalt standards are made in two types, the small
)attern for moderate currents, and the large pattern (in low resistances)
or large currents. The small-pattern form is similar in appearance to Fig.
i4 except that for 1 ohm and less, separate potential taps are provided,
rhey are suspended from mercury cups in an oil bath for cooling purposes.
The current ratings assigned by Otto Wolff and the Leeds and Northrup
I!ompany to small-pattern, Reichsanstalt form of standards are as follows:
[VVhen used for resistance measurements 0.3 and 1.0 watt, for still-air-cooling
ind oil-cooling respectively. When used for current measurements with a
lemperature rise of 10 deg. cent., 2.5 and 10 watts for still-air-cooling and oil-
30oling respectively. Large-pattern low-resistance current standards have
capacities from 100 watts to 2,500 watts and over.
114. Air-cooled current standards employ sufficient material topermit
of use in air without excessive temperature rise. While they are not as
accurate or as reliable as
the Reichsanstalt form,
they are amply satisfactory
for much commercial work,
especially where oil baths
would be inconvenient.
Fig. 36shows a Leeds and
Northrup Co. resistance, of
0.00002 ohm, and 2,000
amp. capacity, for which
an accuracy of 0.04 per
cent, is claimed.
116. Measurements of
conductor resistance.
There is no sharp distinc-
tion between materials
commonly called conduct- Fig. 36.- -Leeds & Northrup air-cooled standard
ors and those called in- resistance.
sulators. Resistances of
the former class may, however, be relatively high or relatively low, and
certain methods of measurement are especially applicable to each class.
116. The fall-of-potential method consists simply in noting the voltage
drop with a known current flowing through the resistance, and calculating
the resistance from Ohm's law, R = 1E,/I. This method is not suitable for

• Bureau of Standards Bulletin, Vol. IV, 1907, p. 121.

143
Sec. 3-117 ME-A.-^lIRTXa APPARATUS
very high or very low resistances and the accuracy depends upon the measure-
ment of two unknown quantities with indicating instruments. Furthermore
the current required to give a readable drop may cause overheating. The
method should therefore be used with caution and only where accuracy is
subordinate to simplicity and convenience. The potential should be
measured, when possible, between points well within the current connec-
tions, especially when the resistance is low and the current is high. Greater
accura y can be obtained by substituting a standard resistance in place of
the ammeter, and noting the drop across it, and across the unknown resist-
ance, in succession. The latter is then equal to the ratio of the two readings
multiplied by the standard resistance. The accuracy will be greatest when
the two resistances are nearly equal.
117. Bridge methods are the most accurate for resistance measurements
because: (a) they are zero methods; (b) comparison is made directly with
standardized resistances, the accuracy of which can be made very high. The
principal types of bridges are known as Wheatstone, slide-wire, Carey-
Foster and Kelvin.
118. Wheatstone bridge. The Wheatstone bridge is most generally
used for the measurement of all but the highest and the lowest resistances.
Fig. 37 shows the theoretical arrangement of a Wheatstone bridge where
r, n, and r? are accurately known resist-
ances and rx is the resistance to be meas-
ured. When using the bridge, the various
resistances are adjusted until the galva-
nometer, G, shows no current flowing
1000 100 1 ^ 10 1 00 1000
-"I' 1

400 100 jUo 30 20 j

'
,1 r
M •*W 1000 iiPPO ^"PQ ">

K.,^{<^Ki
^—^
Fio. 37.
— ^HHHH^
-Diagram of Wheatstone Fig. 38.
J^#[
— Wheatstone bridge
bridge. PostofBce form.

then, rx= (,n/ri)r. The battery switch, Si, should always be closed before
the galvanometer switch, Si, in order to protect the galvanometer from the
momentary rush of current. The galvanometer and the battery may be
interchanged without affecting the result (Sec. 2, Par. 30).
119. Forms of Wheatstone bridges. These bridges are made in a
variety of forms. In most forms the resistances, r, n and ri, consist of a
number adjusted to various multiples
of resistance coils or units carefully
of 10 and so arranged that they can be conveniently connected in and out of
the circuit by means of plugs or switches. The resistances, n and n (Fig. 37)
are commonly called the ratio arms and r the rheostat arm. A very early
form, which is still in use in small portable sets, is the Postofflce pattern,
shown diagrammatically in Fig. 38. Coils are cut out by short-circuiting
them with plugs, so that there may be several plug-contact resistances of an
unknown and variable amount in a given arm. In the improved form, shown
diagrammatically in Fig. 39, this objection is overcome by arranging the
coils of the rheostat arm on the "decade" plan in which there are nine 1-ohm
coils in the "units" division, nine 10-ohm coils in the "tens" division, etc.
Any number of coils in a given division can be connected in circuit by
changing only one plug. In many later types, the ratio-arm coils are also
connected on the decade plan, which in aadition to eliminating plug-contact
resistance errors, permits interchecking the coils. Furthermore, the decade
arrangement permits the use of sliding-brush or dial construction instead
of plugs.

144
 MEASURING APPARATUS Sec. 3-120

120. Use of Wheatstone Bridges. Such bridges are best suited for
isuring resistances of the order of about 1 ohm to 100,000 ohms. Accur-
-i of the order of 0.05 per cent, are obtainable with a first-class bridge
;ic unknown resistance is intermediate in value between the limits last
id. The maximum precision is obtained when the four arms are
hence this condition should
ihvays be approached as nearly as pos-
-ible by keeping n/n small, and n and
2 a.s nearly equal to r as convenient.
A galvanometer with 100 ohms to 500
uhnis resistance will be satisfactory for
Ill-ally all classes of work. The resist-
ance coils will dissipate about 1 watt
without overheating, but care should be
taken that the current does not become
excessive when the ratio becomes large.
121. The slide-wire bridge is one
of the earliest forms of the Wheatstone
bridge. It is convenient and rapid
wlicre many similar measurements are
made. It differs from the stand-
SoooooooJ
to be
ard Wheatstone bridge in the respect ©oasDOOoo
that balance is obtained by varying the
ratio n/n, instead of the resistance r
0OOOOOOO
(Fig. 37). This is accomplished by
moving the contact, b. Fig. 40, along a
^SDOOOOOO
wire, ac, which forms the resistance ri ®000(3D00
-|-rj. This wire should be uniform in
cross-section and homogeneous, so that ©ooooooo
the resistance per unit length will be
constant. At exact balance, the ratio ©oooooasD
of the lengths ab/bc = n/ri and rr =
The precision is a
©ooooooo
(ri/r2)r as before.
maximum when the sliding contact
When the slide wire is
is ©ooooooo
at the centre.
short, the precision decreases rapidly
with settings toward either end. The
©oooooop
1000 100 10 1

length may be increased, in effect, by

inserting equal resistances at n, n',
which increases the sensibility, but also
decreases the permissible difference be-
Fig. 39. —Wheatstone bridge
Improved "decade" form.
tween and _ _.
122. The Carey-Foster bridge Is particularly adapted to the_ compari-
son of low resistances. The distinctive feature is the elimination of the
contact resistance and other unknown resistances, in the arrangement shown
in Fig. 40, by taking two readings. The bridge is first balanced with the
contact at x. The resistances r and rx are then interchanged and a balance
obtained at xi. If the resistance of the slide wire per unit length is p, then
rx — r = p{xi — x). This method
is especially suitable for com-
parison of standard resistances
with each other and for tempera-
ture coefficient determinations.
123. The Kelvin double-
bridge is especially suitable for
measurements of low resistances.
It is the most generally used
form, even in the most precise
work, because of its accuracy
Fig. 40. — Carey-Foster bridge. and convenience. The principle
is shown in Fig. 41. The resist-
ance of the connection between r and Tx is made negligibly small and the
bridge assumes the form of the Wheatstone bridge (Fig. 37) with the addi-
tion of an extra pair of ratio arms, a and (3. When a balance is obtained:
(8 ...
(12)

10 145
Sec. 3-124 MRAfiURINO APPARATUS

In practice, n/ri is kept equal to a/p and the resistance d is made negligibly
small. Then ri = (ri/r2)r, as in the Wheatstone bridge.
In the WolflF bridge, Fig. 42, the ratios ri/n and a/0 arc automatically
adjusted simultaneously, by sliding contacts on the four dials. In the Leeds
and Northrup bridge, Fig. 43, both r and the ratio n/rs are adjusted.

Fig. 41. — Diagram of Kelvin double bridge.

II

aaaaAa
Specimen Standard
Beslstauce

KJjms^j.
,M.
Fia. 42. — Kelvin double bi'idge— Wolff form.
124. Conductivity measurements. The specific conductance or
conductivity of a material is the reciprocal of the specific resistajice or
resistivity. The relative conductivity is the ratio, expressed in per cent., of
the specific conductance of the sample to that of a standard material. The
relative conductivity may be based on equal masses or equal volumes. The
former is in most common use because conductor metals are usually sold on
a weight basis (see Sec. 4).

146
 MEASURING APPARATUS Sec. 3-125

us. Conductivity standards. The present oflacial standard of the

is the International Annealed Copper Standard,* defined as
.. I. E. E.

allows:
Mass-resistivity at 20 deg. cent.:
0.15328 ohm (meter, gram)
875.20 ohms (mile, pound)
Volume-resistivity at 20 deg. cent, and 8.89 density:
1.7241 microhms (cm.')
0.67879 microhms (in.')
10.371 ohms (mil, foot)
For earlier standards of copper resistivity, see Sec. 4.

FiQ. 43. — Kelvin double bridge— Leeds & Northrup form.

126. Methods of measiuring conductivity. Conductivity may be
determined by calculation from the measured resistance or by direct
comparison with standards of conductivity. When the conductivity is
to be calculated from the resistance, the specimen must have a uniform
cross-section. The resistance of a definite length is carefully determined,
the temperature being noted. Then the resistance of a piece of copperhaving
100 per cent, conductivity and the same weight and length as the specimen
(or, for volume basis, the same cross-section and length) is calculated from
the stated definition of the standards. The ratio of these two resistances is
the conductivity of the specimen. The direct comparison methods employ
conductivity bridges which are adaptations of the Kelvin bridge. They are
intended for commercial work, where speed combined with moderate accuracy
is important.

Scale I

\a
Sec. 3-128 MEASURING APPARATUS
about 300 ohms each, in order to eliminate the effect of contact resistance i

at a, b, c and d. When the bridge is balanced, the resistance between o <

and d on r is equal to that between a and 6 on ri. The unknown specimen

Tx is cut to a certain definite length and carefully weighed. The contact,
d, on the standard is then set at the point indicated on the carefully graduated i

scale H, which corresponds to this weight. Then the resistance, cd, is equal i

to that of a piece of wire having 100 per cent, conductivity, a length equal to i

100 parts in the scale I and the same weight per unit length as Tx. Contact i

b is shifted until a balance is obtained and the conductivity is read directly i

from scale I, 100 scale divisions corresponding to 100 per cent, conductivity.
One standard is provided for every three sizes of wire in the American
(B. & S.) gage. The standards are usually of the same material as that being
tested, so that the temperature does not have to be observed.
128. Resistance of rail joints. The testing of rail bonds consists
in determining, either, (a) the ratio of the resistance of a given length of rail,
including a bonded joint, to that of the same length of continuous rail;
or (b) the length of solid rail which has the same resistance as the joint.
The resistance of rail bonds is usually expressed in the latter manner, whether
measured in that way or by the former method. Three methods are em-
ployed: millivoltmeter, bridge, and opposition.
129. Millivoltmeter method of measuring rail bonds. In the milli-
voltmeter method, simultaneous readings are taken with 2 millivoltmeters,
one connected across the bond and the other across a definite length of rail.
If the current fluctuations are not too rapid, only one instrument is neces-
sary, provided there is a suitable arrangement of keys to change the con-
nections in quick succession.
130. In the Roller bond tester the principle of the slide wire form of
Wheatstone bridge is employed (Fig. 44). Balance is obtained by moving
the contact B back and forth.
At balance, ab/bc=(ri-\-m)/
(rj+n); where ab = resistance
of bond and be = resistance of
the standard length of rail.
The resistances n and n have
the effect of extending the slide
wire and providing greater
accuracy (see Par. 121). In
the actual instrument, the slide
wire takes the form of a circle
and the scale is graduated to
Ball
.
give the resistance directly in
Bond terms of the number of feet of
the solid rail being tested.
Fig. 44.- -Diagram, Roller bond tester.
131. The Conant bond
tester is an example of the
class in which the drop across the joint is opjposed to that across a length of
solid rail, the outer contact on the latter (c. Fig. 44) being moved along until
the two potentials are just equal and opposite. The detector is a telephone
receiver in series with a make and break device operated by a clock.
132. Insulation resistance. The resistance of insulating materials
is usually measured by deflection methods. In the case of resistances
of the order of 1 megohm and less, a Wheatstone bridge may be used, but
the accuracy will be low because of the extreme ratio required (Par. 121)
and the low insulation resistance of the bridge.
Two general clas.se8 of deflection methods are used: (1) direct deflection
and (2) leakage. The direct-deflection methods involve a .simple application
of Ohm's law, the current being measured with a voltmeter used as an am-
meter or with a galvanometer,
133. Direct-deflection method (insulation resistance). When
the resistance is of the order, of 1 megohm, an ordinary voltmeter
will give resultswhich are sufficiently accurate for most purposes. Two
readings are taken, one with the voltmeter directly across the battery or
generator, and the other with the resistance to be measured connected in
series with the voltmeter. The resistance is R^r, {d — di)/di; where rv =
148
 MEASURING APPARATUS Sec. 3-134

"Ml-eBistanoe of voltmeter (the greater the resistance per volt, the higher the
-1 d = deflection of voltmeter in first reading, rfi = deflection in sec-
'jrecision),
'a Obviously a portable galvanometer with series resistance may
)nd reading.
>e used as a voltmeter.
't,
1

•d When the resistance is moderately high, a high-resistance reflecting

!

•»1;D'Arsonval galvanometer is employed. Fig. 45 is a simpUfied diagrammatic

irrangement for measuring the insulation of a Jcable. The measurement
•0
'

s made as follows: after the galvanometer shunt, s, is set at the highest

:

jralue (Par. 29 and 30) and r, is short-circuited, the main circuit is closed.
V

The shunt is then decreased until the largest readable deflection is obtained.
;

in A reading is taken after 1 min. This procedure is then repeated with the
i 'Standard resistance r, (usually 0.1 or 1 megohm) in circuit and the specimen
short-circuited. The resistance of the specimen in megohms is: R=G/d\s;
,i
where di= first reading, s=. multiplier corresponding to the shunt setting

I
ITaatis,

m
1,
Fig.

10, 100,
4.5. — Diagram, insulation resistance
1,000 or 10,000) andG= galvanometer megohm-constant
(Par. 24) as obtained from the second measurement.
of cable.

The constant is
G = (hT,; where d= deflection, s= shunt multiplier, r,= standard resistance
megohms. The conductor is preferably negative to the sheath or water.
134. Leakage method of measuring insulation resistance. Very
high resistances such as the resistance of porcelain and glass, and surface
leakage resistance of line insulators, are best measured by the method
of leakage, also known as the loss-of-charge method. This method is based
on the theory that if the insulation resistance of a condenser is infinite, it
will retain a charge indefinitely; whereas if the resistance between the con-
denser terminals (either the internal resistance or a resistance connected
externally) is finite, the rate of loss of the charge (or leakage) will be a meas-
ure of that resistance. The principle of this method is shown in Fig. 46
where the resistance to be measured, r, is connected in parallel with a con-
denser C. Key o is closed and immediately opened, thus charging the con-
denser. Key f> IS closed immediately after o is opened and the deflection,
di, of the ballistic galvanometer noted. The process is repeated, a being
left open a definite time, t seconds, before h is closed
and a second deflection
di observed. The resistance in megohms is then:
t
»= r (megohms) (13)
2.303 C '°«"'(|)
w^here C is the capacity of the condenser in micro-farads.
The insulation resistance of the condenser is usually not infinite.
Correction should be made by measuring the resistance of the condenser in
a similar manner, r being disconnected. If ri is the resistance of the condenser
I
and n the resistance obtained above in Eq. 15, the corrected value is

(megohms) (14)
136. Measurement of specific resistance (resistivity) of solid
Insulating materials. This is obtained by calculation from the
resist-
ance between two similar metallic electrodes of known area in intimate con-
^.'^*,^7*^ *J»^ opposite and parallel faces of a specimen of the material,
lin-fo'l makes convenient and satisfactory electrodes
if backed with
blotting paper and sufficient weight to insure good contact.
136. The specific resistance of liquid insulating materials may be
approximately determined by pouring a specimen into a round glass cylinder

149
Sec. 3-137 MEASURIXG APPARATUS
or graduate in which two circular, closely fitting disc electrodes are supported
One of the electrodes should be movable so that the resistance of column
of several different lengths can be measured. The first measurement shoult
be taken as the zero or base reading and the results checked by calculation
of the increase in resistance and the corresponding increase in the spacini
of the electrodes at different settings.
187. Precautions in measuring insulation resistance. In the meaa
urement of the insulation resistance of specimens haying electrostatic capaof
ity,suflScient time should be allowed for the specimen to become charged
that is, until the deflection becomes constant, at i
minimum value. This usually takes place within Jl

min., except in long lengths of cable. In order t<

eliminate uncertainties in this connection, it
customary to specify 1-minute "electrification." \
As the apparent insulation resistance varies witll
the testing potential, one hundred volts is usualljj
prescribed as the minimum pressure that should bli
used. 1

Leakage over the surface of wire or other specij

mens may be a source of much trouble in dam|»
weather. In] wires and cables, the lead or braid
should be removed for 2 or 3 in. from the ends anijj
Fig. 46. —Leakage the exposed insulation coated_ with hot, clear
method of measuring paraffine; or, just before measuring, these prepare*
insulation resistance. ends may be carefully dried with an alcohol, Bunser
or other flame free from carbon. As a further pre^
caution, a "otiard" circuit may be arranged as shown by the dotted lines ii^
Fig. 45. This consists of a few turns of fine copper wire twisted arounc'
the insulation close to the copper conductor and connected to the batterj
side of the galvanometer. In the case of solid specimens, the twisted wirt
is replaced with a ring of tin-foil as shown in Fig. 97.
'

Specimens having electrostatic capacity should be put in a neutra'

condition by rapidly reversing the current a number of times, beginning a*
a low rate of reversals and gradually increasing. Where the capacity i;
high it may be advisable gradually to decrease the applied voltage at th*
same time.
The side of the circuit which contains the galvanometer should be well
insulated throughout. The battery also should be insulated as thor-
oughly as possible; this is a relatively easy matter when dry cells are used
The important point is to insure that all current passing through the speci
men, and only that current, passes also through the galvanometer.
The galvanometer should, preferably, have a high resistance (orde;
of 1,000 ohms) and a megohm sensitivity (Par. 23 and 24) of several hundrec
megohms. The temperature P_
should always be noted, be-
cause of the large coefficient
which most insulating mate-
p
C^ \e
u ilji^w*^
YuY Y Y Sv
—^— —
rials have. J*^ ?-^>
13B. xaeasunng tne tnsu-
lation resistance of circuits.
' » t
i^sl^'
'

—? '
The insulation resistance of
"dead" circuit conveniently
is
madeby the voltmeter method. piQ. 47.— Insulation resistance of "live'
When there is no source of circuits,
e.m.f. available, various port-
able instruments described be-
low are especially applicable and convenient. (Also see Sec. 21.)
When the circuit is "alive" the following method may be used.* Fig
47 represents diagrammatically a system with lamps and motors connected
The resistances Xi and Xt represent the insulation resistance from the posi
tive and negative sides respectively to ground.

Xi-=-~-^ -•andAi= 3-- (ohms) U'',

di di
;'
* Northrup, E. F. "Methods of Measuring Electrical Resistance
McGraw-Hill Book Co., p. 210.

loO
 MEASURING APPARATUS Sec. 3-139

U .lere if = resistance of voltmeter; Z) = deflection (scale divisions) corre-

.onding to circuit voltage, E; di = deflection corresponding to Vi: d2 = de-
i:

:i corresponding to F:.
'Ction
M .Should the system be continuous current, a D'Arsonval-type volt-
?ter is preferable; if it be alternating current, an electrodynamometer-
„pe instrument should be used. This method in general will measure 1
^ .'jgohm with sufiBcient accuracy to check specifications. If the resistance
„ .over 1 megohm a galvanometer method is more accurate.

;: : 139. Portable instruments for the direct measurement of insula-

;: on resistance are classed either as testing sets or ohmmeters. Testing
v its range from a simple Wheatstone
: idge with self-contained galvanometer
id battery, to elaborate cable-testing sets
:: aich include a small Wheatstone bridge,
1 standard 0.1 megohm resistance for in-
1

;< elation tests by the series galvanometer

ethod, and a standard condenser for
: .pacity measurements.
;
Ohmmeters indicate the resistance
:
rectly.
[ In instruments of the Sage
: Tpe, the principle of the slide-wire bridge
employed. A scale beneath the slide
; ire is calibrated directly in ohms, so that Evershed Megger.
hen balance is obtained, the resistance
. read off directly. The range can be extended by means of a number of
ifferent ratio arms, a separate scale being provided for each. Where alter-
jating current is necessary, as in measuring electrolytes, an induction coil
• introduced in the battery circuit and a telephone replaces the usual galva-
:ometer. Ohmmeters are specially convenient for quantity (factory)
33ting.
I The Evershed '
Megger " is an ohmmeter which indicates the
:;9i8tance by the movement of a pointer over a calibrated scale.* The
rinciple employed is indicated in Fig. 48, where A
is a coil in series with the
asistance to be measured and B, Bi are coils, which, with the resistance R,
re connected to a hand-driven generator D. All three coils are rigidly
loupled together and are connected to the circiut by fine copper strips
-fhich exert no controlling force. When the generator is actuated a current
lows through coils B, Bi proportional to the e.m.f. generated. If the ex-
ternal circuit is open, B and Bi are deflected to the position where the least
flux from the permanent magnets M Mi will inter-
sect them, that is, opposite the gap in the C-shaped
iron piece about which the .coils A and Bi move.
The pointer then stands at "infinity" on the scale.
If now a finite resistance is connected across the
terminals, the current flowing in A will produce a
deflecting torque toward the position shown in the
figure, and, as the system moves, the coils B and Bi
exert an opposing torque of constantly increasing
magnitude. Hence the system comes to rest at a
point where the two forces are balanced, the position
depending upon the amount of the external resist-
ance.
140. Measurement of the resistance of elec-
trolytes. Electrolyte resistances are more difficult
to measure than metallic resistances because of the
counter e.m.f. of polarization. The several methods
in use are based on the method first proposed by
Fig. 49. —
Resistance Kohlrausch, that is, a simple bridge arrangement in
)f electrolytes
nethod.
—
Bridge which alternating current is employed instead of
direct current.
A standard Wheatstone bridge may be used, but
I slide-wire type is found more convenient, especially if the slide wire is
a
ong one wound spirally on a marble cylinder. When such slide-wire resist-
ince 13 a separate piece of apparatus, a bridge may be easily made up and
i sed as indic ated in Fig. 49 where R is a, non-inductive resistance box and
Tz
* Biddle, J. G. Circular No. 740; Philadelphia, Pa., 1910.
151
Sec. 3-141 MEASUniNG APPARATUS
the electrolyte. If the slide- wire scale is divided into 1,000 parts, the resigl
ance of the electrolyte is, at balance,

'^ = {(iodo-'^)}^- (ohms) (16

If the source is alternating-current power of commercial frequenciei

an alternating-current galvanometer (reflecting electrodynamometer) ma;
be used, the fixed coils being connected in series between the source, S, an
the bridge and the moving coil in place of D (Fig. 49). A Vreeland oscilla
tor (Par. 246) is very satisfactory as a source of energy because the wav
form is a pure sine curve and the frequency i
sufficiently high for a telephone at S.
141. Specific resistance of electrolytes^
Where the specific resistance or resistivity is rej
quired, a column of the liquid of known dimen'
sions must be isolated. Fig. 50 shows a satisfat
tory method.* The glass tube is about 20 cm
long, 1 cm. internal diameter and open at botii
ends. The electrodes are of gold or platinum, th-
lower one being fixed in position and perforated
while the_ upper one is adjustable. The averag
cross-section must be carefully determined, preferj
ably by volumetric measurement with mercury,
The temperature is readily kept constant bj
stirring the liquid in the containing vessel.
142. Internal resistance of batteries. Thr
measurement involves difficulties because of polar
ization. One simple direct-current method i
Fio. 50. —
Specific resist- as follows.
ance of electrolytes.
The e.m.f. of the cell or battery i
first measured on open circuit. The circuit i
then closed through a known resistance and thi
e.m.f. measured again quickly before polarization begins. The resistance i;

R^^^SlrJl! (ohms) (17|

'
i

where i? = known resistance, E and ^i = voltage before and after closini

circuit, respectively.
This method assumes that the internal resistance will remain constan
under all conditions, which is not always the ease, especially in dry cells
In a modification of this method, both readings are taken with the circui
closed, but with two slightly different values of R. Then

where Ri and Ei are the first resistance and e.m.f., respectively, and R
and Ei are the corresponding values with the second resistance.
In general, such direct-current methods should be used only with priniarj
batteries of very low resistance and with secondary or storage batteries
Alternating-current methods are more reliable.
143. Alternating-current method of measuring internal resistanct
of batteries. The Kohlrausch bridge shown in Fig. 49 can be used in thii
method, by inserting the cell or battery in place of the electrolyte cell
Without resistance R' connected, the resistance of the cell will be

If the resistance R' is connected, the resistance of the cell with a curren
corresponding to R' flowing, will be

.(«^-«> '''
-=(lFo£|ra-a
144. Effective resistance of alternating-current circuits. The passage
of alternating current through a circuit is opposed by the ohmic resistance

•Northrup, E. F. "Methods of Measuring Electrical Resistance,'

McGraw-Hill Book Co., p. 241.

152
 MEASURIXG APPARATUS SeC. 3-145

o by the resistance-equivalent of all the energy losses except the loss

e to ohmic resistance, and by the reactance. The "ohmic resistance"
the resistance to the passage of continuous current and is therefore
aasured with continuous current by the methods previously described.
145. The effective or alternating-current resistance is that value
i resistance which represents the total energy loss.
' It includes in addition
< the ohmic resistance, the effect of any other source of lost energy, such as
'•
jn losses in a magnetic circuit, dielectric losses, and induced currents in
^ neighboring circuit. This effective resistance produces a potential drop
"
hich is in phase with the current. The simplest method of determining
-
is from the relation: = I^R, where W W
= watts measured with a wattmeter,
current (amperes) and R = alternating-current resistance (ohms)
i

146. Measurement of effective resistance.

• When the power is small,
'irrent large and power factor low, an ordinary electro-dynamometer (Par.
•
1) may stUl be used.
1 The exciting current must be in phase with the current
irough the unknown resistance in order that the reaains obtained with the
'.oving coil across the resistance will be W
— I'R. This condition may be
iitablished in several ways: (a) by connecting the fixed coils across a series
'on-inductive resistance in the circuit (first compensating for inductance
necessary, see Par. 169); (b) by connecting the fixed coils to a phase
r

'lifter (Par. 213) which is first adjusted (the moving coil being connected
) a non-inductive resistance in series with the resistance to be measured)
ntil a maximum deflection is obtained. A
more sensitive method is to
'onnect a condenser in series with the fixed coils and adjust the phase shifter
3r zero deflection. The dynamometer can be caUbrated on a non-inductive
.esistance or on continuous current.

147. Wheatstone-bridge methods of measuring effective resistance

'tay also be used by providing facilities for obtaining a balance for both re-
sistance and inductance. The two "ratio" arms should be non-inductive,
"lad the "rheostat" arm should contain both a variable resistance and a
/ariable inductance, so that complete balance may be obtained. The
letector must indicate both states of balance_ and should be an electro-
^lynamometcr instrument or a synchronously driven reversing key (Par. 39).
When using the former instrument, a resistance balance is obtained with the
ixed coils excited from the same circuit, that is, in series with the bridge
br across a shunt. Inductance balance is obtained with the fixed coils
jxcited from a circuit 90 deg. from the first, the moving coils being connected
jcross the bridge in the usual manner.

148. The measurement of reactance and impedance 'of an alter-

nating-current circuit may be effected very simply with an ammeter, a volt-
meter and a wattmeter, as indicated by the following relations, where Z =
impedance in ohms, X
= reactance in ohms, R = alternating-current resist-
ance in ohms, TF = power in watts, J = current in amperes, £ = total poten-
tial-drop in volts, cos e = power-factor = IF /£/.

Zo|, Z= ^ X=^ tan {d)X = Z

m
(a) (b) , (c) 6, sin 6 (21)
1 U* cos a) i»

POWER MEASUBEMENTS
149. General considerations. When a quantity of electricity, g, is
passed through a circuit against a difference of potential, e, the work done,
that is, the amount of energy expended, is ge. Power is the rate of expend-
ing energy and at any instant is edq/dt = ie, because dq/dt = i, where i and
e are the instantaneous values of current and potential, respectively. Power
expressed in watts is the energy expended per second, or, = QE/t, where W
Q = quantity in coulombs, E = potential in volts and t = time in seconds.
160. Continuous-current power. In a circuit supplied by a battery
or a continuous-current generator, energy is expended at a uniform rate;
hence, edq/dt = QE/t = IE, where Q = quantity in coulombs, = e.m.f. in £
volts, J = time in seconds and 7 = current in amperes. The power in such
circuits is usually determined by measuring the current and the potential,
simultaneously. Wattmeters may of course be used, but they are somewhat
less accurate than permanent-magnet instruments.

153
Sec. 3-151 MEASURING APPARATUS
151. Pulsating power. Whete there are instantaneous variation
in the current and the potential, the power varies from instant to instani
The average power will be the average of the products of corresponding instan
taneous values of current and potential and it can be measured with strict a(|
curacy only with watt-meters of the dynamometer type. In rectifier circuiti
the power consumption of a storage battery or a motor can be approximate!,
measured with a voltmeter and an ammeter of the permanent magnet typ«!
Such instruments would give a more nearly correct result than dynamomete'
instruments. On the other hand, the reverse will be the case with a load of in
candescent lamps or heating de-vices. The error will depend upon the wav,
shape and the character of the load. The safe method is to use a dyna-
mometer-type wattmeter.
152. Alternating-current power. The power in an alternating-cut
rent circuit, at any instant, is the product of the current and potential a
that instant. When the load consists only c
resistance, the current wave, /, and the poten
tial wave, E, are in phase as shown in Fig. 51
and the power-factor is 100 per cent, or unit}
If the products of the instantaneous values c
current and potential are plotted, the curve i
is obtained. The average value of this curv
is the power equivalent of a continuous cui
Fig. 51. —
Relation of cur- rent producing the same effect. Also, W^
rent, e.m.f. and power in EI, where W
= ave age watts, E = mea)
a.c. circuit. and 7 = mean effective amperee
effective volts
These values of potential and current are in
dicated by instruments in which the deflections are proportional to th'
square of the current.
153. When the power-factor is less than unity, due to the fact tha
the circuit contains inductance or capacity (or the equivalent), the curren
and the potential will not be in phase. In the case of an inductive load, th
current will lag behind the potential, as shown in Fig. 52. The powe
curve then will not be all on one side of the axis, but a part will be negative
If the current lags sufficiently. Fig. 53, the power curve will be positive hal
of the time and negative the other half; the average power will then be zer
(or zero power-factor). This difference in phase, or time relation betweei
the current and the potential, is called the phase angle and is usually ex
pressed in degrees, an entire cycle being 360 deg. If the current and th

Fig. 52. Fig. 63.

Figs. 52 and —
53. Relation of current, e.m.f. and power in a.c. circuit.

voltage are sinusoidal, the average value of the power is W

= EI cob 6
where is the phase angle.
tf> Therefore if the current and the potential up
not in phase, it is necessary to know the value of the phase angle if the powe
is to be determined from the current and the potential. Fortunately
power can be measured directly with wattmeters, which not only auto
matically integrate the power curve, but take into account the factor, cos t
164. Precision measurements of power must be made with an instru
ment which is equally accurate on continuous and alternating currents, ii
order that it may be calibrated on continuous current. Such measurement
are most accurately made with reflecting electrodynamometers ii
which deflections are measured by means of a mirror, with a lamp and scale
(See Par. 33, 64 and 97.) The fixed coils are often divided into several sec
tions, which may be connected in various series and parallel combination:
to give large deflections over a wide range of power intensities. Instrumenti
of this type made by the General Electric Company have current capac
ities from 5 amp. to 125 amp. and above, with corresponding eensitivitiei

154
 MEASURING APPARATUS Sec. 3-155

10 and 200 watts respectively at full scale deflection, with a 50-cm.

9.7 in.) scale at 100 cm. (39.4 in.) distance.
"»
166. The Westinghouse "precision" wattmeter similar to the cor-
is
'spending ammeter (Par. 99), except that the moving coils are wound
ith fine wire and are connected across the line instead of in series with the
•xed coil. There are usually two or three current ranges, and the series
^sistance for the moving coil is mounted in a separate box. It therefore
an be used with a wide range of voltages, from 10 volts up. Although con-
iderable metal is used in the construction of this instrument, it is so arranged
ihat the eddy-current error is not appreciable at commercial frequencies.

156. The Duddell-Mather type of wattmeter as made by Paul is a

arefuUy constructed, semi-portable, secondary standard in which the current
lement comprises four fixed coils connected in series, and the potential or
loving element consists of four coils connected in series, all astatically
jTranged. The moving element is suspended by a silk fibre and a spiral
'pring furnishes the controlling force. It is a torsion-head instrument like
he Westinghouse wattmeter.
i 167. Commercial indicating wattmeters are made in two general
orms, the electrodynamometer type and the induction type.
168. The Weston model-16 and the Qeneral Electric type Pj instru-
nents are well-known examples of the electrodynamometer class. Fig.
4 shows the general arrangement. The current or series element con-
ists of two fixed coils wound with heavy wire or strip, which are connected
n series with each other and with the main circuit. The potential or
'hunt element is a moving coil mounted on a shaft supported between
ewel bearings and placed between the two fixed coils. This coil consists of a
arge number of turns of fine wire, as in voltmeters; it is connected in series
with a relatively large amount of
non-inductive resistance, across the
main circuit. The controlling force
comprises one or more spiral springs.

^Fired Colls
(current)
Moving Coil
(potential)

Fig. 54. — Diagram, electrodynamom- Fig. 55. — Diagram, Westinghouse

eter type wattmeter. induction type wattmeter.

169. The inclined-coil type of wattmeter (General Electric Company)

issimilar in principle (Par. 158), but the centre lines of the fixed coils and
the moving coil make an angle of about 45 deg. with each other, instead
of 90 deg., the object being to make the scale more open, or more
uniformly graduated.
160. The_ Westinghouse portable wattmeter is the most important
example of induction-type wattmeters. The principle is exactly the same
as that of the induction watthour meter (Par. 202) but instead of allowing
;

the moving element to rotate, the torque is opposed by a spiral spring and
hence the deflection is proportional to the power. Fig. 55 shows the sche-
matic arrangement, where A A' are the current or series coils, PP' the po-
tential or shunt coils and SS' the compensation coils by means of which,
together with the adjustable resistance, R, the exact quadrature relation is
obtained as in watt-hour meters. This type is also made in polyphase form
by having two sets of current and potential elements acting on a common

155
 Sec. 3-161 MEASURING APPARATUf}
moving disc, or drum, as in the polyphase watt-hour meter. It is ob-\
that instruments of this type are limited to the frequency for which the j ..r
designed.
161. The Whitney wattmeter operates on the dynamometer principV
(Par. 108) except that it is a torsion-head instrument, the moving elemen
being kept in a fixed position by twisting the torsion head to which th"'
control spring is attached. The pointer attached to this head moves ove
the scale. This method permits using a very long scale, extending around i

full circle.
162. Wattmeters for switchboard use employ both the electrodynamic
and the induction principles. Weston instruments are similar to the por
table electrodynamometer instrument (Par. 108). The General Electri(
edgewise type "H" instruments are dynamometer types while type .'

is of the induction type. Westinghouse switchboard instruments ar<

also induction type.
163. The calibration of wattmeters of the dynamometer type
should be done with continuous current. It is customary to make such testi
at a fixed potential, usually 100 or 200 volts, and to vary the current to giv(
the required watts. The potential is held constant at the desired value bj
means of one standard (standard voltmeter or potentiometer) and th(
current is read on another standard (standard ammeter, or potentiometei
with standard resistance). It is more convenient to obtain the potentia
and the current from separate sources, because the process of adjustment o:
one circuit will not affect the other. In the case of instruments of largt
capacity this method economizes energy, because only three or four voltf
are necessary for the current circuit.
164. Calibration of induction- type wattmeters. These instruments
must be checked on alternating current of the frequency for which they are
designed. This check is made by comparison with a secondary standard,
which in turn is checked on continuous current. Polyphase instru-
ments may be checked as single-phase instruments by connecting the
current circuits in series and the potential circuits in parallel. In the ease
of induction-type instruments stray magnetic flux from one element may
affect the other, in which case the calibration should be made on a polyphase
circuit.
160. The inductance error in wattmeters may, under certain condi-
tions, become very important. While the theory of the electrodynamometei
type of wattmeter assumes that the potential circuit is non-inductive, this
is not strictly true in the actual instrument because of the inherent induct-]
ance of the coils. Ordinarily, however, the non-inductive series resist-
ance is sufficiently large to make the effect of this inductance negligible
at ordinary frequencies and power-factors. But with low power-faotorsr
the lag angle in the potential circuit may have to be considered. The power
inan alternating-current circuitis W^EI cob 6, wherePT = power, 7 = current,-
E»=e.m.f. and cos 9 = power-factor of circuit. When the power-factor is
unity, I and E are in phase, but the potential-circuit current lags slightly
behind E, thus producing the effect of a small power-factor. If, for example,
the lag-angle, *, is 2 deg., cos —
= 0.9994 a negligible error. If the line
power-factor is 50 per cent., the lag angle in the wattmeter, 0, is (60 — 2) =58
deg. The cosine of 60 deg. is 0.50 while the cosine of 58 deg. is OJ^S, thus intro-
ducing an error of 6 per cent. (See Par. 169 for compensation and Par. 179
for correction for inductance.)
166. The stray-field error in unshielded, non-astatic, electrodyna-
mometer wattmeters may be anything from zero to 25 per cent, with
an alternating magnetic field of 5 lines per square centimeter, and from zero to
75 per cent, at 10 lines, depending upon the direction of the field and
the coil deflection. Ashield, properly made and placed, is extremely,
efRoient, reducing the effect of a field of 20 lines per <quare centimeter to
practically zero, without introducing eddy current or other errors.
Wattmeters of the Kolvln balance type, in which the coils are asta-
tcially arranged, are practically immune from these troubles except in an
intense field which is not uniform throughout the space occupied by the
moving system; such a condition may arise, for example, when the watt-
meter in close to a conductor carrying a very large current. Induction-
type instruments employ much stronger field Rtrengths and are not appreoi-
, ably'affected except oy very strong fields.
156
 MEASURING APPARATUS Sec. 3-1G7

167. Wattmeter connections to line. Care should be taken so to

annect a wattmeter into the main circuit that the moving-coil end of the
otential circuit and the current coil are on the same side of the circuit
eing measured. Otherwise there may be sufficient electrostatic attraction
etween the two windings to produce an error; or, if the potential is sufficiently
igh, the insulation between the windings may be broken down. The
itter may be guarded against by connecting the binding post at the moving-
oil end of the potential circuit to the proper current post with fine fuse wire.

168. Correction for wattmeter losses or energry consumption.

Vhere small quantities of power are being measured, the losses in the cir-
uits of the instrument itself should be taken into account. It will be noted
a Fig. 56 that the instrument is measuring its own current circuit loss, or
eries I-R loss. If the instrument loss cannot be neglected, it is better to

Load
Fig. 56. —
Power measurements
in single-phase circuits with watt-
Fig. 57.
ment for
—measuring
Electrodynamometer arrange-
small amounts of
meter. power.
Bonnect the potential circuit to the load side (b instead of a) and include the
potential circuit loss in the measurement instead of the current circuit loss,
because the former not only remains constant but is more easily calculated.
Wattmeters are often arranged to correct or compensate automatically for
clxis loss by means of a few turns on the fixed coil, connected in series with the
potential circuit and in opposition to the fixed coil. This arrangement can-
not be used with shunt-type instrument transformers nor when checking the
wattmeter with separate sources of e.m.f. and current. A separate connec-
tion is usually provided, however, for this purpose. In general it is safer
always to use this "independent" connection, making allowance for the
potential loss, when necessary, by calculation.
169. Measurement of very sn^all amounts of power. Where the
power is extremely small, only a few watts, reflecting electrodynamometers
are most accurate. This is especially true when the power-factor is low, the

Fig. 58. — Power in single-phase Fig. 59. —three-ammeter

Powerin single-phase
circuit, three-voltmeter method. circuit, method.
potential high and the current low, as for example the losses
or vice versa,
m a,lternating-current conductors, in dielectrics, instrument circuits and mag-
netic circuits. The fixed coils may be connected directly in series with the
main circuit or to a non-inductive shunt in the circuit. At low potentials,
the series resistance in the moving-coil circuit may not be sufficient to elimi-
nate the effect of inductance but this can be accomplished by shunting the
resistance with a condenser as shown in Fig. 57. When the potential cir-
cuit is short-circuited at a, h, the capacity C or resistance i?2is adjusted until
there is no deflection with full current in the fixed coil (Ldyn. = CRi^) Cali-
.

bration is of course made with continuous current.

1S7
Sec. a-170 MEASVRINO APPARATUS
170'. Measurement of power' in a single-phase circuit. One watt-
meter connected aa shown in Fig. 56 will read true watts. The power may
also be measured without the use of a wattmeter, by three voltmeters or,
three ammeters.
In the "three-voltmeter" method, a known non-inductive resistance,
R, is connected in series with the load as shown in Fig. 58, where E, E\ and
Et are points where voltmeter readings are to be taken. The power in
watts is

W ^ ?
(watts) (22)

Similarly, in the "three-ammeter" method. Fig. 59, the power in watts is

W = R(^ 2 )
(watts) (23)

171. Two-phase, four-wire circuit (not interconnected). Two

wattmeters are connected as shown in Fig. 60, the conditions being equivalent
to two single-phase circuits. The total
"^-^ power is obviously the arithmetical sum
of the readings of the two instruments.

Wy~ — 172. Two-phase, three-wire circuit.

Two wattmeters should be connected
as shown in Fig. 61, the total power being
Fig. 60. —Power in two-phase, the algebraic sum of the two readings..
This connection is correct for all condi-
four-wire circuit (not intercon-
tions of load, balance and power-factor.
nected).
One wattmeter may be used as in Fig. 62,
provided there is no load across the outer conductors and the phases are
balanced as to load and power-factor.
173. Two-phase, four- wire, interconnected circuit. Three watt-,
meters can be used, connected as in Fig. 63, the total power being the algt'-

—
Fig. 61. Power in two-phase Fig. 62. —Power
phase, three-wire circuit.
in two-
three-wire circuit.

hraic sum of the three readings. This fconnection is correct under all con-
ditions of load, balance and power-factor. Two wattmeters, one in each '

phase, will give the true power only when the load is balanced.
17i. Three-phase, three-wire circuits. Two wattmeters may be used,
connected as in Fig. 64, the total power being the algebraic sum of the two

Fig. 63. —Power in two-phase,

four-wire interconnected circuit.
Fig. 64 .
—
Power in three-phase,
three-wire circuit, two wattmeters.

readings under all conditions. If the load is balanced, each instrument will
indicate half the total power at unity power-factor and at 50 per cent, power-
factor one instrument will indicate the total power, the other instrument
reading zero. At less than 50 per cent, power-factor, one instrument will
read negative. (See Par. 209 for method of verifying power-factor.)

158
 MEASURING APPARATUS Sec. 3-175

176. Three-phase, three-wire circuits, balanced load. When the

>ad is power may be measured with one wattmeter by the follow-
balanced the
ig methods.
(») With '
'star' '
box or arti-
cial neutral as shown in Fig. 65.
'he total power is three times
he reading of the wattmeter,
"he resistance in each leg of the
tar box should be non-inductive
nd small compared
f the potential circuit of the
wattmeter, so that the cur-
with that EBI
ent taken by the latter will not Fig. 65. Power in three-phase, three-
wire circuit, one- wattmeter, with
—
listurb the potential at the neu-
ral point, O. "star" box.
(b) With "Y" box as shown
n Fig. 60. The total power is three times the wattmeter reading The
arrangement is similar
to (a), one leg of the
star box being replaced
with the potential cir-

^I cuit of the
itself. The other two
legs have the same im-
pedance as the poten-
tial circuit of
wattmeter

the watt-
;.''io. 66. — Power in three-phase, three-wire circuit, meter.
With a "T" re-
one wattmeter, with "Y" box. (c)
I

actance coil as shown

n Fig. 67. The total power is twice the wattmeter reading. The im-
jedance of the reactance
;oil must be small com-
pared with that of the po-
;ential circuit of the watt-
XiCter, so that the current
.aken by the potential cir-
2uit will not disturb the
potential at 0.
176. Three-phase,
'our- wire circuits. Three
wattmeters are used as
shown in Fig. 68. The t7',„ ct t> ^i. . •
i_

total power is the algebraic „:^'°;-,^^-""^°!?'^ '^ ^Pj^f^^' three-wire

3um of the three readings.
*.^/vf
•=''^^'^'*> one wattmeter, with T" reactance coil.
This method is correct
under all conditions of load, balance, and power-factor. A three-phase,
"star" system with a grounded
neutral isvirtually a four-wire sys-
tem and the power should be meas-
ured with three wattmeters. Ob-
viously, if the load is balanced,
one wattmeter can be used, the
totalpower being the indication of
the wattmeter multiplied by three.
The current^ coil should be con-
nected in series with one conductor
or phase wire and the potential
coil between that conductor and
the neutral.
177. "N"-phase circuit. In
any system whatsoever, of "n"
phases, the true power may be
Fig. 68 .
—Power in
four-wdre
three-phase,
circuit.
measured by connecting a watt-
meter in each phase, the current
, ., , . , .,
"oi^ being in series with the line
,
and the potential coil
,
connected between that line and any common

159
Sec. 3-178 MEASURING APPARATUS
point P of the aystem, which may or may not be the neutral. The tota
power for any load condition is the algebraic sum of the readings of all of thi
*
wattmeters so connected.
178. Power measurements on high-voltage circuits should preferablj,
be made with series-type and shunt-type instrument transformers. If th<
instrument wattmeter is connected directly to the circuit with series re
sistance in the potential circuit, the circuit should be grounded at thi
instrument in order to avoid errors of electrostatic attraction, and also pos
sibls injury to the instrument or the observer. The current-capacity limi
of commercial wattmeters is about 200 amp, beyond which series trans
formers with 5-amp. instruments are used, irrespective of potential.
179. Corrections where instrument transformers are used in accu
rate power measurements. In every case the true ratio and phase angli
should be known (Par. 79 and Par. 104, 106). The general effect of the pha*
changes in the instrument transformers is to make the angle between th'
current and the potential in the wattmeter larger or smaller than that be
tween the current and the e.m.f. of the circuit being measured.
If cos 9 = true power-factor and cos ©2 = apparent power-factor (i.e., power
factor in the wattmeter obtained from the ratio of the watts and volt-ampere
in the wattmeter), true watts = (cos 9/cos 82) X wattmeter reading. Th.
apparent power-factor, cos 02 = cos (.6±a±fi±y), where |j

9 = phase angle in main circuit, |

a = equivalent phase angle in wattmeter,
/3 = equivalent phase angle in current transformers,

y = equivalent phase angle in voltage transformers.

The angles a, j8 and y are given positive (,-{•) signs when they tend to de
crease and negative ( — ) signs when they tend to increase the phase angl
between the current and voltage in the instrument, t
180. Power-factor. The power-factor of a circuit is the ratio of the tru
power in watts, as measured with a wattmeter, to the apparent power ot
tained from the product of the current and the potential, in amperes an^
volts respectively. In the ordinary continuous-current circuits, the power
factor is obviously unity but in rectifier circuits, for example, it may b
slightly less than unity. In alternating-current circuits, the powei
factor is usually loss than unity because the current and the potential ar
not in phase. When the wave form is sinusoidal (and only then), the powci
factor IS also equal to the cosine of the angle of lag.
181. The power-factor of single-phase circuits is obtained froi
wattmeter, voltmeter and ammeter readings, by the relation W/EI ^cc
B where W= watts, E = volts and / = amperes.
182. The power-factor of polyphase circuits which are balanc
the same as that of the individual phases. When the phases ar.
balanced, the true power-factor is indeterminate. For all prnci. ,

purposes, however, it is sufficiently correct to assume the power-factor tn b

that obtained by methods which give the average of the power-factors of tli
separate phases. In the wattmeter-voltmeter-ammeter method, t)i
power-factor is, for a two-phase, three-wire circuit W/\'2 (EI), (1 i

middle wire, E between outer wires) and for a three-phase, three-wire cirrui
the power-factor is TF/\/3 (EI), wherein 17 = watts, £ = volts and / =
amperes. In the two-wattmeter method, the power-factor of a two-pli:i~'
three- wire circuit is obtained from the relation Wi/Wt^tan 0, where U 1 i

the reading of a w&ttmeter connected in one phase in the same manner :i-^
single-phase circuit, and Wt is the reading of a wattmeter connected with ii
current coil in the first phase, in series with the first wattmeter', ami il
potential coil across the second pha.se. Obviously, if the load is steady
wattmeter is sufficient. If the phases are not balanced, the readings .•^i

be repeated with the instruments in the second phase, the true power-i
being taken as the average of the two results. In a three-phase, three
wire circuit, the power-factor can be calculated from the readings of tu
• Bedell, F. "Direct and .'Uternating-current Testing." D. Van Nos(r:i!i
Company (1912), p. 228.
t Robinson, L. T. "Electrical Measurements in Circuits Requiring Ciiri'ii
and Potential Transformers." Trans. A. I. E. E., 1909, Vol. XXVIII, p. 1<">

160
 MEASURING APPARATUS Sec.a-183
as f oUows
LVattmeters connected in the standard method for measuring power,
I iWi-Wi)/(Wi + W2)]\/S = t&ne,yh.eTe TFi is the larger reading, which is
'
Iways positive, and W2 is the smaller reading which may be either positive
r negative. , ,. j- 1 v
183 Power-factor meters are instruments which indicate directly
the
)Ower-f actor of the circuit. Commercially there are two general classes,
those
nvolving the principle of electrodynamometer wattmeters and those
)ased on the principle of induction wattmeters. The essential feature^ of
I Weston single-phase
power-factor meter of the first class are shown in Fig.
')9.It will be noted that the
irrangement is similar to that /(T^v^A:^ L
n wattmeters, except that
here are two coils, M, M\ in
;he mo\'ing system instead of
one. One coil, M, is connected
icross the line and in series
R-ith a resistance R, while the
Jther coil, Af', is connected in
series with an inductance L.
iThe current in the coil, M',
will therefore be about 90 deg.
out of phase with that in coil
M. When the
power-factor is Fig. 69.- -Diagram, Weston single-phase
unity, reaction between
the power-factor meter.
the fixed coils, F, F\ and the
moving coil M
will be a maximum while that between FF' and M' will be a
minimum. The torque exerted on M
will cause the moving system to take
the position of minimum torque, that is, where the plane of M
will be parallel
to that of FF^; the corresponding mark on the scale will therefore be 100.
Similarly, at zero power-factor, coil Afi will exert all of the torque and cause
,the moving system to take a position where the plane of M^ will be parallel
ito that of FF'; the corresponding indication is therefore zero. Theoretically,
•
the indications will be affected by the frequency, becau.se the current in L
.depends upon the frequency, but by proper design of the reactor, L, the
effect of moderate variations in frequency can be eliminated.
, In the polyphase meter. Fig. 70 (for balanced circuits only), the in-
ductance L is not required and
the instrument is therefore entirely
independent of the frequency.
There are three coils in the moving
system, one connected across each
phase. The principle of operation is
exactly the same as in the single-
phase instrument, the moving sys-
tem taking up a position where the
resultant of the three torques will be
a minimum, which position will vary
with the average power-factor of the
circuit.
184. In Westinghouse power-
factor meters, the dynamometer
T, -„ -n,- trr u„,„ principle
Fig. 70.-Diagram Weston polyphase
i 1 , P^
P described in j^Par. 183 is
^^^^^^^ tj,^
power-factor meter.
induction principle is employed in
the same manner that is applied in synchroscopes (Par. 289-291).
186. Qeneral Electric power-factor meters employ the electrodyna-
mometer principle (Par. 183) in polyphase instruments. No single-phase
instruments are made by this company.
ENEEQY MEASUREMENTS
186. The practical unit of electrical energy is the watt-hour, which
is the energy expended in 1 hr. when the power or rate of expenditure
is 1 watt.
187. Energy is usually measured in watt-hours, with watt-hotir
meters (often incorrectly called integrating or recording meters). All
watt-hour meters are, in reality, small motors iu which the speed is propor-

11 161
Sec. 3-188 MEASURING APPARATUS
tional to the power and the revolving element operates a registering me«i
anism on which the energy consumption ia recorded. Meters for co
tinuous current are usually of the type which utilize the electrodynami
principle of direct-current motors, while those for alternating currei
utilize the principle of induction motors. j^

188. Continuous-current watt-hour meters. Continuous-curreii

meters may be divided into two classes, the commutator type and tl
mercury motor type.
189. Commutator-type meters are sim.ilar in principle to shunt motoi
The essential features are shown in Fig. 71. The moving element consis
of an armature,^a, a commutator, c, al
|0O(!)| a light metal disc, d, all mounted on
steel shaft which rotates in a jew!
bearing. The armature is connect*
to the external circuit by means of vei
light silver-tipped brushes. In seriii
with the armature is a light-load cor
pensation coil, s, and a resistance,
The field coils are indicated at/, /.
190. Characteristics of comimv
tator-type meters. The essenti
differences between this type of wat'
hour meter and a two-pole shunt moti
are as follows: (a) entire absence i

iron in the magnetic circuits; (b) tl

armature element is connected acror
the circuit and carries a very sma'
current, while the field element is i?
Fig. 71.— Diagram, commutator-
series with the circuit and carries tbt
main current; (c) the speed increascf
type watt-hour meter. as the field strength increases which ;1

opposite to the effect in a shunt moto*

191. The principle of operation of commutator-type meters :;

as follows. The torque is proportional to the current in the armature coi;

and to the field strength. Since there is no iron in the magnetic circuit, th;
latter is always proportional to the field current, hence the torque is pre!
portional to the two currents (as in a dynamometer wattmeter). The cur
rent in the armature being proportional to the line potential, and the fieVl
current equal or proportional to the line current, the torque is proportionj
to the power. In order to make the speed proportional to the power, (

mechanical load must be provided, in which the counter-torque will be pre

portional to the speed. This load usually takes the form of a circular ais(
d (Fig. 71) of thin copper or aluminum which revolves between the pole
of one or more permanent horseshoe magnets, with poles very close togethel
The eddy currents induced in the disc react with the permanent-magne
field, producing a counter-torque which will always be proportional to th
speed. As the load current increases, the torque of the motor element ir
creases and the speed increases, because there is practically no counte
e.m.f. in the armature, s. But as the speed increases, the counter-torqu
of the disc or generator element also increases and a speed is finally reachei
where the two torques balance eacli other and the speed remains constani
Thus, theoretically, the speed will always be proportional to the power in th
circuit. Each revolution represents a definite amount of energy, and b;
connecting the shaft to a suitable recording mechanism similar to that oi
gas and water meters, the total energy consumed is automatical!;
registered.
192. Effects of friction and temperature in commutator-typi
meters. In practice, certain conditions prevent the speed from beini
always proportional to the load, the principal factors being friction ant
temperature. Bearing friction is reduced to a minimum by using polishec
sapphire or diamond jewels, with either a polished cone-shape shaft-en(
or a steel ball. Thus the contact surface is reduced practically to a point
The weight is reduced by using hollow shafts and very light aluminum o
non-metallic frames for the armature windings. Commutator frlctioi
is reduced to a minimum by making the commutator diameter small, ant

lOli
 MEASURING APPARATUS Sec. 3-193

iriR round brushes so that contact is made practically at a point. The

irs in the registering mechanism are made as light as possible. The effect
friction is smaller as the torque is increased; hence the ratio of torque to
eight is made as large as possible by making the armature spherical, which
\(vs the maximum torque for the minimum amount of wire (weight).
193. Compensation for friction in commutator-type meters.
cannot be entirely eliminated and its effect is marked at light load,
riction
ies3itating the use of a compensating device. This usually consists
a few turns of fine wire on the field coil, which are connected in series
ith the potential circuit. These turns are wound in a separate coil and the
nount of compensation can be adjusted for each meter individually cither
y altenng the positiori of the coil with respect to the field coils, as in General
Irctric and Westinghouse meters, or by changing the number of
turns as
I Columbia and Duncan meters.
194. Compensation for temperature in commutator-type meters.
I'emperature affects the performance of meters by: (a) changing the resist-
;

ace of potential circuit; (b) changing the resistance of the drag disc; and
:

') changmg the strength of the permanent

magnets. These changes pro-
uoe a combined or resultant effect, which is compensated for by using
for
,:ie series resistance in the potential
.
circuit, one or more materials so com-
ined that the final temperature coefficient of resistance counteracts the
.
other
nects when the air temperature changes.
195. The mercury-motor- type meter is most prominently represented
<y the direct-current meter made by the Sangaino Electric Company.
iL'. 72 shows diagranimatically the circuits and scheme of operation.
^ IS a solid copper disc floating in mercury
i,'' a float which supports the shaft and
--eliminates a jewel bearing; // is a lami-
i!,ii»ted iron core and C is a chamber filled
f.vith mercury. The flux produced in the
shore, H, by the shunt coil, traverses the
f'iisc at two points which are diametri-
cally opposite. The line current passes
rom L to Li through the mercury and dia-
,

Vnetrically through the disc. This disc

.,3eing cut by flux, a torque is produced
.which is proportional to the current and
: ;he e.m.f.
> 196. Compensation for friction in
toiercury-motor-type meter. The fric-
•tion due to the disc rotating in the mercury
,;.i9 compensated in two ways. One
"method
ance,
in Fig. 72. A high resist-
r,
is shown
connected in shunt with the
is
—
Fio. 72. Diagram, Sangamo
mercury-motor-type watt-hour
farmature, D, and the e.m.f. circuit is com- meter.
plated by the sliding contact, P.
; When
rthe slider is at h, practically all of the shunt current will pass through D
jbecause of the resistance, r, thus adding to the torque. When the slider
fcis at a, practically none of the e.m.f .-coil current will traverse the arma-

Iture. In the second method, a circuit consisting of two wires of di.s-

,
similar metals, which form a thermocouple, is connected in parallel with
;the mercury chamber terminals, L, Li. This couple is surrounded with a
•
heating coil connected in series with the potential circuit. The e.m.f.
Iproduced by the couple causes current to flow through the disc thus producing
the necessary torque to overcome the effect of friction at light load. The
increased mercury friction at high speed is compensated by a series
turn (or half a turn), t, on the core H. The drag or counter-torque is
obtained with a separate disc and permanent magnets (not shown) in the
usual manner.
197. Speed adjustments. The speed at all loads is equally affected
by shifting the drag magnets diametrically with respect to the meter shaft,
thus altering the retarding torque. This torque is a minimum with the mag-
nets close to the shaft and a maximum with magnets near the edge of the
disc. The speed at light load is adjusted independently as indicated in
Par. 193.

163
Sec. 3-198 MEASURING APPARATUS m
198. Typical Data Applying to Modern 110-Volt, S-amp. or 10
amp., Direct-current Watthour Meters *

•I •
a a
or; ft S i
css
a «
I"

Speed, full load, r.p.m 46 41.7 25 36.7 30

Torque, full load, mm.-grm 170 140 55 180 90
Weight, moving element, grm 97 80 31 130 90
Ratio, torque to weight 1.75 1.75 18 1.39 1.0
Drop, current circuit, volts at rated 1.15 1.0 0.03 . 55
current.
Loss, current circuit, watts at rated 5.75 5.0 0.3 5.5
current.
Loss, potential circuit, watts at 110 5.1 4.5 5.0 5.0 2.0
volts.
Resistance, armature, ohms 825 1,185 1,850$ 2,660
Resistance, compensating coil, ohms. . 65 315 450
Resistance, series resistance, ohms 1,540 800 450 3,000
Resistance, potential circuit, total ohms 2,430 2,300 2,300 6,110
Ampere-turns, field 300 600 910 700
Ampere-turns, armature 800 1,500 2,100

199. Three-wire circuits are metered with two, two-wire meters ol

the kind described (Par. 188 to Par. 198), or a three-wire meter. The-
latter which is usually made in the commutator type, is the same as the
two-wire meter except that the two field coils (which should be alike) are
separated electrically, and one is connected in each outer wire in such a manner
that their fields are cumulative as before. When the load is exactly balanced,
the conditions are obviously the same as in a two-wire meter, and when;
unbalanced the two field strengths add together so that the speed is pro^:
portional to the total current, t '

200. The metering: of heavy-current circuits by means of standard

meters becomes troublesome because of the large conductors required in the
fields. While such meters have been made in capacities up to 20,000 amp.,
they are very costly and not satisfactory at light loads. Watthour meters
have been developed by some manufacturers, along standard lines, for oper-
ation with shunts. In order to develop sufficient torque without an exces-
sive shunt loss, it is necessary to employ shunts having small drop, large field
coils on the meters and relatively large leads from meter to shunt. Where
the meter has to be some distance from the shunt, the leads may have to be
nearly as large as the wires in the main circuit, in order to keep down the
resistance.
Another way to avoid the use of large meters is to connect several-
smaller meters in parallel. Care should be taken to make the resistance
of the several branches equal, if the meters are of the same capacity; or, if
the meters are of different capacities, inversely proportional to the capaci-
ties of the meters. This will insure that none of the meters are overloaded.
201. Alternating-current watt-hour meters. Alternating-current
energy is almost always measured with induction type meters. Com-
mutator meters are seldom used on alternating-current circuits for the very
practical reason that induction meters are not only more accurate, but
much less expensive in first cost and in maintenance.
• From Electrical Meterman's Handbook, N. E. L. A., 1912, to which
See also Fitch, T. T. and Huber, C. J.
readers are referred for further data.
"A Comparative Study of American Direct-current Watthour Meters,"
Bureau of Standards Bulletin, 1913, Vol. X. p. 161. (Reprint No. 207.)
t The Sangamo Co. has recently developed a three-wire mercury meter (see
'

Par. 196).

164
 MEASURING APPARATUS Sec. 3-202

Ijtating magnetic field of the induction motor. The essential features of

_l ae principal makes of watt-hour meters are shown in the diagrammatic
^"letch, Fig. 73. P is the potential coil; S the series coil, and C a compensat-
igcoil. A metallic disc is free to revolve between the poles. The alter-
sting magnetic fluxes from these poles will establish currents in the disc
bout as indicated by the arrows in the sketch at the right, which shows
portion pi the disc and the poles. The potential winding, P, has many
urns and is therefore highly inductive, while the series winding, S, is prao-
ically non-inductive;
hus the fluxes produced
ly these two circuits are
)ractically 90 time-de-
apart.
crees Each flux
phase with the cur-
8 in
ent which produces it;
ind the e.m.f. generated
n the disc, which is cut
the flux, is in time
I jy
fl juadrature with the gen-
R irating flux. Therefore,
? f assumed that the
it is
i 3uxes duo to P and S,
'-
respectively, are inquad- -Diagram, induction-type watt-hour
jTature, the eddy currents meter.
produced by P will be a
I maximum at the same instant that the flux fromS is a maximum, and vice
' 'versa. Thus a torque will be produced which is proportional to the instan-
taneous product of the eddy currents in the disc and the flux from the pole
under which the current is flowing. This torque is proportional to the power
1 used m
the load circuit provi^Jing the time-phase difference of the currents
la coils P
and S is exactly 90 deg. at unity power-factor. The necessary
retarding action or counter-torque is obtained with permanent magnets on
I

;
this same disc as described under direct-current meters (Par. 191) .

203. Compensating coil on induction-type meters. If the phase

quadrature is not exact (Par. 202), the meter will obviously not register
correctly under any condition. In consequence of the ohmic resistance of
the potential circuit, the current is never exactly 90 deg. behind the impressed
e.m.f. At any instant, the flux Ef (Fig. 74) from the potential pole,
instead of being in phase with the eddy currents, 7e, due to the line current!
13 sUghtly behind, as indicated, The torque is therefore proportional to
the product le and oa, instead of le and E//. The meter will therefore run
slow, but as a practical matter the error is so small that at unity
power-
tactor It is insignificant. The error rapidly becomes large, however, as the
power-factor decreases. As practically all alter-
nating-current circuits have a power-factor less
than unity, a compensating coil is used to elimi-
nate the error. This coil is a short-circuited coil
placed on the potential pole (see Fig. 73) and in
which a current is induced 90 deg. behind the
generating (potential) flux. Its flux, S/, will be in
phase with that (induced) current and therefore
90 deg. from E/, with which it will combine. By
adjusting the value of the resistance (lag adjust-
ment) r (.Fig. 73) the resultant flux can be brought
into exact phase with /« and the meter will then
74. —
Theory of register correctly on all power-factors. It is evi-
adjustment, indue- ^^^*' that with lagging power-factor in the circuit,
tion watt-hour meter. » meter will be slow if "under-lagged" and fast if
'over-lagged." The opposite results will occur
with a leading power-factor.
2*'*- ^."ction compensation.
• The friction in an induction-type meter
ismuch less than in a commutator-type meter because of the absence of a
commutator and an armature. On the other hand, the torque is less (com-
pare tables of characteristic data. Par. 198 and Par. 206) and the effect of
motion at light load has to be compensated. The principle employed in

165
Sec. 3-205 MEASURING APPARATUS
practically all meters is that in which a flux is produced at the potential
pole face, slightly out of phase with the main flux. Thus eddy currents will
produced in the disc which will be in phase with a small component of the
he,
main flux, giving rise to a slight torque which can be made sufficient to over-i
come the friction torque. This "out-of-phase" flux is produced in various'
ways in different meters. A common method is to place a short-circuited
copper circuit or thin copper punching ("shading strip") in the potential-'
pole air-gap, in an unsymmetrical position, so that the desired unbalanced^
flux will be obtained. In the Columbia meter, the effect is accomplished
by unbalancing the flux of the two potential poles by means of magnetic
shunts.
205. Adjustments of induction-type meters. Facilities are usually
provided for conveniently adjusting the meter accuracy at light and full load.
The position of the light-load compensation coil can be changed with
conveniently located screws, and the light-load speed thus altered. Speed
adjustment at all loads is obtained by shifting the drag magnets with
respect to the axis, as in direct-current meters, or by shunting the flux
by means of a movable soft-iron keeper bridging the air gap. The
power-factor or lag adjustment is made at the factory and if properly done
should never require readjustment.
20S. Typical Data Applying to Modern 110-volt Single-phase 60-
cycle, 5-amp. Induction-type Watt-hour Meters*
 MEASURING APPARATUS Sec. 3-209

less than oO per

hon one element tends to run backward (power-factor
rit ), it simply reduces
the torque of the other one, so that the actual speed
still proportional to the net power
in the circuit.

209 Polyphase meter connections. Obviously it is extremely impor-

connected.
^nt that the various circuits of a polyphase meter are properiy
for example, the current-coil connections
are interchanged and the
n.- power-factor is 50 per cent., the meter will run at the normal 100 per cent,
jwpr-factor speed, thus giving an error of 100 per cent.
for correct connections is as follows: If the line power-factor la
\ test
potential or the
ver 50 per cent rotation will always be forward when the
,

arrent circuit of either element is disconnected, but in one

case the speed
•ill be less than in the other.
If the power-factor is less than 50 per cent,
he rotation in one case will be backward. ^ ^u en
When it is not known whether the power-factor is less or greater than 5U
T cent , this may be determined by disconnecting one element and noting
he speed Then change the potential connection from the middle wire to
If the power-factor la
he other outside wire and again note the speed.
ver 50 per cent., the speed will be different in the two cases,
but in the same
iirection. If the power-factor is le.ss than 50 per cent., the rotation will be
n opposite directions in the two cases.
310 Use of instrument transformers with watt-hour meters.
Vhen the capacity 200 amp. series-type instrument
of the circuit is over
ransformers are generally used to step-down the current to 5 arnp. If the
jotential is over 440 volts, series transformers are almost invariably
used,
rrespective of the magnitude of current, in order to insulate the meter
from
he line; in such cases, shunt-type transformers are also used to reduce the
•oltage to 110 volts. The ratio and phase-angle errors of these trans-
ormers (Par. 79 and Par. 104) should be taken into account where high accur-
»-3y is important, as in the case of a large installation.
These errors can be
argely compensated for by adjusting the meter speed. The per cent, error
3orresponding to various phase angles is given in Par. 179.
ail. The accuracy of a watt-hour meter is the percentage of the total
aaergy passed through a meter which is registered by the dials. The watt-
hours indicated by the meter in a given time are noted, while the actual
watts are simultaneously measured with standard instruments. On ac-
count of the time required to get an accurate reading froin the register,
it is customary to count revolutions of the rotating element instead of the
register. The accuracy of the gear ratio between the rotating element and
the first dial of the register can be determined by count. Since the energy
represented by one revolution, or the watt-hoUT constant, has been assigned
by the manufacturer and marked
on the meter, the indicated
watt-hours will be KhXR, where

the
= watt-hour constant and R =
if »
number of revolutions. (See
Testing Formulse, Par. 222.)
812. Laboratory tests. Ob-
viously the source of energy for
M
meter testing should be as steady
Storage batteries
as possible.
are largely used for direct-current
meters; and special alternators,
Amperes
A/VWVW —
whose speed can be controlled,
'

are usecf for alternating-current Fig. 75. — .

Connections for testing watt-

hour meters— separate circuits.
,
meters. The testing load may
i be banks of lamps, to which the
'

meter and standard instruments are connected. . , .

A better method is to separate the current and the potential circuits

and connect them to independent sources, the former being a relatively
large-current, low-voltage source and the latter a high-voltage, low-current
source. Conditions are more easily adjusted by this method and in large
meters a saving of energy is effected.
'
Where separate sources are used for the current and the potential coils,
(iarbon rheostats are convenient for adjusting the current, and high-resistance
rheostats connected "potentiometer" style are convenient for controlling

167
Sec. 3-213 MEASURING APPARATUS
the voltage, as indicated in Fig. 75. Resistance in the potential circuit
alternating-current meters will alter the quadrature phase relation, and then
fore voltage regulation should be obtained with a variable ratio auto-tran
former, an induction regulator or by field control.
213. Power-factar variation, in meter testing, can be obtained b
several methods. In the two- alternator method, two generators ai
mounted on a common base, with a common shaft. The stationary member
(armature or field) are made movable about the shaft with respect to the baF
and to each other. Thus with the potential coil of the meter connected t
one machine, and the current coil to the other, any phase relation can b
obtained by adjusting one movable member with respect to the other.
In the transformer method, a transformer with a large number of step;
or a variable-ratio auto-transformer, is connected across one phase of
polyphase circuit and the potential coil of the meter is connected in such
manner that any phase relation can be obtained. Thus, referring to Fig. 7t
the current coil of the meter
is connected in series with
conductor a of a three-
phase circuit, and the po-
tential coil la connected to
o and to p, the latter being
a tap on a transformer con-
/
/
nected across phase 6c. It
\3/ is apparent that any phase
6>Ww TOin)Wii« a a < c
TO! angle between the current
and the potential can be
obtained in a range from
Fig. 76. —
Power-fac- deg. to 60 deg. by moving Fig. 77.— —Power-fac
tor variation —trans- the connection point c tor variation trans
former method. along the transformer former method.
winding. Angles from 60
deg. to 90 deg., lead or lag, can be obtained by changing the transfornur U
either of the other two phases and the meter connection from o to x or y
These changes can be instantly made with suitable switching arrangements:
A similar arrangement can be made for a two-phase circuit. Fig. 77. It"
is also convenient to introduce such a transformer between the taps o, p and
the meter, for the purpose of compensating for the variations in the voltage
between o and p, and keeping the voltage constant at the meter. Twc
variable-ratio auto-transformers arranged in this manner make a convenient
phase shifter.
In the reactance-coil method, a reactance coil is introduced in the
current circuit, the reactance being varied by moving an iron core in and
out of the coil. It is difficult to obtain low power-factors with this method
unless a separate low-potential current circuit is used, and then there is
danger of wave-form distortion.
214. Measurement of meter torque. The torque is measured undei
normal conditions at full load by measuring the force in grams exerted at the
edge of the disc, or at the end of an arm attached to the shaft. This force
may be measured by means of weights, a calibrated watch spring, or by
utilizing the principle of the pendulum.* By measuring the radius of the
disc or the arm in millimeters, the torque is obtained in millimeter-grams,
the usual unit.
21B. Measurement of watt-hour meter losses. The losses in the wind-
ings of c.c. meters are calculated from the resistances, as determined with con-
tinuous current by standard methods. The losses in alternating-current
meters are measured directly with wattmeters, but gre.at care is required
because of the very small amount of power and the small power-factor.
216. The standards for direct-current meter tests may be ammeterc
and voltmeters, in portable or special laboratory types, or potentiometers;
in alternating-current meter tests, use is made of indicating wattmeters,
The time in measuring the meter speed is usually determined with stop-
watches, reading to tenths of seconds. Where a large number of meters

• Agnew, P. G. Bureau of Standards Bulletin, 1911, Vol. VII, No. 1.

(Reprint No. 145.)

168
 MEASURING APPARATUS Sec. 3-217

being adjusted, it is customary to use standardized or master watt-

)ur meters and thus eliminate the measurement of time and watts.
217. Service tests of watt- hour meters. There are two general methods
aking tests on meters where they are with indicating
installed; (a)
: unents and a stop-watch and (b) with standard watt-hour meters
: 218).
. the indicatingr-instrument method, the time of a given number of
iutions at a known load is dulj' noted. The load on direct-current
rs is measured with an ammeter and a voltmeter. In a modified
;,of this method, the load is an accurately standardized resistance and
. a voltmeter is required, the watts being W=
E^/R, where TF watts, =
= volt and R=
ohnis resi.stance of load. In the case of alternating-
! urrent meters, the load is preferably measured with a wattmeter.
f 218. The rotating-standard method of watt-hour meter testingf
I
the most used, becau.se only one observer is required and it is more accurate
i

,
rith fluctuating loads. Rotating standards are watt-hour meters similar
I standard house-type service meters, except that they are made with extra
! are, are usually provided with more than one current and one potential
i ange, and are more portable. A
pointer, attached directly to the shaft,
i aoves over a dial divided into 100 parts, so that fractions of a revolution are
asily read. This standard meter is used by connecting it in series with the
neter to be tested; the accuracy of the latter is determined by the "switch"
aethod or the "eye-and-ear" method.
In the "switch" method the register only (in direct-current standards),
)r the entire moving element (in alternating-current standards), is started
.it the beginning of a revolution of the meter under test, by means of a
luitable switch, and stopped at the end of a given number of revolutions.
The accuracy is determined by direct comparison of the number of whole
evolutions of the meter un-
ier testwith the whole revo- ~>
utions, and a fraction, of the
Jtandard.
In the "eye and ear"
method, the number of
.whole revolutions of the
standard is compared with a
whole number of revolutions,
and a fraction, of the meter
under test. The revolutions
of the standard are counted
Carbon CompreBsIoa
I
by ear by means of a tele-
phone receiver and an elec-
trical contact on the shaft,
while those of the test meter
are observed by eye.
210. A Wheatstone-
bridge method for testing
large watt-hour meters
whichcannot be conven-
iently cut out of service, and
are on a load which fluctuates
excessively, such as a railway
—
load, has been developed by Fig. 78. -Connections for testing large watt-
Messrs. Ingalls and Cowles. * hour meters -Wheatstone bridge method. —
The connections are shown
in Fig. 78, where a and b are two fixed standard resistances or .shunts, forming
two arms of the bridge. The third arm is shown at c. A rotating standard
with an adjustable fixed resistance d and a carbon rheostat e constitute the
fourth arm. When e is adjusted until the portable galvanometer shows zero
deflection, the ratio of watts passing through the two meters is a/(.a + b).

* Ingalls, C. H. and Cowles. J. W. " Wheatstone-bridge Rotating- standard

Method of Testing Large-capacity Watthour Meters;" Trans. A. I. E. E.,
1912, Vol. XXXI, p. 1551.

169
Sec. 3-220 measurixg apparatus
220. Qeneral precautions to be observed in testing watt-hour meten
are as follows: (a) The test period should always be sufficiently long hik
a sufficiently large number of independent readings should be taken u
insure the desired accuracy. In service tests, the period preferably should
be not less than 30 sec. and the number of readings not less than three. Ir
laboratory tests, 100-sec. periods and five readings are preferable, (bl
Capacity of the standards should be so chosen that readings will be taken a1
reasonably high percentages of their capacity, in order to make observationa
or scale errors as small as possible, (c) Where indicating instruments art
used on a fluctuating load, their average deflections should be estimated in
such a manner as to include the time of duration of each deflection, as well as
the magnitude, (d) Instruments should be so connected that neither the
standards nor the meter being tested are measuring the potential-circuit loss
of the other, that the same potential is impressed on both, and that the same
load current passes through both, (e) When the meter under test has not
been previously in circuit, sufficient time should be allowed for the tempera-
ture of the potential circuit to become constant, preferably not less than 10
rain.; this is important with direct-current meters, especially in the case of
rotating standards. In some types of the latter, special provision is made for
rapid heating, (f) Guard against the effect of stray fields by locating the
standards and arranging the temporary test wiring in a judicious manner.
221. Meter constants. The following definitions of various meters'
constants are taken from "Code for Electricity Meters."*
Register constant is the number by which the register readings must be
multiplied to obtain the registration. They are ordinarily used only on
large-capacity meters and are marked on the register.
Qear ratio is number of revolutions of the rotating element per revolu-
tion of the first dial hand.
Watt- hour constant is the registration reduced to watt-hours per revolu-''
tion of the rotating element. It has a definite value for each type and rated '

capacity of meter.
Watt-second constant is the registration reduced to watt seconds
per revolution of the rotating element. It is equal to watt-hour constant
multiplied by 3,600.
Test constant is the constant assigned by the manufacturer for use in
the test formula for his meter.
222. Testing formulas. The accuracy of a watt-hour meter is the per-
centage of the total energy passed through a meter which is registered on the ,

dials. Accuracy in percent. = meter watt-hours X 100/ true watt-hours. The

value of one revolution having been assigned by the manufacturer, the meter
watt^hours = /L«iXi2, where X* = watt-hours per revolution or watt-hour con- '

Btant and iJ = revolutions in S seconds. The corresponding power in watts

iaP=(,3,600XRXKk)/S = meter watts and lOOXmeter watts/actual watts-
per cent, accuracy. This is the standard formula for watt-hour meters.
223. Manufacturers' formulas for meter watts. When the test
constant K differs from the watt-hour constant, Kh, the formula is changed
accordingly as follows:

Manufacturer
 MEASURING APPARATUS SeC. 3-225

-aze accuracy for all loads. Such a value obviously must be based on
rbitrary rule. The "Code for Electricity Meters" recommends the
iiowing:* When and 100 per cent.
feasible, test the meter at 10 per cent,
iparity of meter and at the normal load. Multiply the accuracy at normal
id by three, add (to this) the accuracies
found at each of the other two
•ids and divide the sum by five. This result is to be taken as the average
ruracy. The "normal load" shall bo taken as the percentage of the total
itiug of the connected load indicated in the table in Par. 226.
225. Table of Normal Loads of Watt-hour Meterst
cent, of connected load which is equal to the "normal load" in
calcula-
tion of average accuracy (Par. 224)
Residence and apartment lighting 25 per cent.
Elevator service 40 per cent.
r Factories (individual drive) churches and offices 45 per cent.
: Factories (shaft drive) theatres, clubs, entrances,
hallways and general store lighting 60 per cent.
,. .

restaurants, pumps, air compressors, ice

Saloons,
machines and moving picture theatres 70 per cent.
Sign and window lighting and blowers 100 per cent.
'
tS6. Watt-hour meter specifications. Probably the most extensive
ind authoritative specifications for the performance, installation, testing and
maintenance of watt-hour meters in the United States are those included in
esting
the "Code for Electricity Meters" prepared by the Electrical 1
Laboratories under the joint direction of the Meter Committees of the A. E.
I. Co.'s and the N. E. L. A. It is the basis of the rules issued by most of those
state public utility commissions which have adopted regulations covering
the subject of electricity meters. While scientific accuracy and correct
technical principles are the basis of the code, the commercial phase of meter
practice is not neglected. It covers the entire field of representative Amer-
ican meter practice including definitions, standards, specifications for meters
and auxiliary apparatus, installation tests and maintenance.
J27. Ampere-hour meters measure only quantity, that is,
coulombs
or ampere-hours, and therefore where they are used in the measurement of
electrical energy, the potential is assumed to remain constant at a "declared
value, and the meter is calibrated or adjusted accordingly. Meters of this
type may be divided into two general classes: electrochemical (Par. 228)
and electromotor (Par. 231).
228. Electrochemical ampere-hour meters are essentially vol-
tameters, because the quantity is measured by the amount of chemical
decomposition of a substance caused by the passage of all or a part of the
load current. In the Edison chemical meter, now obsolete, two zino
plates were immersed in a jar containing a zinc sulphate solution and con-
nected in parallel with a shunt which in turn was in series with the load.
The energy consumption was obtained by measuring the decrease in weight
of the anode (positive) plate; 1.224 grams represented one ampere-hour.
229. Modern types of electrochemical ampere-hour meters. The
principal modern types utilize the electrolysis of either water or mercury.
The Bastian meter is an example of the former in which the change of the
length of a column of water, as it is decomposed, is a measure of the quantity
of electricity. A little caustic soda is added to decrease the resistance and
B layer of oil is floated on top of the water to prevent evaporation and facih-
tate reading. A scale at the side of the tube is calibrated to read kilowatt-
hours according to a "declared" voltage.
The Wright meter is the principal example of the mercury type.
Metallic mercury is carried into a mercurous nitrate solution from a platinum
cup anode and deposited in a platinum cup cathode, from which it flows
into a fine tube. The height of this column is a measure of the energy con-
sumption, a graduated scale being placed at the side of the tube. The
electrodes are connected in parallel with a shunt, so that only a small portion
of the load current passes through the solution. Provision is made for

• Page 99, 1912 Edition.

t "Code for Electricity Meters;" A. E. I. C. and N. E. L. A.; 1912 ed., p.
100.

171
Sec. 3-230 MEASURING APPARATUS
easilyemptying the mercury from the tube into the anode receptacle whe
the former becomes filled. This type of meter has been highly develope
and inherent errors due to variation in temperature, concentration of tb
solution, level of mercury, effect of vibration, etc., are largely eliminate'
in the latest forms.
230. The principal advantages of electrolytic-type anipere-hou<
instruments are their low first cost and their simplicity, which results i
low maintenance cost. These are important items to power companit
serving very small customers, especially where the rates are low; and ma
outweigh the disadvantages, the principal among which are elimination c
the potential element and relatively low accuracy.
231. Electromotor ampere-hour meters are similar to watt-hou
meters, except that the field is produced by permanent magnets instead c
electromagnets. The rotating element is geared to a register which is cali
brated in watt-hours for a given assumed voltage. There are two genoro
types, the electromagnetic and the mercury flotation. The former i
'

not made or used very much in this country.

The Chamberlain and Hookham meter is an example of the electro
magnetic type. It employs a flat (pan-cake) armature winding mounted oi'
an aluminum disc which also serves as the drag element. Connection is madf
to the circuit through a commutator and brushes in the usual manner. Th«'
armature is connected to a low-resistance shunt which is in series with th<!
load.
The mercury tsrpe meter is well represented by the Sangramo metei
which Is practically the same as the Sangamo direct-current watt-hour mete:
(Par. 195), the electromagnet being replaced by permanent magnets.
232. Maximum demand meters. Some methods of selling energy
involve the maximum amount which is taken by the customer in any porioc
of a prescribed length, that is, the maximum demand
Many types of meters for measuring this demand have]
been developed but space permits only a brief descrip-i
tion of a few types. *
The Wright demand meter is a time-lagged
thermal instrument. It consists of a hcrmetif-ally
sealed U-shaped glass tube (Fig. 79), partly filled with
a liquid. One leg R is connected near the top to a
smaller graduated tube T. Around the top of the tube,
B, is wound a resistance wire through whicli the current
flows. The resultant heating of the air forces the licjuid
up the tube R and, if sufficient, over into the graduated
tube. The air heats up gradually and the necessary
time lag is thus obtained. According to the maker.'<, if
the overload continues 5 min., 80 per cent, of the load
will be indicated; 10 min., 95 per cent.; and 30 min. 100
per cent.
\S-.-// 233. The Oeneral Electric Type W meter is time-
lagged. It utilizes the principle of the induction watt-
Fig. 79.— Dia- hour meter. The torque of the moving element is
gram, Wright de- opposed by springs and a powerful drag on the drag
mand meter. disc. This arrangement provides the necessary time
lag. Two sweep-hands are provided on a dial. One
is geared to the moving element, while the other is moved by the first one
and left at the last position reached by it. This second pointer indicates
therefore the maximum energy, until it is reset. Oeneral Electric type H
and Westinghouse type RO meters are also time-lagged.
234. Integrating demand meters measure an integrated value of
the quantity, usually kilowatt hours. In the Oeneral Electric type P
meter the kilowatt-hours -indicated on a watt-hour meter are printed on a
paper tape at intervals of any desired length. The hourly intervals are
also indicated. It is separately mounted and can be electrically connected
to any standard make of watt-hour meter. The Westinghouse type RA
is similar in principle. The Oeneral Electric type O meter produces a
* For a more complete discussion see Farmer, F. M. "Electrical Meas-
urements in Practice," McGraw-Hill Book Co. 1917.

172
 MEASURING APPARATUS Sec. 3-235

ontinuous graphic record which shows at a glance the maximum of all

he intervals during the day and when it occurred. Type M meters merely
ndicate the demand.

CUEVE-DRAWING INSTRUMENTS
235. Curve-drawing or recording inatruments are essentially indi-
ating instruments so arranged that a permanent, continuous record of the
ndication is made on a chart. They are made for recording all electrical
luantities that can be measured with indicating instruments: current, poten-
ial, power, frequency and power-factor._ Here the fundamental principles
^re, in general, those of standard indicating instruments, with the addition
of a suitable recording mechanism. The two general classes are those in
which the record or chart is made directly by the moving element and
those in which it is made by a separate rnechamsm._ In all types the chart
'is driven by a clock mechanism which la entirely separate from the
instrument proper.
236. Direct recording type. Examples of this class are Bristol, Gen-
eral Electric and Esterline meters. The distinguishing feature of the
;
Bristol instrument is the use of a circular chart. The direct-current am-
, meters and voltmeters employ a stationary coil or solenoid, the moving ele-
, ment being a soft-iron armature working against flat springs. The alternat-
1 ing-current instruments employ the electrodynamometer principle, with
one movable coil and one stationary coil. Suitable provision is made for
1 multiplying the armature movement, and damping is obtained with a vane
I immersed in oil. These instruments are extremely simple and relatively
inexpensive. The sensi-
tiveness is seriously af-
j
fected by pen friction and
where high sensibiUty is
_

essential, a smoked chart

. with a very light pointer
is used instead of the usual
paper chart with pen and
; ink.
The principle of General
Electric alternating am-
meters is shown in Fig. 80,
where A A are fixed coils
connected in series, and B
is a soft-iron armature
upon which the field acts
and produces a torque, and
which carries the pen. The
chart is a continuous
straight one, moving from
1 in. to 12 in. per hour, as
desired. The record is
made in the form of a
straight Une on rectangular
coordinates. The pen in
Fig. 80. — Diagram, G. E. alternating graphic
ammeters.
this instrument carries an
ink-well and is self-inking.Magnetic damping is employed. The volt-
meters and wattmeters are similar except that they utilize the electro-
dynamometer principle, with fixed and moving coils. The greater friction
and complication necessary to get the straight-line record necessitates a
high torque and therefore a larger and more expensive construction.
Esterline direct^current instruments are of the D'Arsonval moving-coil
type. The pmmeters are 50-milIivolt voltmeters connected to shunts.
The alternating-current instruments are of the moving-coil or electrody-
namometer type. The record is a straight-line one, made with a pen inked
by siphon action from a stationary well. These instruments are made in
portable as well as in switchboard form.
237. Where pen friction is particularly objectionable, as in low-
reading millivoltmeters, the indicator is so arranged that it is in contact with
the chart for only an instant at a time. In one form of Bristol instru-
^ ments, a lever presses the end of the iK)inter against a smoked chart once

173
Sec. 3-238 MEASURING APPARATUS
a minute, the pointer being perfectly free in the interim. The record i'!

therefore a succession of dots. In other types of instruments, an inke

thread or ribbon is interposed between the pointer and the paper chart.
238. The Westingrhouse recording instruments are the principt'
example, in American practice, c
the class where the recordin'
mechanism is separate from th
instrument proper. The movin
element, by means of contactl-
operates a relay which in tur'
operates the recording mechan
ism. Thus the moving elemen!
does not have to produce a largi
torque, while ample power can B.:i
applied to the recording mechan'
ism, and hence friction does no i

affect the sensitiveness of thi

instrument. The direct-curren
instruments employ the D'Arson -

„ „, T-i- xTr i- u - -_ I.- val principle, using two sets of coils

Fig. 81.— Diagram Westmghouse graphic ^^^ magnets, astatically arranged
voltmeter. -p^jg alternating-current instru-
ments use the principle of thf
Kelvin balance. Fig. 81 shows the scheme as employed in a voltmeter.
239. The Callender recorder made by the Cambridge Scientific Instru-
ment Co. employs the princi-
ple of a slide-wire bridge (Fig.
82) in which the resistance of
one arm, X, varies with the
current, potential or power to
be measured. As soon as the
bridge is unbalanced, a D'Ar-
sonval galvanometer operates
a relay, r or r', which moves a
contact, c, alongtheslidewires,
until balance is restored, when
the relay circuit opens. This
contact also carries the record-
ing pen, which leaves an ink Fio. 82.
record on a rectilinear chart.
—
Diagram, Callender recorder.

INDUCTANCE MEASUREMENTS
240. Oenersl. The self -Inductance, or coefficient of self-induc-
tion, of a circuit is the constant by which the time-rate of change of the
current in the circuit must be multiplied, to give the self-induced counter
e.m.f. Similarly, the mutual inductance between two circuits is the
constant by which the time-rate of change of current in either circuit must
be multiplied to give the e.m.f. thereby induced in the other circuit. Self-
inductance and mutual inductance depend upon the shape and dimensions
of the circuits, the number of turns and the nature of the surrounding medium.
241. Standards of inductance are usually simple coils of copper wire
suitably mounted on a non-conducting, non-magnetic frame. The turns
are held rigidly in place by shellac, paraffine or other insulating medium.
Inductance standards are made in single units like standard resistances, or
in combinations, with plug connections, like a subdivided condenser or a
resistance box. In the Ayrton-Perry variable standard there are two con-
centric coils, one fixed and the other movable. When connected in series
these coils form a variable inductance, the value of which at any relative
position is read from a circular scale at the top. Additional range is secured
by connecting sections of the two coils in series-parallel combinations by
means of plugs.
242. Methods. The moat commonly employed methods of measuring
inductance are (a) Wheatstone-bridge methods, where the inductance is
determined by comparison with a known inductance or known capacitance;
and (b) impedance methods where the inductance is determined by calcula-
tion from measurements made with- alternating current.

174
 MEASURING APPARATUS Sec. 3-243

343. In Wheatstone-bridge methods a varying current must be em-

oyed. The potential drops, with steady current, are proportional to tho
whereas with a varying current the drops are proportional to
sistances,
le inductance, because e=Ldi/dt, where L=inductance and e = e.m.f.
duced by the current varying at the rate di/dt.
When the detector is an ordinary D'Arsonval efalvanometer
244.
le may be varied by simply opening and closing the battery circuit,
current
le galvanometer circuit being left closed; or a secohmmeter may be
Tiployed which rapidly reverses the current going into the bridge and
multaneously rectifies the galvanometer current, so that the latter is used
i in ordinary bridge measurements.^ The current may also be rapidly
iterrupted with an induction-coil interrupter »«AtA».»
itl» a telephone receiver as the detector. p^«ri^>-VvWVA^/WvWv-
245. A method in which a standard in- ^s rg \ Vi
: uctance is used is shown in Fig. 83. If a con- /j!^
..nuous current is used, the bridge is first balanced vi/
I'ith a steady current by adjusting rs and n, and » ,. j ,.
gain balanced with transient currents (battery
_o«7rLAAAAM—
OOO^-'VvVV^*—AAAAMA>V_
ey opened and closed) by adjusting n and n; the p 'VVYVVVV^
ridge is then rebalanced with steady ciyrent, and
gain for transient currents, the process being re-
peated until the bridge is perfectly balanced
I
#—
^^
nder both conditions. At complete balance
'=L,ri/n; where L = inductance being measured,
Fig. 83. —
Inductance
measurements with
nd L, = standard inductance. L will be in the standard inductance.
a me units as Lt
24S. Use of Vreeland oscillator. Small inductances, as well as large
)nes, may be measured with special convenience, accuracy and rapidity by
his method (Par. 245) if a source of high-frequency, sine-wave alternating
•urrent is available. A very satisfactory apparatus for this purpose^ is a
i^reeland oscillator.* which delivers an absolutely pure sine-wave having a
requency which can be varied from a few hundred to about 2,000 cycles
3er second. It is operated from continuous current and is entirely static,
;he alternating current being derived from a circuit in which oscillations are
iet up by the rapid shifting of a mercury arc back and forth between two
modes. A telephone can be used as the detector, with a high degree of
sensibility.

Fio. 84. —
Inductance measure- Fig. 85. —Inductance measure-
ments with a condenser. ments with a condenser.
247. A method
using' a known
capacitance is shown in Fig. S4. It is a
modified form of Maxwell's method
in which the condenser is connected in
parallel with )-i, and two adjustments have to be made which are not inde-
pendent of each other, one with steady currents and the other with transient
currents. The two adjustments have to be repeated until complete balance
is obtained. In Fig. 84 (Bimington's methods, the bridge is balanced with
steady current by adjusting n, and then with transient currents by varying
r without changing the first adjustment. At balance.
L=^^'10- (henrys) (24)

• Physical Review, 1908, Vol. XXVIII, p. 286.

175
Sec. 3-248 MEASURING APPARATUS
where I/= inductance of Z in henrys, r = ohms in parallel with C,C = capa
tance of condenser in micro-farads, n = total ohms of bridge arm to which ci
denser is connected and Ri = ohma of Z.
248. A similar method (Par. 247) is indicated in Fig. 85 in which t,

adjustments are independent of each ot*heT, the bridge being first balanc
with a steady current and then with a transient current by adjusting r
shifting the condenser contact as in Fig. 84. At balance,
L = CrnO-» (henrys) (2 .

where L = inductance of Z in henrys, C = capacitance of the condenser

mioro-farads and r = ohms in parallel with C.

r-^H-^H

— Inductance
— — Inductance
Fia. 86. measure- Fig. 87. measur
ments connections
meter method.
for three-volt- ments — vector diagrani
volt-meter method.
for thre

249. Impedance methods of measuring inductance are based on tl

law of the impedance of a circuit carrying sine-wave alternating current ar
containing only inductance and resistance, that is,
i.-liRi
Z='j=y/R^ + ^L2Tf)'oTL= -W''( (henrys) (2(

where L = inductance in henrys, E = drop in volts, 7 = current in ampere

R = resistancein ohms, and /= frequency in cycles per sec. Obviouslj
due allowance should be made for the voltmeter current where its magnitud
is sufficiently important.
250. In the three-voltmeter method, the inductance to be measured i

connected in series with a non-inductive resistance as shown in Fig. 8(i

.V_^@J
FlQ. 88. — Inductance measure- Fio. 89. — Inductance measure-!
—
ments connections for three-am- —
ments vector diagram
meter method.
for three-am*
meter method.
The current, 7, measured, also the total volts, and the volts across the
is
inductance Z andthe resistance R. From these readings a triangle is con-
structed. Fig. 87. If R is known, the quantity 2irfLJ can be calculated from
the triangle. If R is unknown, 2it/LI can be obtained by graphical construc-
tion. 7 and / being known, L is obtained by calculation.
251. The three-ammeter method is similar. The connections are
shown and from the three currents, Fig. 89 is constructed
in Fig 88, The .

e.m.f., E, can be measured directly or, if R is known, by calculation from

the relation E-Rh. Honoo L nan be obtained from the quantity AV^tt/L.
252. In circuits containing iron the inductance varies with the
frequency and with the current; hence alternating current of known
frequency and Intensity must be used. In such cases a bridge method
with a standard inductance is convenient. A vibration galvanometer, a

170
 MEASURING APPARATUS Sec. 3-253

r'nchronoua contactor or a separately excited electrodynamometer can be

aed as the detector. The bridge is first balanced for resistance (that is,
alanced for bridge-arm drops in phase with the supply current) and then
'yr inductance (bridge-arm drops 90 deg., from the phase of the supply
urrent)
253. The mutual inductance, M, between two coils may be
aeasured by several methods, as follows:

LR IK-

_i^
•—V//Ar -AMAVlr
'

F I o. 9 0. —M u t u a 1 inductance Fig. 91. —

Mutual inductance
measurements with known self
neasureraents with inductance of
)ne coil known. inductance.

(a) When the inductance, one coil is known (Heaviside). The

L, of
connections are shown in Fig. 90. The bridge is balanced as in inductance
'
measurements for both steady and transient currents. Then

^ = 7-=X^
(ri-f-rs)
(27)

M and L are in sameand rz in ohms.

units, ri
(b) By comparison with a known self -inductance. Connect as in
Fig. 91. First balance for steady currents; then balance for transient
currents' by adjusting t,. Then
m=-l'4"+'^
(«+ri)»
(28)

where r = resistance of secondary of mutual in-

-VMM- -\AAMV-
ductance M, and B = resistance of self-induct-
ance, L. M is in same units as L. / L
(c) By comparison with a known capaci-
tance.Connected as in Fig. 92. Balance as
before for steady and transient currents by ad- M
justing ri and n.
Then
Af = Cnr2lO"« (henrys)
Fig. 92. Mutual in-
(29) ductance measurements
—
where Af = mutual inductance in henrys, C = with known capacitance.
capacitance in microfarads, n and n in ohms.
(d) By connecting the secondary in series with a ballistic galva-
nometer and noting the quantity, Q, in coulombs, discharged into the gal-
vanometer when the primary circuit is closed through a known resistance,
of R ohms, the steady value of the current being I amperes. Then = QR/I M
in henrys. The quantity is determined from the galvanometer constant, or
more directly, by calibrating the galvanometer with a standard condenser.

CAPACITANCE MEASUREMENTS
J64. General. The electrostatic capacitance of two conductors separated
by a dielectric depends upon the surface area of the conductors, the distance
between them, the character of the dielectric, the temperature and the
pressure.
266. Condensers are groups of conductors separated by insulation and
especially constructed to have a known capacitance. Commercial forms are
generally made of sheets of tin foil separated by mica or paraffined paper,
alternate layers of tin foil being connected to the same terminal. One box
may contain one or more of these groups, with plug or other arrangements
for connecting them in various series or parallel combinations.

12 177
Sec. a-256 MEASURING APPARATUfi
956. The capacitance of a ffroup o{ condensers in series Is
1

L .L4.L4.
When connected in parallel,
C = Cl+C2+C3+ . c. (3

267. In high-grrade standard condensers, the aim is to reduce t

absorption, the dielectric hysteresis and the ohmic losses to a minimui
Commercial standards are made with tin-foil and high-grade niir
bound together under high pressure. Primary standards, howevt
are made with air aa the dielectric, in which absorption and leakage are n

368. Methods. Electrostatic capacitance measurements are made I

bridge methods (Par. 269), with a ballistic galvanometer (Par. 260), by lo.
of charge (Par. 262), and by impedance methods (Par. 263).

269. A bridge method of measuring capacitance is shown in Fig. 93. Ti

ratio, ri/rj, or thestandard condenser (if adjustable), is adjusted until th
bridge is balanced; with an ordinary D'Arsonval galvanometer this conditio
is indicated when there is no "kick" as the reversing switch is changed froi
one position to the other. If interrupted currents or high-frequency altei
nating currents are used, with a telephone receiver, balance is indicated b
silence in the receiver. Then Ci = Cin/rj. The resistance should be not
—
inductive, anti-capacity and relatively large several hundred ohms.
viously, maximum sensitivity is obtained when C2 and Ci are about equa.
Ob
By employing a Vreeland oscillator (Par. 246) and an adjustable air or 01
condenser, small capacitances can be very accurately measured by this method

m
Fig. 93. —
Capacitance measure-
ments, bridge method.
Fig. 94. —
Capacitance measure
ments, method of mixtures.

860. In the ballistic galvanometer method, the deflection is noted;

when the unknown capacitance is discharged through it, immediately after:
haring been charged at some known potential. A reading is then obtained
with a standard condenser, the deflection being made about the same as
before, by varying the capacitance or the charging potential. The capacitance
can then be computed from the relation d/di = C£/CiEi where d,di,C,C\, and
;

E, El are the respective deflections, capacitances and potentials. This method

is best suited to relatively large capacitances, such as lead-covered, paper-
insulated cables, etc.
261. The Thomson method of mixtures is shown in Fig. 94, where Ci^
is a cable, transmission line or other capacitance to be measured, and C2 is a
standard condenser. First the switches are closed at 1, 1, and the condensers
charged to potentials corresponding to ri and rs respectively. After complete
charge (a cable may require several minutes), the switches are shifted to
2, 2 and the charges equalized. If, then, the switch at 3 is closed, the deflec-
tion of the galvanometer will be proportional to the difference of the charges.
This operation is repeated with various ratios n/ri until there is no deflection.
Then Ci = Ctn/n.
262. In the loss of charge method, Fig. 95, the condenser to be
measured is first completely charged by moving switch b to a, and then imme-
diately discharged through a ballistic galvanometer by moving b to c. The
condenser is again charged and allowed to discharge through a known high

178
 MEASURING APPARATUS Sec. 3-263

sistance, R, a given number of seconds, t,

before being connected to the
ilvanometer a second time. The capacitance in microfarads is
(-ic-farads) (32)
^-RTogJ/d.2.303
here (ii = first deflection, (f2 = second deflection and i? = resistance in meg-
. hms. This method is applicable only where the resistance of the condenser
'
eing measured is very high, such as porcelain insulators.

sb

'
FiQ. 95. —Capacitance measure- Fio. 96. —
Capacitance measure-
'
ments, loss of charge method. ments, impedance method.
263. In the Impedance method, the capacitance is computed from the
reactance a.s measured with an ammeter and a voltmeter, with alternating

•urrent of known frequency as shown in Fig. 96. Then

C = s-^(10») (microfarads) (33)

where microfarads, £? = volts, I = amperes, and/= frequency

C — capacitance in
'.n cycles per second. Unless the voltmeter is an electrostatic instrument it
should be disconnected when taking current readings. With small capaci-
tances where / is small, care should be taken that the high inductance of a
low reading ammeter does not introduce an error. The capacity given by this
method depends upon the wave form. Therefore the test should be made
from the circuits to which the apparatus being measured will be connected
in service. Obviously this method is correct only for a zero power-factor
condenser.
264. The specific inductive capacity of a material is the ratio of the
capacitance of a condenser with the material as a dielectric to that of the same
condenser with air as a dielectric. The following substitution method is
convenient for sheet material. An air condenser formed by two metal
plates is set up and measured. Then several sheets are slipped into the air
space and the measurement repeated. The spacing of the plates minus the
thickness of the sheets gives the air space in the second measurement. From
the capacitance of the latter (by calculation from first measurement or by
Par. 266) the capacitance of the material is computed by formula 30. Ex-
ti;rnal capacitance can be determined by keeping one plate grounded and
making an initial measurement with that plate removed.

1 U

Fia. 97. —Guard ring in specific inductive capacity measurements.

266. The "fringe
effect" (electrostatic field in the dielectric extending
beyond the area corresponding to the electrodes) may be eliminated by using
a guacd ring, a, a, of tin-foil as shown in Fig. 97. It is very close to the
electrode b and is so connected in the circuit that only the charge on 6 is
measured.
286. The capacitance of an air condenser isC = A /iwt X 9 X 10», where
C — capacity in microfarads, A = area in square centimeters and, t =« thickpess
of layer pf air in centimeters.

179
Sec. 3-267 MEASURING APPARATUS
WAVE-FOBM MEASUREMENTS
867. Methods. The instantaneous variations of current and poteoil
in a circuit are measurable by step-by-atep methods (Par. 268), and with «
oscillograph, (Par. 271.) The former is applicable only where the current 'i
the potential are strictly periodic and recurrent, as in a normal alternati;-
current circuit. The oscillograph can be used under all conditions, but isii-
pecially applicable to measurements of transient phenomena (Par. 268), 8 h
as those which occur during switching operations on direct-current and -
ternating-current circuits. Where the wave form is to be analyzed, the fori r
is the more convenient and accurate.

368. A convenient "step-by-step" arrangement is shown in Fig. .

The contact device consists of two slip-rings and a four-part comniutai

One slip-ring is connected to one terminal of the source, the other to a vi-
meter, and the commutator to a condenser. By means of this arrangeni€ ,

the condenser after being charged is immediately discharged through :

voltmeter. These impulses follow each other so rapidly that a steady •

flection is obtained, and by suitable adjustment of R and r on continuu
current, the voltmeter may be made direct reading. The instantaned
values at any point on the wave are obtained by shifting the brushes aroul
the shaft. The switch is closed at 1 for voltage measurements and at 2 •

current measurements. *
_
The General Electric wave meter operates on this principle. Thoro ;

eight segments, four connected to each of two slip rings. There are two n
tact brushes so that two waves can be taken simultaneously. Suita
provision is made for tracing the wave form on a photographic plate.

Fig. 98. — Wave-form measurements FlQ 99.— Wave-form tneasure"

"Step-by-step" method. raents, zero method.

269. In the zero method shown in Fig. 99, the e.m.f. of a battery B
opposed to the potential across c and d, which are connected to the conta
devices described above. The contact point, b, is adjusted until G shows i
deflection; then the length ha is a measure of the e.m.f. G may be a portab
galvanometer, or a telephone in conjunction with a slide wire and a contai
stylus as used in the Sage ohmmeter (Par. 139).
270. The form of a high-tension wave may be obtained by using tL
device in Par. 277. The indication of the voltmeter is obtained at variou
positions of the brushes, from which the wave form may be plotted. A
oscillograph (Par. 271) may be utilized in conjunction with a special!
designed current transformer, t
271. The oscillograph is a form of galvanometer in which the natun
period of the moving system is so small that the deflections will always, b
proportional to the instantaneous value of the current flowing through th
coil. The indicator is a beam of light from an arc lamp, reflected from ai
extremely small mirror attached to the moving system. The path of th
beam is determined visually or photographically.^ Recurrent or perii>di
waves may be rendered stationary and therefore visible bv suitable optica
systems as indicated below. Transient phenomena must be photographed
272. In the movlng-lron type of oscillograph, first proposed bj
•See also Frederick Bedell. "Condenser Current Method for the Deter-
mination of Alternating Wave Form," iS/ec<rico2 World, 1913,Vol.LXII,p. 378,
t Bennett, Edward, "A Milliampere Current Transformer," Trans.
A. I. E. E., Vol. XXXIII, p. 571 (1914).
•180
 MEASURING APPARATUS Sec. 3-273

londel, * a very small piece of soft iron is suspended in a strong magnetic

-jld,thus forming a polarized magnet. Near this strip are placed two
nail coils, whichcarry the current to be investigated. Because of its very
nail period, thismagnet will follow every variation in the current.
i 273. The moving-coil type of oscillograph developed by Duddell
'insists of a single-turn coilformed by passing a phosphor-bronze strip
ver a pulley suspended by a spring, and between the
oles of shown in Fig. 100.
a powerful electromagnet as >
1 1 has a much lower inductance than the moving-iron >
/pe and therefore a wider range of application. This %
Ype is now in most general use and in this country is
[ rominently represented by the General Electric oscillo-
graph, a very simple, rugged and practical in.strument.
. 'hree elements or vibrators are usually provided in the
itter, and three waves may be taken simultaneously,
'he electromagnets are wound for 110 volts, at which
xcitation the sensibility of the vibrators is of the order
f 0.005 amp. per millimeter deflection. The moving
,
ystem is immersed in a well, with a glass front, and filled
nth oil to dampen the oscillations. The natural fre-
luency is of the order of 5,000 vibrations per second. o
274. Various receiving devices are used to render
he wave visible to the eye. One scheme employs a
otating mirror driven by a synchronous motor con-
lected to the circuit being tested. In the General ^ "
Electric oscillograph the beam of light from the arc, a,
upon
Fig. 100.
the mirror, ment of moving
Ele- —
^ig. 101, is concentrated by a lens, b,
of the vibrator, which is oscillating about an axis per-
,
coil type of oscillo-
jendicular to the beam. The mirror, m, is driven by graph,
i cam, d, which gives a comparatively slow forward
stroke and a quick backward stroke. When this mirror is stationary the
mage of the reflected beam at s is a straight line the length of which is
proportional to twice the angular deflection of the vibrator. If the mirror
s rotated forward, the image at s is spread out thus tracing a wave. The
wave is made to appear stationary by automatically cutting off the light on
the return stroke of m
by means of the shutter e.
276. Permanent oscillograph records may be made bytracing the wave
on transparent paper or tracing cloth placed on the screen, s, referred to above
(Par. 274) For making pho-
.

tograph records, or oscillo-

grams, the visual attachment
is replaced by a light-proof
cylinder containing the film
and fitting over an opening
,-
r-r- "'T
rr in the oscillograph
through which the beam of
case
._ ;
light passes to the film. The
film is unrolled from one spool
on to another and past the
Fig. 101. —
Visual attachment, G. E.
oscillograph.
opening by a motor-driven
mechanism; its speed is ad-
justed to suit the condi-
tions. In the case of transient phenomena it is often found necessary
to arrange special devices to start the film automatically at the proper time
in order to get the phenomena on the film. A record of elapsed time in di-
rect-current phenomena can be obtained by connecting one of the elements to
a source of alternating current of known frequency, or by means of an electric-
ally driven tuning-fork of known frequency. A small mirror mounted on
the end of one prong and so placed that it will reflect a part of the beam,
will give an excellent time record. The scale of ordinates is obtained by
calibration on continuous current, the deflection of the spot of Ught corre-
sponding to a known current, or voltage, being noted.
276. Standard wave form. It is desirable that commercial alter-
nating-current wave forms be as near a sine curve as possible in order to
* Blondel. A. E. Comptes Rendus, 1893, Vol. CXVI, p. 502.

181
Sec. 3-277 MEASURING APPARATUS
reduce iron losses, excitation currents, charging currents, etc., to a minim i.

The present A. I. E. E. standard method of measuring the deviation fa

a sine curve is simply to measure the greatest diflference between coi-
sponding ordinates at any point along the axis of abscissae. In anot^r
method for determining wave form distortion which has been tentati'\(r
adopted by the A. I. E. E., the admittance of a carefully prescribed netw^
of resistances and inductances is measured with the unknown wave ftj
and compared with that for a sine wave.
877. In hlgrh-voltage testing it is particularly important that the va 9
of the maximum instantaneous voltage be available, because the stis
to which insulation is subjected depends upon this value. When the Wij
is distorted, the maximum value and the ratio of the maximum to me -
effective (amplitude or peak factor) have to be obtained from a plotf
the wave. This may be taken with a wave meter or with an oscilloRrp
preferably connected to a test coil in the high-tension winding or t
secondary of a shunt-type instrument transformer connected to the
tension circuit.
A method which can be used directly on the highest ToItag<
is indicated in Fig. 102. where C is a series of condensers connected acr 1

the high-tension circuit. The end ci-

denser d is grounded and connected
l.QQO.Q.Q-Q-Q-QjJ parallel with a commutator, R, driven
a synchronous motor. The bars on t
commutator are very narrow and <
one polar space apart, so that contact
Ci practically instantaneous. The brusl
r=zi^ are shifted until the voltmeter, V, im
I

I EiTTL cates a maximum. The multiplying rai

I'— |_j is obtained from the ratio (C + Ci)/(
The instrument may be calibrated V
noting the indication corresponding ,

the mean effective value, which is o'

tained with the motor stationary ai
the brushes resting on the bars. TL
Fio. 102.— Wave meter for high indication is compared with a spark gi
The method a
voltage circuits. or other standard.
sumes that the capacity of V is negligib
in comparison with Ci. Obviously the condensers can be dispensed with b
connecting directly to a test coil on the high-tension winding.
Another method which is simpler has been developed bjr J. R. Crai(
^

head.t A thermionic electric valve (kenotron) is connected in series wit

a condenser and an electrostatic voltmeter is connected across the coi
denser. Measurements may be made directly on voltages up to 25,000 c
30,000 volt3 and indirectly up to any voltage where a voltage coil has bee
installed in the transformer.

FREQUENCY MEASUREMENTS
278. Oeneral. The frequency of an alternating current is /= nr/i
where /= frequency in cycles per
second, n = number of poles, and
r — revolutions per second. It ^^old«r Weight
may therefore be determined by
measuring the speed of the gen-
erator supplying the circuit or
the speed of a synchronous mo-
tor operated from the circuit.
279. Frequency meters indi-
cate the fre<iuency directly.
the reed type as made by Hart-
— —
In Fia. 103. Frequency meters Heed type

man and Braun or Siemen.s and Halske, there are numerous steel strips o
different lengths, each rigidly fastened at one end and free to vibrate at th(
other. The strips are placed in the field of an electromagnet which is ener
• Sharp, C. H. and Farmer, F. M. "Measurements of Maximum Valuei
In High-voltage Testing;" Trans. A. I. E. E., 1912, Vol. XXXI, p. 1617.
t Craighead, J. R., "Measurement of the Crest Value of Alternatini
Voltage by the Kenotron, Condepscr and Voltmeter," Oeneral Ekctrii
Revieiv, 1919, Vol. XXII, No. 2, p. 101.
182
 MEASURING APPARATUS Sec. 3-280

: .;d from the circuit to be measured, as shown in Fig. 103. The strips have
erent natural periods, and the one with a period corresponding to the
.'

(Jrnations of the magnetic field will be set in vibration. The ends are
rned up and painted white so that the particular reed in a row, which is
grating, will be in-
by a white
iated \v^^" "/''/,,
^^
iidorblur. Each ' ''

d is carefully ad-
; ted to an exact
j'iod by attaching
minute we i ghts.
[
ese meters are
.ide in various
'
iges and with
;ds adjusted from
;5 cycle to 2 cycles
art.
280. The West-
.ghouse fre-
lency meter cen-
two voltmeter
ts of Fig. 103a.- -Circuits in Westinghouse frequency
jvements, mechan- meters.
tdly so intercon-
;cted that they tend to rotate the pointer in opposite directions. non- A
;iuctive resistance R
is connected in series with one movement, Ti (Fig.
I3a) and an inductance X
is connected in series with the. other element, ^2.
ne apparent resistance of the inductive movement varies with the fre-
liency and thus varies the amount of current taken by it. Therefore
:ch frequency will cause the pointer to take up a different position.
'
881. The Weston frequency meter is
own in Fig. 104, where 1, 1 and 2, 2 are fixed
dis,90 deg. apart, and c, c is the movable
ement consisting of a simple, soft-iron core
' ounted on a shaft, with no control of any
.nd. One coil, 2, 2, is connected in series
ith a non-inductive_ resistance, Ri, and the
;her coil, 1, 1, in series with an inductance,
'
1. A second non-inductive resistance Ri is
)nnected in parallel with 1, 1_ and Xi. A

Fig. 104. —Circuits Weston frequency

meters.
in Fig. 105. —High sensitivity
frequency indicator.

jcond inductance, X2, is connected in parallel with 2, 2 and Rt. The soft-
en core takes up the position of the resultant field produced by the two
ails. When the frequency increases, the current decreases in 1, 1 and
icreases in 2, 2, thus shifting the direction of the resultant field and the
osition of c, c to which the pointer is attached. The opposite efifect takes
lace when the frequency is decreased. The series inductance, X, serves
lerely to damp the higher harmonics.
SS2. A very sensitive frequency indicator is shown in Fig. 105, in

183
 Sec. 3-283 MEASURING APPARATUS
which the principle of resonance (Sec. 2) in an electrical circuit is employe^
In a 60-cycle instrument, one main circuit is adjusted forresonaii
at about 70 cycles, another at about 58 cycles and the third circ
at about 36 cycles. The latter two are connected in parallel, and then)
series with coil A; the first circuit is in series with coil A', both coils being
series with the field F. With the centre of a 6-in. (15 cm.) scale marked :

60 cycles, half-scale deflection is obtained for a variation of only 5 eye

either way.
SLIP MEASUREMENTS
283. Qeneral. The slip of a rotating alternating-current machine
per cent, is the difference between its speed and the synchronous spet
divided by the synchronous speed. It may be determined by noting t
difference between the measured speed of the machine and the synchrono >

speed but direct methods are more accurate.

Millivoltmeter method. If sui
cient stray field is produced by tl
current in tlie secondary of an indu
tion motor, a direct-current niillivol
meter connected to an adjacent coil
wire or across the motor shaft or f ran
will oscillate at slip frequency, eai
swing being one pole slip.
284. Dooley's method of meai
uring slip. One form of device f(
indicating the slip of an induetio
motort is shown diagrammatically i
Fia. 106. —
Slip measuring device. Fig. 106. A small eyhnder made
conducting material, and in two parti
c

each insulated from the other, is mounted in a frame. Four small brushes
1, 2, 3, and 4, bear upon the cylinder as shown. The brushes, 3, 4, ar
connected through a resistance, r, across one phase of the supply circuit an.
the brushes, 1, 2, are connected to a low-reading continuous-current ammetei,
I. Each time the brushes, 1, 2, bridge the insulating strip as the cylinde
rotates, the circuit is completed in alternate directions
through the ammeter. The cylinder should have as many IndJUotor Shaft
segments as the motor has poles. The ammeter will in-
dicate a constant current at synchronous speed, and an
oscillating current for any speed above or below syn-
chronism, because the impulses of current through the
brushes, 1, 2, will occur at the same point on the wave
at synchronous speed, and at constantly advancing or
retarding points for other speeds. Thus, the ammeter
will be reversed each time the motor loses one-half of a
cycle, and will reach a maximum positive value each time
the motor loses one complete cycle. If the motor loses n
cycles per min., then the slip in per cent. = lOOn/CO/,
where /= frequency of the system in cycles per sec.
285. Stroboscopic method. The device indicated in
Fig. 107 does not require the measurement of frequency.
A black disc with white sectors, equal in number to the Syn.Motoi Shaft
number of poles of the induction motor, is attached with
wax to the induction-motor shaft. It is observed Fig. 107.— Slip'
through another disc having an equal number of sector- measurements —
shaped slits and carried on the shaft of a small self-start- S t r oboscojiic
ing synchronous motor, in turn fitted with a revolution method.
counter which can be thrown in and out of gear at will. If
n is the number of passages of the sectors, then 100n/7i,nr = slip in per cent.
where n. = the number of .sectors, and Ur = the number of revolutions recorded i

by the counter during the interval of observation. For large values of slip
the observations can be simplified by using only one sector (n« = l); then 7i«» ,

the slip in revolutions.

286. A direct-reading: slip-measuring device is shown in Fig. 108.

•Pratt W. H. and Price D. R. "Resonant Circuit Frequency Indicator;"

Trans. A. I. E. E., 1912, Vol. XXXI, p. 1595.
t Dooley. CR. Elec. Clvh Journal, 1904, Vol. I, p. 690. ^t!
1S4

1
 MEASURING APPARATUS Sec. 3-287

f : is a carefully turned and hardened conical drum driven by the motor being
jf
'ated, through a flexible shaft, S. The long screw, H, moves a carriage,
', parallel to the surface of D. This carriage carries a wheel d, also care-
[illy turned and hardened, which has a line edge and is kept in contact at
j,
{' I 1 times with the surface of D
by means of a light spring. Thus it revolves
j[
,ith D. On the same shaft is a disc, sd, with alternate black and white
;ctors painted on it, the number of sectors being equal to the poles of the
lotor being tested. The
: iameter of d is made equal
'
1 3 that of the small end of Z).
* ?.t the setting corresponding
'd the small end of D, the
~ -^alealong which the carriage
loves is marked zero. This
' 'orresponds to synchronous
peed. As the speed of D =^H
ecreases, it is necessary to
'aove d toward the large
nd of Z) in order to keep
'
'he speed of d the same as at ---...^^aiiiii:::!!^^
'ynchronous speed. This

i lip.
a measure of the
listance is
The synchronous speed
Fig. 108. —
Slip measuring device.

if sd is indicated when it appears to stand still, when illuminated by an

.re lamp connected to the same circuit to which tbe motor is connected.
iChus, if D is 2 in. (5.1 cm.) in diameter at the small end, 2.5 in. (6.35 cm.) at
],he large end and 5 in. (12.7 cm.) long, slips from to 20 per cent, can be
neasured with a precision within 0.2 per cent. A more sensitive detector
'
.'onsists of a commutator in place of sd, connected in series with a direct-
lurrent voltmeter and the circuit to which the motor is connected. The
ndication is a maximum at synchronous speed.
j
287. Synchronism indicators. In order to connect any synchronous
'machine in parallel with another machine or system, the two voltages must
jOO made equal and the machine must be synchronized, that is, the speed
30 adjusted that corresponding instantaneous values on the two waves are
reached at the same instant,
when they will be in exact
phase. Furthermore, with
polyphase machines, the direc-
tion of phase rotation must
assuredlybe the same. This,
however, is usually made right
once for all when the machines
are installed, the phases being
so connected to the switches
that the phase rotation will
always be correct.
288. The lamp method of
synchronizing is the simplest.
Fig. 109. -Connections for synchronizing The principle of lamp synchro-
with lamps. nizers is shown in Fig. 109,
where a, ai are the sources be-
ing connected in parallel and t, ti are transformers, the secondaries of
which are connected in opposition through incandescent lamps, I, h. When
the two sources are in synchronism, the secondary e.m.fs. neutralize each
other and the lamps will be "dark." As the phase difference increases,
the current through the lamps will increase, reaching a maximum at 180
deg. of phase difference. If the secondary of one transformer is reversed,
the lamps will be brightest at synchronism and dark at 180 deg. of phase
difference. The former connection is preferable because the point of total
darkness" is more easily detected than the point of maximum "brightness."
A voltmeter may be substituted for the lamps by connecting it so that
syncliromsm is indicated when the reading is a maximum. The disadvantage
of this method is that it does not indicate which frequency
is the higher.
Synchronism indicators (Par. 287) are instruments which not only over-
come this objection, but indicate the point of synchronism more accurately.

185
Sec. 3-289 MEASURING APPARATUS
289. The principle of the Westinghouse synchronizer is showii
Fig. 110, where a rotating field is produced by the coils, and JV, conned M
to the buses through the reactance P and the resistance Q, respectively, i
iron vane A, free to rotate, is mounted in this rotating field and magneti*!
by the coil C, which in turn is connected across To Bus
the incoming machine. As the vane is attracted
or repelled by the rotating field from and A^, M
it will take up a position where this field is zero
at the same instant that the field from C is zero.
Hence the position at any instant indicates the
difference in phase. When the two frequencies
are different, this position is constantly changing
and the pointer will rotate "fast" or "slow,"
coming to rest at the zero-field position when the
frequencies are equal. In a larger type, the split-
phase winding is placed on the movable member,
similar to the arrangement shown in Fig. 111.
290. The scheme of the Weston synchro-
scope is shown in Fig. 112. There is no iron in
Inoomlng
Mkohln

Pointer- B
Shaft -5
Iron ArtDftttire

m K
HoTing Elemin« To Incoming
BoMfl Machine
Fig. no. — Circuits Westinghouse syn-
chronizer.
in Fia. 111. — Circuits in C
E. synchroscope,
the instrument and the moving elernent is not allowed to rotate. TIm
'-

ments are practically the same as in an electrodynamometer watti:

The fixed coils, F, F, are connected in series with the resistance R and t

buses. The moving coil, M, is connected in series with a condenser ( m

the incoming machine. The two circuits are adjusted to exactly 90 des

Lamp Transformer

Bus Bars

Fig. 112. —
Circuits in Weston synchroscope.
difiTerence in phase. At synchronism there is no torque and
zero position by the control spring.
is held at th< M
If the frequencies are the same, but
there is a phase difference, a torque will be exerted and
position of balance at the right or left ("fast" or "slow").
will move to j M
If the fre^
quencies are different, the torque will continually vary and the pointer wil
oscillate over the dial._ A
synchronizing lamp illuminates the scale siraul
taneoosly and the direction of apparent rotation indicates the faster machine.

18C
 MEASURING APPARATUS SeC. 3-291

. 891.The General Electric synchroscope operates on the same principle

* - the Westinghouse instrument (Fig. 111). The split-phase winding, C, B,
mounted on the movable element, E, the two coils being connected to the
a i coming machine through slip- rings.

MAaNETIC MEASUREMENTS
292. General. The intensity of a magnetic field, X, may be con-
lered the average fall of magnetic potential along the path and is expressed
- gilberts per cm. In a long straight solenoid 3C = 4wNI/10l, where / =
irrent in amperes and X/l = turns per unit length. Magnetic induction
•
flux density, (B, is measured in lines of magnetic induction per square
ntimeter (gausses). When the substance in which the field exists is non-
agnetic, (B = 3C and the ratio (B/JC, or permeability, isM=l. When the
ibstanee is magnetic, (B becomes much greater than 3C, due to the decreased
agnetic resistance; in general it varies with 3C.
293. The normal induction or
(B-3C curve of a magnetic material is the
between the strength of the magnetic field existing in the
irve plotted
laterial, 3C,and the magnetic induction, (B, produced by that field, when the
. . material is in a neutral or normal condition. A permeability curve is
lotted between the permeability ti and (S>, or between n and 3C.
294. The hysteresis curve is a curve plotted between (B and 3C, for
arious values of 3C from a maximum value in the positive direction to a
laximum value in the negative direction, and back again, or through a
jmplete cycle of values. The ends of a hysteresis loop will lie in the normal
iduction curve.
296. Magnetic measurements may
be divided into two classes, (I)
lose in which the strength of a magnetic field is determined (such as the
irth's field, the field due to a conductor carrying a current, the field in the
ir gap of a magnet, etc.) and (2) those made to determine the properties
f magnetic material.
296. Field-strength measurements may be made by induction methods,
ath an oscillating bar magnet (Par. 299), or witha bismuthspiral (Par. 300).
n the induction method a coil of known turns and area is so arranged that
can be made to cut the field in a known area in a direction perpendicular
;

the field. _ The e.m.f. generated in the coil, and hence the field producing
;, is determined from the quantity of electricity discharged through a ballistic

alvanometer connected to the coil terminals.

In measuring the field strength in air gaps, the coil is so arranged that one
•
ide can be moved quickly across the entire gap, or through a definite dis-
aace, by means of a spring or weight suddenly released. When there is
iufficient space, a more accurate and convenient method is to rotate the
.oil through 180 deg. Very weak fields, such as the earth's field and that
lue to conductors, may be measured in this manner by using a sufficiently
arge coil.
297. Formula for field strength. The flux density in lines per square
Iientimeter = (B, and by definition equals in air
3C (field strength) = (gilberts per cm.) (34)

^here d = deflection, i- = constant of galvanometer in coulombs per scale

iivision, R = total resistance in galvanometer circuit, n = turns in coil, a =
nean area of coil in square centimeters, x = linear distance moved in centi-
Tieters or, when the coil is turned through 180 deg., x = 2.
298. The Orassot fluxmeter is a portable instrument with which mag-
may be read directly on a scale. It is essentially a ballistic galva-
letic flux
lometer with the moving element suspended by a torsionless suspension so
:hat itremains deflected. The instrument is connected to an exploring coil
which is placed in the air gap to be measured. The flux is measured by
loting the deflection when the magnetizing circuit is either opened or closecl.
299. In the oscillating-magnet method, a small simple bar magnet
ISsuspended by untwisted silk fibres. The magnet is set to vibrating through
an angle of about 5 deg. and the period of oscillation determined. The aver-
age of at least three observations should be taken. The field strength is
^" ivfTi
(gilberts per cm.) (35)
Sec. 3-300 ME ASSURING APPARATUS
where K = momentof inertia computed from the mass and dimensions, At
magnetic moment, and r = period of oscillation. M
may be determii
with a magnetometer, or by calibration in a known field (Helmholtz co;
This method is only suitable for weak fields, such as the earth's field, i

mounted in a wooden box with a glass front, it will be protected from

currents and can be conveniently moved about when making magno
surveys.
800. Bismuth-spiral method. The resistance of bismuth wire increat
when placed in a magnetic field. This property is utilized by noting t
increase in resistance of a flat spiral coil of bismuth wire when placed in t
field to be measured, the leading-in wires being arranged non-inductive
The device is calibrated with known field strengths. It is particulai
suitable for exploring small air gaps such as those in motors and generatoni
301. Measurement of magrnetic properties. The magnetic properti
of iron and steel which are of most commercial importance are norm
induction or permeability, hysteresis loss and total losses with altc
nating magnetizing forces of commercial frequencies.
302. Normal-induction data. The various methods are distinguishc
principally by the method employed to measure (B, for in most methods OfC
determined from the magnetizing coil. (B can be measured directly as in tl
ballistic methods or indirectly with permeameters.
303. Ballistic methods are usually employed in the more accurate meal
urements. The best-known methods are the ringr method, the diyide
bar or Hopkinson, and the double-bar double-yoke methods. In all >

these methods the flux is measured with a ballistic Kalvanometer connectc

to a test coil which is cut by the flux when the exciting current is reversed.
304. The ring method, devised by Rowland, is one of the earliei
methods of measuring the magnetic properties of iron. The connections ai
shown diagrammatically in Fig. Hi
where T is the teat specimen. Th
latter is an annular ring, either solid c;
built up of punchings of sheet meta
with a diameter preferably 8 or lOtime
the radial thickness. After coverin
with a thin layer of insulation, a tea
coil of very fine doublo-silk-coverei
wire is wound on a portion of the rin^
The magnetizing coil is wound uni
formly over the test coil and the entir
ring. It is usually magnet wire, o
Kev. sufficient size to carry the maximun
Sw. current without raising the tempera
ture of the iron appreciably. Th.
Fig. 113.— Permeability
^ tests— ring
*
j^g^^jjQj
Par. 306, excepi
formulse are those in
2an instead of an.
SOS. The divided-bar method devised by Hopkinson avoids the neces-
sity of winding each specimen separately, permits the use of a more con-
venient test piece, and avoids the errors in ring specimens.* The device
consists of a test piece, BC (Fig. 114), in the form of a bar about 15 in. (.'58.1
cm.) long and 0.5 in. (1.27 cm.) \-i

diameter, which is divided at A

and inserted in a massive frame, p A
p
^ f \

F. The secondary coil, S, is so

arranged that it will be thrown "H.
clear of the yoke by a spring
when the part, AB, of the test
bar is suddenly withdrawn. In
calculating 3C, the length of the
magnetic circuit is taken as that
between the inside faces of the
yoke, the reluctance of the yoke
Fio. 114. — —
Permeability testa divided-
bar method.
being considered This
negligible.
introduces an indeterminable
* Lloyd M G"Errors in Magnetic Testing with Ring Specimens;" Bureau
of Standards, Bulletin, 1908, Vol. V, No. 3; p. 435.

188
 MEASURING APPARATUS Sec. 3-306

-•
fji and, therefore, the method can be suitable only for rough measuremonts.
i '
3 leakage error due
to flux through the coil, but not through the bar, can
Idetermined by preliminary test with a non-magnetic bar. The formulaB
''^

i
f X
and (B are 3C=4irNI/10l and (B = lO^dkR/an, where A^ = total turns of
:
< iting coil, /
= exciting current in amperes, i = length of magnetizing coil
s izm. (;V//i = ampere-turns per cm.), (i = deflection, 5=
total resistance of
» t coil circuit, k = galvanometer constant, o = area of specimen in square
» « timeter and n = turns in test coil.

I
106. The double-bar, double-yoke method is the one recommended
'
f the American Society for Testing Materials. It was devised by

Fig. 115. — Permeability tests, double-yoke method.

W. Burrows* and is the standard method used at the Bureau of Stand-

ds for both solid and sheet specimens. Not only is the precision high,
t the method is also rapid and convenient when the observer is experi-
ced. The essential feature is the_ distribution of the magnetizing wind-
g in sections, which permits the independent adjustment of the magnet-
ng force in various parts of the magnetic circuit. Thus the effect of
)ii-uniform reluctance at joints, etc., can be overcome and the induction
:ade uniforrn throughout the entire magnetic circuit. Exploring coils are
aoed at various positions bo that the uniformity of the induction can be

-To Potontiometer (or MilVivoltmoter)

Fig. 116. —Connection diagram for double-yoke method.
The scheme for rod
specimens (similar for specimens of sheets)
shown in Fig. 115 where 6, b are two bars (standard size, 1 cm. diameter,
i cm. long) one to be tested and the other an auxiliary bar of similar material.

y are yokes of Norway iron about 15 cm. long and about 4 or 5 cm.
,

lameter, into which the bars are clamped. The magnetomotive-force is

pphed in three sections: one coil, Ni, is placed over the test specimen;
nother, A^„, over the auxiliary rod; and the third, Nj, is divided into four
arts, one near each joint. The corresponding exploring coils are nt, na
ad 71;. These coils all have the same number of turns, that is, nt = na =
le two parts of », in series. They are so connected to a switch that Ua or
;•may be connected through the ballistic galvanometer in opposition to
/.thus providing a zero method of determining uniformity of flux. The
;neme of connections is shown in Fig. 116. The magnetizing coils are
^nnected to special reversing switches so made that they can be operated
multaneously.

• Burrows, C. W. Trans. A. S. T. M., 1909; Vol. XI, p. 31.

189
Sec. 3-307 MEA,<?VRTNG APPARATUS
307.Frocedur* in double-bar double-yoke method. The inet>]
of procedure is as follows: After demagnetizing (Par. 321), the current!
Ni ia adjusted to the value of 3C required. The current in all magnetit;
coils is then simultaneously reversed several times to get the specimen i|i
cyclic condition, the current in Na and A', being adjusted during the pro<s
until the flux is uniform as indicated by zero deflection when na and n, )

successively opposed to m. The galvanometer is connected to ni and >

defleeticm noted when the current in the various magnetising coils is

versed simultaneously- Then
4xA'7
3C= .^ (gilberts per cm.)
,
10 I

10»dkR

The units are the same as in Par. 305. The quantity in the parenthesiji
the correction factor for the space between the surface of the bar and ii
test coil. o = area of bar and A = area of test coil. Ordinarily this corr.
tion is very small because the brass tube is jnade very thin and the ti.
coil is wound under the magnetizing coil.
308. Permeameters are commercial instruments for the rapid test}
of iron and steel for permeability. The Thompson permeameter is an i

ample of the type employing the tractive force exerted between the pole o
magnetized bar and a piece of steel in direct contact with the pole. 1'

force in dynes is F = (B2a/Sx, where (B = induction in bar in lines per squi

centimeter and a = area of barin square centimeters. Koepsel and Pic
permeameters are examples of induction-type instruments.
309. S. P. Thompson's permeameter is shown schematically in F
117, where AB is the test specimen in the form of a rod which passes throu
a hole in the top of a heavy yoke, F. The surfaces of the end of the rod a
the yoke at F are carefully machined. The force necessary to move the r
ia measured with a spring balance at S. The induction is
If
i= 156.9 +5C (gausses) (3
>J^
where (B = induction in lines per square centimeter (gausses) P = pull in grar
and o = area of specimen in square centimeters.

Ay
Fia. 117. — Thompson permeameter. Fig. 118. — Koepsel permeamete
310. The
principal advantages of traction permeameters are thei
ruggedness and simplicity, which are important features in shop testing whepj
rapidity is essential and only comparative data are required. ij

311. The Koepsel permeameter, as made by Siemens Halske, f

shown schematically in Fig. 118, where JJ is a massive yoke divided at th'
centre so as to admit a moving coil c to which a pointer is attached, th
arrangement being similar to standard D'Arsonval-type direct-current instru
ments. This pointer moves over a scale graduated directly in line.s per squar!
centimeter. The magnetic circuit is completed through the test piece T
firmly clamped between the ends of the yoke in the usiial manner. The valui
of (B corresponding to various magnetizing currents in C is indicated directlj
by the deflection with a known small current through c. Separate coils an
placed on the yoke pieces, JJ, by means of which the reluctance of the varioui
gaps is approximately compensated. But even with these coils, there is l
flux leakage, so that correction or "shearing" curves have to be used.

190
 MEASURING APPARATUS Sec. 3-3 11a

8118. The Esterline permeameter is a modification of the Koepsel ap-

*
ratus which requires no corrections.
312. The Picou permeameter is a double-yoke, single-bar instrument
which joint reluctances are compensated. The scheme is indicated in
j

II?.
119, where Fi, Fi are the two yokes and T is the test specimen. The
I
o auxiliary magnetizing coils on Fi, Fz are first connected with their mag-
Itomotive forces in series. There is then supposed
_

I
be no flux in the test bar, its magnetizing coil being
t of circuit. The two coils on Fi, Fi are then op-
sed and the current in the test-bar coil adjusted
rtil the flux in Fi, Fa is the same as before, as indi-
ted by a ballistic galvanometer or otherwise. The
.nditions in the test bar are then supposed to be the
me as in a long, uniformly magnetized bar. 3C is
:lculated from the current and the constants of the
it-bar coil as before, (B being measured with a test
il on the test bar.

312a. The Fahy permeameter is a recently de-

loped induction-type permeameterof high accu-
cy t employing an H
form of magnetic circuit. The
stinctive feature is the measurement of 3C with a
parate test coil instead of the magnetizing coil.
- curves are obtained by any of Fia. 119.— Picou per-
313. Hysteresis
i methods described above, for permeability tests,
e meameter.
coil is used to measure the flux.
which a In
rect-indicating permeameters such as the Koepsel type, (B is noted for
;iriou3 values of 3C, first descending from a positive maximum value of 3C
I
the negative maximum, and then ascending in the opposite direction.
f 314. Ballistic step-by-step method of determining hysteresis.
''here high precision is desired the ballistic "step-by-step" method^ is
ied._ This method is carried out as follows: The current in the magnetizing
rcuit is adjusted to a value corresponding to maximum (B. It is then
'versed a few times to get the specimen in a cyclic state. By means of
.litable switching arrangements, some resistance is suddenly cut into the
rouit, thus reducing _3C to_ a new value, which is carefully noted. The
)rresponding change in (B is determined with a ballistic galvanometer in
le usual manner. This process is continued, step by step, until zero current
reached, when the circuit is reversed and the resistance cut out, step by
ep, until the same maximum value of X is reached in the opposite direction,
he whole process is then repeated and the other side of the loop obtained.
1 this method, the errors will be cumulative, but can be eliminated by going
ick each time to the original maximum X furthermore, it is then a simple
;

latter to insure that the conditions remain constant, by occasionally

lecking the value of (B corresponding to maximum X.
Knowing the value
of (B at the start, the values corresponding to the var-
'us steps in the stei>-by-step method are obtained by adding algebraically
le various changes in (B to this initial value. The resulting values of CB
ad 3C suitably plotted on cross-section paper form the hysteresis loop.
316. Hysteresis loss measurements. The area of the hysteresis loop,
'leasured in the units of the ordinates of the curve (by planimeter or ether-
ise) and divided by 4x, gives the hysteresis loss in ergs per cubic centimeter
er cycle, between_ flux densities -|-(B max. and (B max. —
This method of
leaauring hysteresis loss is much too slow and expensive for commercial
urposes, and several methods have been devised by means of which
ysteresis losses can be measured directly, by electrical or mechanical
.leans.
> 316. Bobinson's method of measuring hysteresis loss. An example
f an electrical method of measuring hysteresis loss is one used by L. T.
lobinson.t It was designed primarily to reduce to a minimum the time and
* ^po Esterline, J. W., Trans. A. S. T. M., 1903, Vol. Ill, p. 288; 1908, Vol.
Til, p. 190.
t Burrows, C. W. and Sanford, R. L., Experimental Study of the "An
aliy Permeameter," Bulletin Bureau of Standards, Vol. 14, p. 267 (1917)
Scientific Paper No. 306).
{Robinson, L. T. "Commercial Testing of Sheet Iron for Hysteresis
,-oss;" Trans. A. I. E. E., 1911, Vol. 741. XXX,
191
Sec. 3-317 MEASURING APPARATUS
expense in preparing the sample, as well as the time spent in testing. Tl
specimen is a bundle of strips 0.5 in. (1.27 cm.) X 10 in. (25.4 cm.), weigl
ing 1 lb. (0.45 kg.). It is placed in a simple straight solenoid, with a sens
tive wattmeter (reflecting electrodynamometer) in series with the magneti:!
ing coil. A separate winding is provided for the wattmeter potential coi
thus simplifying the correction for the wattmeter loss. The induction
determined from the indication of a voltmeter, which is also connected to
separate winding at the centre of the specimen. The flux which it indicati
is much higher than that at the ends, but experiment has shown that tl
ratio of the maximum to the average is 1.3 to 1. Due allowance is therefoi
made, when adjusting the magnetizing current to such a value that tl
voltmeter deflection will correspond to the required average flux-densit;
Measurements are made at 10 cycles, or less, in order to reduce the edd}
current loss to a point where it can be eliminated by means of empiric'
corrections without serious error. The precision obtained is about ±
per cent.
317. In the Holden and the Ewing hysteresis meters, the loss :

determined mechanically. In the Holden meter the test specimen,

ring of laminations about 1 cm. X 2 cm. (0.4X0.79 in.) cross-section, an
9 cm. (3.55 in.) diameter, is placed between the poles of a pair of revolvir
magnets. The torque exerted on the specimen is resisted by a spiral sprin;
The deflection of this spring which is necessary to bring the specimen bac
to the zero position is a measure of the loss in ergs per cycle.
The Ewing apparatus is operated on a similar principle, except that tt
specimen is rotated instead of the magnets. The specimen is a bundle t
strip I in. (1.6 cm.) square and 3 in. (7.6 cm.) long.
318. Core-loss measurements. The total loss in iron or steel sul
jected to an alternating magnetic field is most accurately measured with
wattmeter. In making precision measurements, the Hopkinson ring-specime
can be used, but the Epstein apparatus is more convenient and has bee
adopted by the American Society for Testing Materials. * Fig. 120 shows tl
scheme diagrammatically.
The specimen is arranged in the form of a rectangle. The magnetijit
winding is divided into four solenoid
ms:^Qss2^ each being wound on a form into whi(
one side of the rectangular speoime
is placed. The form is non-maKneti
non-conducting and has the followii
dimensions: inside cross-section, 4 ci
(1.57 in.) X 4 cm.; thickness of wf,
not over 0.3 cm. (0.12 in.); windii
K'C-VV.V-MV^.A.-'^ length, 42 cm. (16.5 in.). Each lin
Fio. 120.—
—
Core-loss measurements of the specimen consists of 2.5 k
Epstein method. (5.5 lb.) of strips 3 cm. (1.18 in.) wif,
and 50 cm. (19.7 in.) long. Two
the bundles are made up of strips cut in the direction of rolling and two ;

right angles to the direction of rolling. The strips are held together wi(
tape wound tightly around the bundle. The bundles form butt joints t
the corners with tough paper 0.01 cm. (0.004 in.) thick between. They a^
held firmly in position by clamps placed at the corners.
The magnetizing winding on each solenoid consists of 150 turns ut
formly distributed over the 42 cm. (16.5 in.) winding-length, and has a resie
ance of between 0.075 and 0.12.5 ohm. A secondary winding is uniform
wound underneath the first; it also contains 1.50 turns in each solenoid, ar
energizes the potential circuit of the wattmeter and also the voltmeter wil
which the induction is measured. The resistance should not exceed 0.5
ohm per solenoid. Witli a sine-wave e.m.f. impressed on the magnetiiii
winding, the maximum induction is
^=
®
E 41D\0*
rr
— , ,
(gausses)
J
(3i
4 J,xr
..
Is nla

where F = volts indicated by voltmeter, Z = length of specimen, Z) — specif

gravity (7.5 for alloy or high-resistance steels and 7.7 for standard or Iot

•Standard Magnetic Tests of Iron and Steel; Trans. A. 8. T. M.,

-
191
Vol.XI; p. 110.

192
 MEASURING APPARATUS SeC. 3-319

ince steels), /=form factor of magnetizing electromotive

force (1.11 for
iV = total secondary turns, » = cycles per second, and
-w.ive),
= totalM
ss in grams. The wattmeter gives the total loss in the iron, plus that in
[i secondary circuit. The latter is calculated from the resistance and the
'Itage, and deducted from the wattmeter reading.
319. For comparative commercial measurements of
core losses,
ingle simple solenoid may be used.* The wattmeter indications arestan-
rdized with a standard sample. The accuracy obtained is quite sufficient
• most factory purposes.
Separation of eddy-current and hysteresis losses in the core
i320.
usually accomplished by taking advantage of the fact that with a given
Bmaz, the hysteresis loss varies directly with the frequency and the
,lue of
:'dy-current loss with square of the frequency. The specimen is arranged
in a core-loss test and the loss noted at two frequencies, the
induction
ling kept the same in the two cases. By means of two simultaneous
uations, with two nnknown quantities, both losses can be calculated.
'
321. Precautions in magnetic testing. Where the induction is meas-
i
ed by means of a stationary test coil surrounding the specimen, the space
i>tween the coil and the test specimen should be as small as possible. This
iin ordinarily be made so small that the leakage
error is negligible.
Before induction measurements are made, the specimen should be care-
,illy demagnetized. This is best done by first magnetizing to a value
ell above the maximum at which measurements will be made;
the current
then gradually reduced to zero, being rapidly reversed meanwhile. Alter-
ating current of 25-cycle frequency is convenient where much work is to
done.t
e
In loss measurements, the temperature of the specimen shouM be care-
, ^
•illy noted, because this affects the eddy-current loss. The exciting winding
-lould therefore be sufficiently large to avoid heating of the specimen. In
'reciaion work, the apparatus is placed in an oil bath.
In tests of sheet materials, the strips should not be too narrow, because
f the hardening at the edges due to cutting. This effect is negligible with
: mdth of 2 in. (5 cm.). Care should be taken that burrs are removed from
'hi! edges and that the only insulation between sheets is the natural scale
'r oxide. The test specimen should be composed of strips cut from the sheets
a both directions.
'

The readings of a ballistic galvanometer should be kept at about the

ame magnitude by varying the resistance in series with it. The observa-
tional error is thus kept about constant.

BIBLIOGRAPHY
li 8SS, Selected list of reference literature on electric and magnetic
neasurements.
Gr.<.y, a. — "Absolute Measurements in Electricity and Magnetism."
The Macmillan Company, New York.
Reed, Lyman C. "American Meter — Practice." McGraw-Hill Book,
jompany. Inc., New York.
Fleming, J. A.
.

Room. D. Van Nostrand Company, New York.

—
Handbook for the Electrical Laboratory and Testing
—
SwENsoN AND Frankenfield. "Testing of Electromagnetic Machinery."
The Macmillan Company, New York.
Fisher, W. C. —
"The Potentiometer and Its Adjuncts." D. Van Nos-
trand Company, New York.
[
—
Du Bois, H. "The Magnetic Circuit." Longmans, Green & Company,
New York.
G. P. Putnam Sons. —
Reports of the Standards Committee of the British
•Association for the Advancement of Science; Cambridge University Press,
New York.
I ^
____^ . __— I

'
Robinson, L. T. "Commercial Testing of Sheet Iron for Hysteresis
*

Loss;" Trans. A. I. E. E., 1911, Vol. XXX, p. 747.

t Burrows, C. W. "Best Method of Demagnetizing Iron in Magnetic
Test:..g;" Bureau of Standards Bulletin, 1907, Vol. IV, No. 2, p. 205.
'^
193
Sec. 3-323 measuring apparatus
SoLOMAN, H. G. — "Electricity Meters." B. Lippincott Company;
J. Phil
delphia. Pa.
—
GERHA.RDI, C. H. W. "Electricity Meters." D. Van Nostrand Compan
New York. — i

Bedell, "Direct- and Alternating-current Manual." D. Van No

F.
trand Company, New Tork.
—
Parr, G. D. A. "Electrical Engineering Measuring Instruments." 1

—
Van Nostrand Company, New York.
EwiNG, A. J."Magnetic Induction in Iron and Other Materials." 1
New
Parr, G. D. A.— "Practical Electrical Testing in Physics and
Van Nostrand Company, York.
Electric
Engineering." Longmans, Green & Company, New York.
Carhart and Patterson. — "Electrical Measurements." Allyn Baco
Sharp, C. H. — "Electricity Meters." International Congress
Boston, Mass.
the Appl of

Franklin and Estt. — "Elements of Electrical Engi«eering." The Ma'

cation Turin, 1911.
of Electricity,

millan Co., New York.

Nichols, E. —"Laboratory Manual of Physics and Applied
I^. Electricity.
The Macmillan Company, New York.
Shepard and Jones. — "The Watt-hour Meter." Technical Publishin
Company, San Francisco, California.
Farmer, F. M.— "Electrical Measurements in Practice." McGraw-Hi
Book Company, Inc., New York. 1917. —
Fitch, T. T. and Hober, C. J. "A Comparison of American Direct-cui
rent Switchboard Voltmeters and Ammeters." Bulletin Bureau of Standard;
Vol, VII, No. 3. page 407.
—
(Reprint No. 163.)
Franklin and Williamson. "Alternating Currents." The Macmilla:
Company, New York.
Kempe, H. R. Handbook
New York.
— of Electrical Testing; Spon Chamberlain
Electrical Meterman's Handbook; National Electric Light Association
New York. —"Electrical Meters." McGraw-Hill Book Company, Nev
Janskt, C. M.

W. — "Electric and Magnetic Measurements." McGraw-Hil

York.
Roller, F.
Book Company, New
Karapetopp, V. — "Experimental Electrical Engineering." John Wilej
York.

Sons, New York.

Laws, F. A. — "Electrical Measurements." McGraw-Hill Book Company
Inc.,New York. 1917. — "Methods of Measuring Electrical Resistance.'
Northrup, E. F.
McGraw-Hill Book Company, New York.
Annual Reports, Meter Committee; National Electric Light Association
New York.
Code for Electricity Meters; Association of Edison Illuminating Companiei
and National Electric Light Association, New York.
—
Brooks, H. B. "Electrical Instruments and Meters in Europe." BuUetii
66, Bureau of Foreign and Domestic Commerce, U. S. Dept. of Commerce
Fitch, T. T. and Huber, C. J.
—
"A Comparative Study of American Con
tinuous Current Watt-hour Meters." Bulletin Bureau of Standards, U. S
Dept. of Commerce, Vol. X, page 161. (Reprint No. 207.)

MECHANICAL POWER MEASUREMENTS

BY F. MALCOLM FARMER, M.E.

333.
TORQUE MEASUREMENTS
Torque is best measured with dynamometers, of which there an
I
two classes, absorption and transmission.* Absorption dynamometeri
absorb the total power delivered by the machine being tested, while trans
mission dynamometers absorb only that part represented by friction in th(
dynamometer itself.

'Carpenter and Diedrichs. "Experimental Enginoering" (Wilej

Bona, 1912). J. A. Moyer. "Power Plant Testing" (McGraw-Hill Bool
Co., 1913).

194
 MEASURING APPARATUS Sec. 3-324
I
.
324. The Prony brake is the most common type of absorption dyna-
lometer. It is simply a brake applied to the surface of a pulley on the
laft of the machine being tested, together with suitable means for vary-
g the friction produced. The torque developed by the machine to over-
. >me the friction is determined from the force required to prevent rotation
the brake.
325. The principal forms of Prony brakes are shown schematically
I Figs. 121, 122, 123 and 124. In Fig. 121 the load is applied by tightening

. Fia. 121.— Prony brake.

he brake band at o, and the corresponding torque is measured by noting
he force required at the end of a lever-arm of known length in order to pre-
'ent rotation. This force is usually measured with ordinary weighing
icales or a spring balance. In Figs. 122, 123 and 124, the brake band is a
)elt or rope applied directly to the surface of the pulley, and the force is
neasured at the pulley surface by the various methods indicated. The load
is applied by tightening the brake band as in Fig.
124, or adding weights as in Figs. 122 and 123.
326. A self-regulating brake for small torques*
can be made by attaching copper rivets to the
leather belt in Fig. 122, the rivets per unit of sur-
face ranging from zero at one end of the working
A surface to a maximum at the
other end. For very small

Figs. 122, 123, and 124. — Prony brake.

torques a round belt in a grooved pulley and with small steel wire wound
spirally around it, zero turns per inch at one end to maximum turns at the
other, makes a simple and very satisfactory brake.
327. Formulas for calculation of torque from dynamometer
measurements. The torque, T, in the various forms of Prony brakes (Par.
324) is determined as follows: In Fig. 121, T=FpL, where Fp = force measured
at end of brake-arm, Z/ = length of brake-arm or distance from centre of
shaft to point at which the force is measured. In Figs. 122 and 123, T =
(Fa— Fp)L, where Fv, = weight attached to end of brake-band, Fp = reading
of spring balance, L = brake-arm = radius of pulley plus one-half the thick-

• H. M. Scheibe. "A Self-regulating Brake." Electric Journal, 1907, Vol.

IV, p. 118.

id^
Sec. 3-328 MEASURING APPARATUS
neaa of belt or rope. In Fig. 124, T—FpL, where ii'p = force weighed i

scales, L = brake-arm = radius of pulley plus one-half the thickness of belt (

rope. If F and L are measured in pounds and feet respectively, T will I

in lb. ft. '

328. Dissipation of heat in friction brakes. The energy dissipated i

the brake appears in the form of heat. In small brakes natural cooling
sufficient, but in large brakes special provisions have to be made to dissipal
the heat. Water-cooling is the most common method, one scheme en
ploying a flanged pulley. About 100 sq. in. of rubbing surface of brak
should be allowed with air cooling, or about 50 sq. in. with water coolini
per horse power. i

329. For very Iarg:e torques, other forms of absorption brakes ar'
used. In the Alden brake, a rotating cast-iron disc rubs against thi
copper discs which are held stationary. The friction is adjusted by varyin
the pressure of the cooling water in the chamber surrounding the coppe
discs. The tendency of the copper disc member to rotate is measured wit
a lever as in the Prony brake.
The Westlnghouse turbine brake employs the principle of the watet
turbine and is capable of absorbing several thousand horse-power at verj
high speeds.
In the magnetic brake, a metallic disc on the shaft of the machine bein,
tested is rotated between the poles of magnets mounted on a yoke which i
free to move. The pull due to the eddy currents induced in the discs is meaa,
ured in the usual manner by counteracting the tendency of the yoke t"
revolve.
330. The principal forms of transmission dynamometers are th^
lever, the torsion and the cradle types. An example of the lever type i

Fia. 125. —-Transmission dynamometer.

shown in Fig. 125, where F is the force applied to tlie dynamometer, and
F' is the force being delivered. When the downward force. A', is balaivid
by the weight W, the following formula holds,
F = V2(ltM)^ (40);
a 3

where m = coefficient of friction determined experimentally. i

331. In torsion dynamometers, the deflection of a shaft or spiral spring,

which mechanically connects the driving and driven machines, is used to
measure the torque. The spring or shaft can be calibrated statically by
noting the angular twist corresponding to a known weight at the end of a
known lever-arm perpendicular to the axis. When in use the angle can be
measured by various electrical and optical methods. In one method the
angular displacement between two points on the shaft is determined by means
of two discs of insulating material, in the periphery of each of which is set
a very thin piece of metal. The two pieces of metal are connected electric-
ally through the shaft. A light, thin metal brush rests on the periphery
of each disc, and the two brushes are connected together through a battery
and an indicator such as a bell, or a telephone. At no load, one brush is
moved until the electrical circuit is completed once every revolution. The
196
 MEASURING APPARATUS SeC. 3-332

ingle through which either brush lias to be moved as the load is increased, in
)rder to keep the circuit closed, is then measured.
3S2. The cradle dynamometer is a convenient and accurate device
vhich is extensively used for routine measurements of the order of 100 h.p.
hr less. An electric generator is mounted on a "cradle" supported on trun-
lions and mechanically connected to the machine being tested. The pull
jxerted between the armature and field tends to rotate the field. This
;orque is counterbalanced and measured with weights moved along an arm
n the usual manner.
SPEED MEASUREMENTS
333. Revolutions are measured with speed counters and tachometers.
Speed or revolution counters are attached directly to the shaft to be meas-
I

and record the total revolutions from the instant that the mechanism
lared
.3 connected. They usually consist of an arrangement of worm and gears,
the total revolutions being shown by a graduated dial moving under a pointer,
:Dr by a cyclometer dial on which the total revolutions are indicated numer-
cally at each revolution. In order to obtain the speed, the intervening time
.must be observed simultaneously.
'
334. Tachometers or speed indicators indicate the speed directly and
thus include the time element. The principal types are centrifugal, liquid,
reed and electrical. In the centrifugal type, a revolving weight on the end
of a lever moves under the action of centrifugal force in proportion to the
speed, as in a fly-ball governor. This movement is indicated by a pointer
which moves over a graduated scale. In the portable or hand-type, the
tachometer shaft is held in contact with the end of the shaft being measured,
and in the stationary type, the instrument is either geared or belted. In
the liquid tachometer of trie Veeder type, a small centrifugal pump s driven
by a belt consisting of a light cord or string. This pump discharges a col-
ored hquid into a vertical tube, the height of the column being a measure of
the speed.
Reed tachometers are similar to reed-type frequency indicators (Par.
279), the reeds being set in
resonant vibration corresponding to the speed of
the machine, by various means. The instrument may be set on the bed-
frame of the machine where any slight vibration due to the unbalancing of
the reciprocating or revolving member will set the corresponding reed in
vibration. Some forms are belted to the revolving shaft and the vibrations
imparted by a mechanical device. Electrical tachometers may be either
reed instruments operated electrically from small alternators geared or belted
to the machine being measured, or ordinary voltmeters connected to small
permanent-magnet, direct-current generators driven by the machine being
tested.
338. Chronographs are speed-recording instruments in which a graphical
record of speed is made. In the usual forms, the record-paper is placed on
the surface of a drum which is driven at a certain definite and exact speed by
clock-work or weights, combined with a speed-control device so that 1 in.
on the paper represents a definite time. The pens which make the record
are attached to the arm.atures of electromagnets. With the pens in contact
with the p.aper and making a straight line, an impul.se of current causes the
pen to make a slight lateral motion and therefore a sharp indication in the
record. This impulse can be sent autom.atically by a suitable contact-
mechanism on the shaft of the machine or by a key operated by hand. The
time per revolution is then determined directly from the distance between
marks.

THERMOMETRY, PYROMETRY AND HEAT

CONDUCTIVITY
BY a. K. BURGESS, SCO.
AND
PAUL D. FOOTE, Ph.D.
THERMOMETRY
336. Temperature scale. The standard temperature scale is fixed in
the mterval —40 deg. to 450 deg. cent, by means of the platinum resistance
thermometer calibrated in ice, steam, and sulphur vapor (444.6 deg. cent.).

197
 Sec. 3-337 measuring apparatus
In the interval 450 deg. to 1100 deg. cent, it is defined by the fixed points
melting points of antimony (or aluminum) and of gold (or copper), an^
interpolation between these points is based on the temperature scale define'
by the rare-metal thermocouple (Pt, OOPtlORh) calibrated at these twi
temperatures and a third temperature, melting point of zinc as determinei
by the resistance thermometer. The temperature scale above 1100 deg
cent, is based upon the extrapolation of Wien's law using as the fiducis
point the melting point of gold= 1063 deg. cent, and C2= 14,350 micron deg
337. High, temperature thermometers. Mercury in glass ther
mometers are useful from —35 deg. to 550 deg. cent. In order to preven
vaporization of the mercury at high temperatures the top of the capillar;
is filled with nitrogen under pressure. The thermometer must be well an
nealed at as high a temperature as the glass will safely stand. _ Errors of 21
deg. or more may result from imperfect annealing. Industrial merury-
in-glass thermometers have the bulb encased in a metal tube and thi
stem is well protected by a metal frame. This construction introduces twi
questionable factors, lag and conduction of heat along the frame. It i
consequently necessary that the instruments be used for the purpose de
signed. Industrial thermometers calibrated to read gas temperatures wil
not necessarily give true temperatures when immersed in liquids. In-
dicating thermometers of the dial and pointer type and recording ther-
mometers employing a mechanism for recording temperatures on a chan
are of three classes, electrical (thermocouple or resistance) thermometers
pressure thermometers, and bimetallic thermometers. Pressure ther-
mometers consist of a bulb containing a liquid or gas or both, connectec
by capillary tubing to a pressure gage graduated to read temperature
Bimetallic thermometers utilize the turning rnoment produced when a
strip of two metals of different expansion coefficient and brazed together h
heated. These instruments are not as accurate as mercury-in-glass ther-
mometers but are very useful and are extensively employed.
338. Low-temperature thermometers. For the measurement ei
temperatures below the range of the mercury thermometer (—35 deg. cent.),
there are available alcohol ( — 70 deg. cent.), toluene ( — 90 deg. cent.), and
petroleum-ether or pentane ( — 200 deg. cent.) liquid-in-glass thermometers,
copper-constantan and other thermocouples, and electric resistance ther-
mometers. With these types of liquid-in-glass thermometers the same pre-
cautions apply as with mercury, and in addition special care must be taken
to prevent the liquid from sticking to the sides of the glass. On account of
viscosity of the liquid at low temperatures the. thermometer must be slowly
cooled to the temperature of the bath, cooling first the bulb and then th«
stem.
339. Correction for emergent stem of mercury-in-glass ther-
mometers. Thermometers are usually graduated for total immersion in
a bath, while frequently in later use part of the stem protrudes from the
bath and may be at a considerably different temperature. Under such
conditions the following stem correction should be added to the observed
reading. Stem correction = /Cn(r° — <°), in which X = 0.00016 for centi-
grade thermometers and 0.00009 for fahrenheit thermometers; n = number
of degrees emergent from the bath; T = temperature of bath; < = temperature
of emergent stem. The value of t may be roughtly measured by an auxiliary
thermometer the bulb of which is placed about three-fourth the distance
down the exposed mercury column. Stem corrections may amount to
40 deg. or more at high temperatures and hence become very important
where accuracy is desired.
340. Calorimetric mercury thermometers are of two types, the
ordinary mercury thermometer with a total stem length of 10 to 15 deg.
cent., graduated in 0.05-deg. to 0.02-deg. intervals, and the Beckmann
thermometer arranged so that part of the mercury may be removed from
the bulb in order to utilize the short scale (5 or 6 deg. cent, graduated in
0.01-deg. intervals) for differential work at various temperatures. In addi-
tion to the stem corrections the Beckmann type requires a setting
correction depending upon the amount of mercury remaining in the bulb.
Calorimetric thermometers may be in error by I per cent, of the indicated
temperature scale differences, and consequently should be calibrated. The
highest accuracy attainable is from 0.5 to 0.1 per cent. For greater precision,
thermocouples or resistance thermometers are available.
198
 MEASURING APPARATUS Sec. 3-341

PYROMETRY
341. Thermoelectric pyrometry. In pyrometers of this type tempera-
-ures are measured by the magnitude of the electromotive forces
set up be-
ween wires of different materials when one junction is exposed to the
measured and the other junction (or junctions) is kept at
eraperature to be
iome known temperature.
343. Material of couple. Couples extensively employed are: copper-
onstantan to 300 deg. cent.; iron-constantan to 900 deg. cent.; alumcl-
hromel or nichrome-alumel to 1100 deg. cent.; (Pt-90PtlORh) from
';00 to 1500 deg. cent. The following table shows the calibration data
')f these couples, based on a
cold unction temperature of zero deg. cent.
;

Different rare-metal couples of the same type should be reproducible to

'±2 deg. cent, and base metal couples to ± 10 deg. cent.
343. Calibration Data of Representative Couples
Cold-junction temperature, deg. cent. E.m.f. in millivolts
Sec. 3-345 MEASURING APPARATUS
rectly. When Ra is low it is still possible to graduate the scale to read true
e.m.f. for a definite Une resistance, but if this changes on account of de-
terioration of the couple, etc., serious error may result. Thus a SOO-ohm,
indicator designed for use with a 2-ohm line resistance will be in error by
only 7 deg. at 1000 deg. cent, if the line resistance changes to 4 ohms.whik
a 10-ohm indicator under similar conditions would read 140 deg. cent, too
low. This emphasizes the importance of the use of galvanometers of high
resistance.
345. The Brown Heat Meter (Harrison-Foote Method), is a compen-
sated millivoltmeter which eliminates errors arising from variable line re-

>,

Fig. 126.- -Harrison-Foote compensated indicator (Brown Instru-

ment Co. Improved Heatmeter).

sbtance. The circuit CDGF in Fig. 126 is an ordinary niillivoltmeter, in

which G represents the moving coil, in series with which is an adjustable
rheostat C/J. The maximum value n of this resistance is chosen equal to
the maximum line resistance likely to occur in practice, a convenient value
being 15 ohms. With the rheostat set for n = rs, the instrument is graduated
to read potential drop across AH. Hence in use n should be adjusted until
ri-\-L+T = rt. This adju.stment is made by moving n until no change in
deflection is produced by depressing the key K. By properly proportioning
the variou.s resistances, this sotting may be easily made to correct for changes
in line resistance which would occasion an error of only 0.01 scale division.
The method accordingly is exceedingly sensitive, yet so simple that it in no
'manner complicates the use of the indicator. The device is adaptable to
multiple installations either with indicators or recorders.
346. Potentiometers. The most accurate method for measuring
thermoelectric e.m.f.'s is by means of the potentiometer, the principle of
operation of which is described in Par. 49 to 62. Special low-range instru-
ments adapted to pyrometry are made by Leeds and Northrup. This
company also makes a portable potentiometer for either rare-metal or
base-metal couples, or for both with a double scale. The potentiometer
affords the advantage that its indications arc independent of line resistance.
On the other hand a balance must be effected for each reading, so that the
instrument is not so convenient for general practice as a high-resistanc
galvanometer. It is possible to employ the potentiometric principle with an
indicating instrument. Thus the galvanometer may be used as an ammeter
in adjusting the battery cvirrent through the potentiometer to a fixetl value
and then it mav be connected by a suitable switch into the couple circuit
and used as a detector for zero current or balancing. It is also possible to
arrange the circuit so that after the balance the galvanometer deflects
showing the true e.m.f., as is done in the Northrup Pyrovolter. The
deflection potentiometer principle (Par. 64) has been employed advantag-
eously in pyrometry but at present the method is not used very extensively.
347. Cold-junction corrections. If a couple is calibrated with a cold
junction temperature of to deg. cent, and used with a cold junction tem-
perature of t'o, it is necessary to add to the observed e.m.f. the value of
the e.m.f. developed when the hot junction is at I'o and the cold junction at

200
 MEASURING APPARATUS Sec. 3-348

to obtain correct temperature from the calibration data. If the indicator

trraduated in temperature add to the observed reading (,t'o — to)K, where K
a factor depending upon the couple and temperature. Values of K for
pical couples are as follows (Par. 348) :

348. Cold-junction correction factors

'
Engelhard
"LeChatelier"
Sec. 3-351 MEASURING APPARATUS
the wiring diagram. On a coke oven installation of nine couples it is thi
possible to save 600 feet of compensating cable.

Selective Switch

It
Secorder

Junction
Box

Copper Leadi:
Compensating Zl~
Leadi:

Fig. 127.- -Illustrating use of junction box with controlled

cold-junction temperature.
351. Electrical resistance pyrotaetry. This method of high-tempera
ture measurement ordinarily makes use of the variation in the electrica
resistance of platinum and is capable of great sensitivity. In one of it:
simplest forms the pyrometer consists of a coil of platinum wire wound oi
mica, and encased in a protecting tube of porcelain. On account of the dis-
tillation of platinum, high-resistance coils of small wire are not used mucl,
above 900 deg. cent. However, coils constructed of 0.6-mm. wire may sem
satisfactorily to 1,200 deg. cent, for investigational work.
362. Three-lead type—Wheatstone bridge method. For the pur-
pose of eliminating the resistance of the leads to the coil, a third wire ii

P b

Fig. 128. —
Three-lead resist-
ance thermometer.
Fig. 129.— Four-lead resist-
ance thermometer.
''•

frequently introduced as in Fig. 128. The coil P forms one arm of a dial-
type bridge, of which the others are n, n
and R, whence from the principle
of the bridge, if the galvanometer G remains undeflected,

p.rj(R±m.aa' (41)

202
 MEASURING APPARATUS Sec. 3-353

',
is made equal to ri and 66' is constructed as nearly as possible
usually
ienticalwith aa', so under these circumstances P = R regardless of the tem-
erature or resistance of the leads. This type of thermometer may also be
sed with a differential galvanometer.
353. Four-lead type —Wheatstone bridge method. The compensat-
ig leads are inserted in one arm of the bridge R and the thermometer
sads in the other, as shown in Fig. 129. This type may be used with a slide-
'ire bridge.

364. Four-lead potential-terminal type (Fig. 130). The resistance of

he coil is measured by sending the same current from a storage battery
hrough the thermometer and a known resistance in series, and measuring
he potential drop by means of a potentiometer, first across the known resist-
nce and then across the thermometer coil. Two of the thermometer ter-
ainals are current leads and two are potential leads. The current ordinarily
ised is of the magnitude 0.003 to 0.05 amp., and should be the same as that
ised during the calibration of the instrument, to eliminate the errors due to
he heating effect of this current.

To PotenUometeff
To Fctectiomelot
D&ilU'Ammeter
<rHf~l Bhooetat
[«1 Cf

Mercnrj Contact KestBt&nce Box

,01_.C1_^02__.02_.06_.J_.2_ _S_6_10_20_20_L60 lOJ
[5] ffc]

Current Leads Fotentlul LeodB

I
Tberm. CoiK^

. 130. —Foiu:-lead resistance thermometer—potential terminal type.

366. Formulas. The relation between temperature and resistance of the
platinum coil is of the form
Rt^Roil+at-U^, (42)

I
In general it is more convenient to refer to an arbitrary scale known as the
iJatinum temperature, and to correct this scale by a certain difference for-
inula. If pt denotes the platinum temperature corresponding to a resistance
R, we have the relation
^^^imR^ U3)
where iJioo and are the resistances at 100 deg. cent, and
i2o deg. cent, respec-
tively. The relation between the centigrade temperature t and the platinum
temperature pt is as follows:

(44)
'-^" 100
'

866. Calibration. For the calibration of a thermometer, the coil of

which is of the highest purity platinum, resistance measurements are made at
three temperatures, as follows: the ice point, the steam point and the boiling
point of sulphur. Substituting the values thus obtained in formula for
pt (Par. 365) the value of pt corresponding to the sulphur point is known.
Referring to the formula for t (Par. 366), the value of & should be found a
constant of the magnitude 1.49 ± 0.01, whence from the two formulas a
table of R and t may be computed. Such a calibration will indicate tempera-
tures in the range —50 to 1,200 deg. cent, as closely as they are known in
terms of the gas scale. If 5 is found considerably greater than 1.49 on
account of impurity of the platinum, there is advantage in using a fourth
calibration point, such as the silver freezing-point as a check.

203
 Sec. 3-357 MEASURING APPARATUS
367. Adaptability. The resistance thermometer ia especially adapte<
to the measurement of small temperature changes such as occur in calor
imetry, to the determination of freezing-points, etc., and to special physica
and thermochemical investigations where an accuracy of one or two parti
in 10,000 may be attained (see Bur. of Standards, Sci. P. No. 68 and No
124). In the technical industries this type of thermometer with one of th(
many forms of indicators available is employed for special processes but ii
general a thermocouple installation is more satisfactory.
3S8. Radiation. The temperature of bodies may be estimated from th(
radiant energy which they send out in the form of visible light or Of the longei
infra-red rays which may be detected by their thermal eflfects. Since th<
intensity of radiation increases very rapidly with a rise in temperature, il
would appear that a system of pyrometry based on the intensity of the lighl
or total radiation from a hot body would be an ideal and simple one. How-
. ever, different substances at the same temperature show vastly different
intensities at a given wave length, or in other words, the absorbing or emis-
sive powers may vary with the substance, with the wave length and also
with the temperature.
369. Black-body radiation. A substance which absorbs all the radia-
tion of any wave length falling upon it is known as a black body. Such a-
body will emit the maximum intensity of radiation for any given temperature
and wave length. No such material exists, but a very close approximation
is obtained by heating the walls of a hollow opaque enclosure as uniformly as
possible and observing the radiation coming from the inside through a very
small opening in the wall.
360. Stefan-Boltzmann law. The relation between the total energy
radiated by a black body and its temperature is expressed by the equation
J = tr{T*~To*), where./ is the energy of all wave lengths emitted per second
per squafe centimeter of surface, T and To the absolute temperatures of the
radiator and surroundings respectively, and <r a constant of the value 5.7 X
10~i2 watts cm.~2 deg."*. In general 7'o* is negligible in comparison with T*
so that the above relation becomes J = <tT*. Although the total energy emit-
ted by any substance is not that emitted by a black body at the same tem-
perature, it may be considered as some fractional part of that from the ideal
radiator, this fraction E being known as the total emissivity. If S denotes
the apparent absolute temperature, i.e., the temperature on the black-
body scale corresponding to an amount of energy equivalent to that emitted
by the non-black substance at a true temperature T dcg. absolute, the re-
lation between its total emissivity E and the quantities S and T is:
Log E = 4(log S-log T) (45)

361. Radiation pyrometry. F^ry mirror telescope pyrometer.

(Fig. 131.) Radiation of all wave lengths is brought to a focus by means
of a concave gold mirror Mupon
the hot junction of a minute ther
mocouple located at T. The cold To Indicator
junctions of the couple are suit-
ably screened irom the direct
radiation of the hot body. The
concentration of heat at the hot a
junction develops an c.m.i. which E%
may be measured by a potentio-
meter or galvanometer. In prac-
tice the galvanometer is usually
calibrated to read temperature di-
rectly. The relation between the Fio. 131.— F6ry radiation pyrometer.
e.m.f. and the temperature for this
and other types of radiation pyro-
meter may be expressed by the equation e<=aT'>, or in log form, log e"A+6
log T, where T is the absolute temperature and a or k and b are empirical
constants. In general b approximates the value 4, but may have a range
varying from 3. .5 to 4.5 depending upon the construction of the individual
in.strument. The pyrometer should be sharply focused upon the radiating
source and for this purpose an ingenious device is mounted in the instrument
by means of which straight lines appear broken until the mirror is adjusted
by the thumb screw S to the proper position. Foster has transformed the
204
 MEASURING APPARATUS Sec. 3-362

placing the thermocouple

prv telescope into a fixed-focus pyrometer by
foci of the gold mirror.
lid"a small front diaphragm at the conjugate
362. Thwing pyrometer. In the Thwing pyrometer the reflecting
lirror is replaced bv an aluminum cone which
by multiple reflections con-
>ntrates the radiatidn at its apex on one or more small thermocouples in
"ries with a portable galvanometer. The instrument requires no focusing,
'le front diaphragm acting as a source. The object sighted upon must be
the projection of the cone through this diaphragm.
irge enough to cover
Precautions in the use of radiation pyrometers. The mirrors
363.
devices must be kept bright and free from dust.
r reflecting
In the case of
'he F6ry pyrometer, errors amounting to 100 deg. cent,
have been observed,
-
n account of ordinary accumulation of dirt upon the large gold mirror.
; Many radiation instruments require several minutes of exposure to the
lOdiating source to indicate a maximum reading on account of the
slow
,»ating of the hot junction, while others require less than 20 sec. The
(laximum indication should be accepted. Care mu.,t be taken that the
ource i.s large enough to completely "fill" the aperture of the pyrometer.
t is usually impossible to focus upon
the back of a furnace through a very
mall peep-hole and obtain reliable results; in such cases the hole must be
nlarged so that it does not cut into the cone of rays entering the instrument,
'ir the pyrometer may be focused upon
the hole itself. In the latter case the
lole must be large enough to cover the thermocouple in the F6ry pyrometer
)r the front diaphragms of the Thwing and Foster pyrometers. Variations in
'•com temperature in general affect the hot and cold junctions nearly alike,
10 that very little error is introduced in the reading of a radiation instrument
rom this cause. It is desirable to employ the same ratio of diameter of
'

.source sighted on to sighting distance both in calibration and use of all radia-
;ion pyrometers.
364. Emissivity corrections for radiation pyrometers. In the case
Df sighting upon peep-holes in furnaces, kilns, etc., the total-radiation py-
'rfimeters indicate approximately true temperatures. When sighting upon
'

aljjects in the open, certain corrections must be applied. These corrections

are but roughly known. The following table (Par. 365) shows the true tem-
'peratures corresponding to the pyrometer indications when sighting upon
molten iron (E = 0.2S), molten copper (0.15), copper oxide (0.60), iron
oxide, and nickel oxide. The data are obtained from the work of Thwing,
Burgess and several experiments of the authors.
365. Total Emissivity Corrections

Observed tem-
Sec. 3-367 MEASURING APPARATUS
absolute temperature corresponding to the wave length X of a non-blac
body at a true absolute temperature T, it f oUows that
1 1 / >^ \. p XlogBx
f-Sl'^ K^J^er^ ^X = -62327
^^'

where E-)^ = emissivity = unity minus reflecting power of the radiator at tk

particular wave length X and temperature T.

367. Optical pyrometry. Optical pyrometers are based upon th

photometric principle of matching the intensity of visible monochromati
radiation emitted by a substance, with that of the same wave length c
color from a standard reproducible source such as the amylacetate lamp, o
a constant source such as an electric lamp. The instruments are calibrate-
by comparison with the intensity of radiation from a black body, the primar;
standard to which all measurements are referred.
368. Ftfry absorption pyrometer. (Fig. 132.) The apparatus con
sists essentially of a telescope carrying a small oil or gasoline lamp L. Th
image of the flame of this lamp is projected on a silver strip at M
adjustec,
to the focal point of the ocular and objective .system. By
means of thi
black-glass absorbing wedges w, w, the intensity from the source may b<
varied until a match
of the photometric
field (see small Fig.)
is obtained. A red-
glass screen is used in
the ocular so that
fairly monochromatic goutcei
light of this color
(0.6,5 or 0.63/u) is com-
pared. The relation
between the thickness
of the wedges x, read
on a scale, and the ab-
solute temperature T is
x+P = Q/T, where P Fig. 132. —F6ry optical pyrometer.
and Q are constants
determinable by two .
calibration points. The instrument must be focused upon the radiating
source but no corrections for distance need be applied. The LeChatelier
pyrometer, the first optical pyrometer developed, is similar in principle
but is not of constant aperture and important corrections must be made
with change of focus. The Shore pyroscope has a direct-reading tem-
perature scale controlled by a diaphragm before the standard oil lamp.
In all of these instruments the purity of the gasoline, oil, or even the
amylacetate used in the comparison lamps is of little importance. Con-
siderable impurity may be introduced without aff'ecting the calibration
perceptibly. The F. and F. pyrometer employs a semi-circular wedge and
an electric lamp with the filament in the line of sight.
369. Wanner pyrometer. (Fig. 133.) The comparison light is a six-
volt incandescent lamp illuminating a glass matt surface; monochromatic
red light is produced by means of a direct-vision spectroscope P
and a slit .4.j
cutting out all but a narrow band in the red (X = 0.6.5m) and the photo-
metric comparison is made by adjusting to equal brightness both halves of
the photometric field by means of a polarizing arrangement. The slit St
is illuminated by the incandescent lamp while light from the furnace enters Si.
After passing through a Wollaston prism and a biprism, the light from the
two slits polarized in planes at 90 deg. to each other reaches the Nicol prism
N. Rotation of this analyzer serves to extinguish one field and brighten
the other simultaneously, until a match is effected. A reference angle is
chosen, usually about 30 deg., corresponding to the apparent temperature
of a section of an amylacetate flame. The instrument is set at this normal
goint and sighted upon the ground-glass screen of the flame gage. The
rightness of the electric lamp is then varied by altering the current through
it until the halves of the photometric field are matched. Maintaining this

206
 MEASURING APPARATUS Sec. 3-370

liirent constant, the pyrometer isready for calibration or for temperature

easurements. The instrument follows the law

log-tan <p = a +j (48)

here the angular reading of the analyzer, T the absolute temperature

<p is

ad a and b empirical constants. The relation between log-tan <p and 1/T
linear Two calibration points serve to determine o and 6, whence a table
r plot may be made of >p vs. t deg. cent. (T
- 273). Frequent adjustments
lould be made of the current through the electric lamp necessary to obtain
"
match at the normal point when sighted on the amylacetate lamp. The
lectric lamp burns at a high temperature (about 1,800 deg. cent.) and con-
equently deteriorates rapidly. For the highest accuracy this adjustment
hould be made before and after a series of temperature readings; in indua-r
rial plants once a day or once a week will answer depending upon the
mount of use. In the low range Wanner pyrometer the spectroscope is
eplaced by a red glass thus furnishing more light and still of sufficient purity
n color.

Fig. 133. —Wanner pyrometer.

370. The Scimatco pyrometer is an improved form of the Wanner
'(Par. 369). The delicate optical parts are encased in a strong ni' tal sheath
aad the addition is made of a direct-reading temperature scale, besides
many adjustments for convenience of operation.
Lamp

wvWa
Fig. 134 — Leeds & Northrup optical pyrometer.

371. Disapipearing-fllaineiit pyrometers

(Fig. 134) The filament of
is placed at the focal point of an objective
a small electric lamp F, Fig. 134,
L and ocular, forming an ordinary telescope which superposes upon the lamp
the image of the source viewed. Red glass, such as Corning "High Trans-
mission Red," is mounted at the ocular to produce approximately mono-
chromatic light. In making a setting, the current through the lamp is ad-
justed by rheostat until the tip or some definite part of the filament is of
the same brightness as the source viewed. The current is read on an
ammeter and the corresponding temperature is computed from a plot or
table. The relation between the current, i, through the lamp and the
temperature I deg. cent., is of the form: i = a + bt + ct^ where a, b, c, are con-
stants requiring for their determination at least three standardization points.

207
Sec. 3-372 MEASURING APPARATUS
The lamps should not be operated at. temperatures higher than 1500 dei
cent., on account of deterioration of the tungsten iilament. If this tem
perature is not exceeded, the calibration of the lamp is good for hundred
of hours of ordinary use. For higher temperatures, absorption glaase,
S, Fig. 134, are placed between the lamp and the objective, or in front of th
objective, to diminish the observed intensity of the source. The relatioi
between the temperature of the source, T deg. abs., and the observed tem
perature, To deg. abs., measured with the absorption glass interposod, is a
follows: \/T — \/To = A, where A ia for most practical purposes a constant
Usually the instrument is furnished with a table showing the relation be
tween the current through the lamp and the temperature both with an<
without the absorption glass. If, however, this relation is not given fo
the use of the absorption glass, it may be readily determined by measurini
the constant A in the above formula. To do this, sight without the ab
sorption glass on a muffle or any uniformly heated furnace at 1200 deg. t<
15C)0 deg. cent, and observe the temperature T, in degrees absolute. Then
with the absorption glass in place, match the filament again and observe t<
what temperature, Tn, in degrees absolute, the current through the lamj
corresponds. The difference in the reciprocals of these two temperature:
is the constant A, which is usually of the order of magnitude —0.0002
This determination should be repeated several times and at several differ
ent temperatures of the furnace. The separate values of A should noi
differ by more than 1 per cent, and the mean value Is used for computing
the relation between the observed absolute temperature with the al)sorptior
glass and the true temperature of the source. The range of current requirec
is small, in general about 0.26 to 0.6 ampere. Thus, if the ammeter is de-
signed to give full-scale deflection with 0.6 ainpere, nearly half of the scale
from to 0.26 ampere, is never used. The Hickok depressed-zero am-
meter, now furnished with the Leeds & Northrup pyrometer, meets this
objection. The moving-coil system, including the supports, pivots, and
pointer, may be adjusted relative to the magnet by turning a lever on the
case of the instrument to one of two positions. In one position the pointer is
adjusted on open circuit so that it falls over the first graduation on the
scale; this adjustment is similar to the ordinary zero adjustment on any-
ammeter. In the second, or working, position the zero is depressed from:
the scale an amount equivalent to 0.26 ampere.
372. Emissivity corrections for optical psrrometers. Optical pyrom^
eters will indicate true temperatures when sighted upon a black body.'
Black-body conditions are approximated in practice by a peep-hole in the,
side of a furnace or kiln, or a closed porcelain tube thrust into molten metals
or salts. When sighting upon objects in the open, certain corrections must
be applied. The relation between the amissivity (monochromatic light),
of a material and its observed and true temperatures is given by eq. 47,
so that if the emissivity is known the true temperature may be computed
from the observed temperature. Par 373 gives the emissivity of various
substances for red light (X = 0.65m).
S73. Monochromatic Emissivity for Red Light (X= 0.66m)
Material ^^ Material E^

Silver 0.07 Nichrome, 900° C 0.90

Gold, solid 0.13 Nichrome, 1200° C 0.80
Gold, liquid 0.22 Cuprous oxide 0.70
Platinum, solid.. . 0.33 Iron oxide, 800° C 0.98
Platinum, liquid.. 0.38 Iron oxide, 1000° C 0.95
Palladium, solid.. . 0.33 Iron oxide, 1200"^ C 0.92
Palladium, liquid. 0.37 Nickel oxide, 800° C 0.96
Copper, solid 0.11 Nickel oxide, 1300° C . 85
Copper, liquid 0.15 Iron, solid and liquid 0.37
Tantalum, 1100° C. 0.60 Nickel, solid and liquid. . . . 0.36
Tantalum, 2000° C. 0.48 Iridium 30
Tungsten, 1000° C. 46 Rhodium 0.30
Tungsten, 2000° C. 0.43 Graphite powder (estimated) 0.95
Tungsten, 3000° C. 0.41 Carbon 0.85
Nichrome, 600° C. 0.95 Porcelain (? ?) 0.25 to 0.50

208
 MEASURING APPARATUS Sec. 3-374

374. Curve of emissivity corrections. Fig. 135 shows the correc-

:is to apply to the pyrometer readings for a number of values of A, using

leg. cent, as abscissas and (< — «) deg. cent, as ordinates. To obtain the
ue temperature corresponding to an observed temperature s deg. cent.,
id to s the value of the ordinate at the particular emissivity E-^ and abscissa
As an example, let Ey =
30, s = 2,006 deg. cent.; true
1200
•inperature = 2,000 320 =
+ 1100
1,320 deg. cent.
Eecording pyrome- «1000
t
37B.
ry. The following types of B 900
'yrometer may be made auto- o
'latically recording. (1) Gas, ^ 800
Uturatedvapor, and liquid
tiermometers; (2) resistance
hermometers; (3) radiation
yrometers; (4) thermoelectric
•yrometers; of which the last
vas the greatest applicability.
'^he usual type of curve re-
4uired is temperature versus
ime, in which case the indi-
ating instrument is equipped
•nth a mechanism for periodi-
: ally recording its indications
:ipon a chart which moves with
i uniform speed.
Sec. 3-380 MEASURING APPARATUS
closing a circuit which may operate a bell. The alarm in this form
general operates for too great a part of the time unless the contacts a
widely separated, when their usefulness is much lessened. The acti'
may be made intermittent, but even then the alarm is best employed on.
when there is danger to life or property.
380. Manual Signaling. Temperatures are measured in a centr
station and instructions given to the furnace operator through pneumat
tube service, by telephone or by colored lights. Signaling is usually accoi
plished by three lights at each furnace, different combinations representii,
certain departures from proper control.
381. Automatic signaling. A galvanometer or recorder may V
equipped with a device including relays for operating the system of col(»»|
lights referred to in Par. 380, '
i

382. Standard temperatures. From a consideration of determ natioi

made since 1900, and selecting only temperatures in the location of whi(
two or more independent observers have participated, and which are suitab
for use as check points in physical and chemical operations, the foUowii
table is presented (Par. 383). Temperatures above 1,550 deg. cent, are bast
on C2 = 14,350. Boiling-points are given for a pressure of 760 mm. Hg.
383. Table of Standard Temperatures; (deg. cent.)

Tempera-i
Substance Phenomenon ture

Hydrogen Boiling -252.7

Oxygen Boiling -182.9 ,

Carbon dioxide Sublimation (in inert liquid).. -78.5 1

Mercury Freezing -38.87

Freezing
NajSOV+iOHzO.'.'.'.'.! Transformation to anhyd. salt 32.384
Water Boiling 100
Naphthalene Boiling 217.96
Tin Freezing 231.85
Benzophenone Boiling 305 90
.

Cadmium Freezing 320.92

Lead Freezing 327 .

Zinc Freezing 419.4

Suljjhur Boiling 444. G
Antimony Freezing 630.0
.Muminum Freezing 658.7
71.9% Ag 28.1% Cu. Eutectic freeze 779
NaCl Freezing 801
Silver Freezing 960.5
Gold Freezing 1063
Copper Freezing 1083
Palladium Freezing 1550
Platinum Melting. 1755
Alumina Melting 2050
Tungsten Melting 3400
Carbon arc Pos. crater 3600
Sun Surface 6000

Oxygen boiling-point* t= -182.9 -1-0.013 (p- 760)

Carbon dioxide, sublimation
point - 78.6 -1-0.016 (p-760)
Water, boiling-point 100 -1-0.037 (p-760)
Naphthalene, boiling-point. 217.96-1-0.058 (p-760)
Benzophenone, boiling-point 305.9 4-0.063 (p-760)
Sulphur, boiling-point 444.6 +0.0908(p-760)-0. 000047
(p-7G0)2
Of the boiling substances, benzophenone and oxygen are the only ones to
the purity of which special attention need be given, but the metals used for
freezing- or melting-points must be of the highest purity.
• p denotes pressure in mm. of Hg.
210
 rj MEASURING APPARATUS SeC. 3-384

'
'J84. Automatic temperature control. Automatic control at low
npe'ratures, or "thermostating," is usually obtained by means of the
'.vement of bimetallic springs or the thermal expansion of rods or fluid
'
umns. For higher temperatures thermoelectric instruments are em-
)yed, the principle of operation being similar to that
used in automatic
'naling. Instead of operating lights, however, the relays control electro-
ignetin valves for oil or gas, or switches in the case of electrical heating,
itomatic control is comphcated by the interrelation of such factors as
ermal lag and the magnitude of the corrective changes in heat supply
ring each period of reversal. The sensitivity of the control instrument
termines the range of temperature which must be covered by the couple
iring each reversal of the valve or switch. The range of temperature
vered by the source of heat is greater than this, the magnitude being
ected by the type of furnace, method of firing, and location of the couple.
)r closest regulation, which is best
accomplished electrically, the couple
1 ust be very near if not in contact with the heater. In electrical heating
' '

e current is changed by opening and closing a switch which shunts a

Srtion of the controlhng resistance or changes series and parallel connec-
Sna of the heater or transformer. In gas and oil heating the supply pipe
by-passed and the control valve is located in the shunting line.

HEAT CONDUCTIVITY
Heat Conductivity. Three processes exist by means of which
385.
iat may be transferred from one body to another, by radiation, by con-
iction and by conduction. All of these factors enter into the computation
the heat losses from a furnace, but frequently the loss by convection and
idiation may be made small or negligible in comparison with the loss by con-
uction. The quantity of heat which flows through a plate of area A and
lickness e in a time t is expressed,
Q = A;(9i-fl2).A«/e (49)
here Biare the temperatures upon each side of the plate (a plate
and 6i
leoretieally infinite in extent) and A; is known as the thermal conductivity.
is defined by the quantity of heat which flows per unit time through unit
rea of a plate of unit thickness, having unit difference of temperature
etween its faces. Numerically A; is usually expressed as the quantity of
eat in small calories which is transmitted per second through a plate 1 cm.
hick, per square centimeter of its surface, when the difference in temperature
etween the two faces is 1 deg. cent. Q then refers to g-cal., 6 to deg.
entigrade, A to square centimeters and t to seconds, k is found to vary with
he temperature of the plate and is expressed approximately by the equation
k, = ko{l+at) (50)
: yhere t is the temperature centigrade and a a constant. As an example be
t required to find the quantity of heat lost per hour by conduction through a

ection 100 cm. by 100 cm. of a fire-brick furnace wall 20 cm. thick, the con-
iuctivity being 0.00028 cal./(cm.-sec.-degree) and constant with temperature,
he inside temperature of the furnace being 1,500 deg. cent, and the outside
100 deg. cent.
il

•500-300
Q = 0.00028 1
iqqx 100X3,600 = 605,000 g.-cal.
P
i
BIBLIOGRAPHY
Selected list of references to literature on thermometry, py-
386.
ometry and heat conductivity.
"Thermometry." Circular No. 8; Bur. Standards, Washington, D. C
Uso same title, Sci. P. (in press).
Pyrometry. "Measurement of High Temperatures." Burgess and Le-
^hatelier, 3d Edition, 1912, John Wiley & Sons, N. Y.
"Characteristics of Radiation Pyrometers." Burgess and Foote. Bur.
Standards Scientific Paper (No. 250).
"Pyrometric Practice." Foote, Fairchild and Harrison. Bur. Standards
Tech. Paper No. 170.
"Pyrometer Symposium," Chicago; a series of papers published in book
I orm by A. I. M. M. E.
"Heat Conductivity." Ingersolland Zobel, Ginn Co., 1913. '•''"'^

211
Sec. 3-387 MEASURING APPARATUS

FUEL AND GAS ANALYSIS

BY F. MALCOLM FARMER, M.E.
S87. The purpose of this section is to indicate very briefly the mor
important features in connection with fuel and gas analysis. For furth(
information, the reader is referred to the numerous publications on fuel an
gas analysis. See Par. 402.
388. Coal for steaming: or producer purposes is usually subjecte
only to a proximate or engineering analysis, which includes the di
termination of the heating value and the percentages b.v weight of moistur'
fixed carbon, volatile matter, sulphur and ash. When a complete (

ultimate analysis is made, the components of the volatile matter are .il^
determined.
389. The details of manipulation in coal analyses have a marke
effect on the result and .since many of the determinations are made in a raai
ner more or less arbitrary, care should be taken to conform to standar
practice. The accepted standard practice is that recommended by th
American Society for Testing Materials in their Specification No. D22-1
entitled, "Standard Methods for Laboratory Sampling and Analysis of Coal.
It gives complete details for the preparation of the sample in the laborator
and for making the various determinations indicated in the precedin,|
paragraph.
390. The sampling of coal is of the utmost importance. The gre^it ^

care is necessary in order to

obtain a sample which is truly (5)3
representative of all of the coal
in the lot which the sample is to
represent. In general, a large
sample of .500 to 1000 lb. should
be made up of small quantities
taken from various parts of the
entire lot. This is gradually re-
duced to a 30-lh. sample about
pea size, by crushing, mixing
and quartering.*
391 Heating values of fuels
.

are determined with calorime-

ters, or instruments in which
the heat evolved by the com-
bustion of a sample of the fuel
is absorbed by water, the weight
and rise in temperature of which
are observed. There are two
general classes, the non-con-
tinuous class in which only a
small quantity of the fuel (solid
or liquid) is burned at one time,
and the continuous class where
the fuel (liquid or gaseous) flows
continuously through the calori-
meter.
392. The Berthelot or bomb
type calorimeter of the non-
continuous class is most gen-
erally used for high-grade com-
mercial work. Fig. 136 shows Fia. 136. —calorimeter.
Atwater-Mahler fuel
the arrangement of parts in an
Atwater-Mahler calorimeter,
which is similar to the Mahler, Emerson, Hempel and other well-knowi
bomb calorimeters The "bomb" is the strong steel vessel, B, with

*See A. S. T. M. Specification No. D21-16, "Standard Method foi

Baropling of Coal." Excellent instructions arc given in Bulletin No. 339
U. S. Cieological Survey, and in later bulletins of the Bureau cf Mines ol
coal sampling. .-^al " .xn-nr.'Ui:

212
 MEASURING APPARATUS Sec. 3-393

gold, nickel, enamel or

a»iv fittinir screw-top and lined with platinum,
.^
A valve provided at the fj^J^ZY^^^ll;
Ca co'rrosiv" ma'lerial.placed is
in the crucible, C, and ignited by the
,

'

fLvJen The sample is

heated to incandescence by an electric cur-
:
V
J
fine iron
through
ner which
V wire /.which
aAd V'.
is filled with water.
is
The bomb is placed in the calorimeter vessel
Heat insulation is provided by plac-
and F, separated by air spaces
:

The calorimeter in two other vessels, Tand its temperature measured

'

>e water is agitated by the stirrer, S,

briefly as follows.: About g of coal is

The proceXre in operation is 1
is placed in the bomb with the
VefuUy weighed in the crucible, which After the top
ie iron wire carefully arranged
in contact with the coal.
bomb is filled with oxygen at a pressure of 300 lb. to
screwed on tn
'screwed the .^ tank, which contains a
^^^^ ^^^ calorimeter
"radiation" rate is obtained^ the
•own weight of Water. After the initial the water observed. When
^clme^s ignited and the rise in temperatureconstant, the final radiation
of
er^te of change of temperature becomes from the weight
te 3 obSned.
! The heating value per pound is calculated
the specimen, the weight of the
water and the rise in temperature. Cor-
(' water eqmya-
cKs
made for the heat capacity of the calorimeterthe heat
>atT the "radiation" during the' combustion interval, from the
heat of combustion of the
^"ctricenergy used in heating the wire and
the
range only a few degrees centigrade and is
te" The temperature is
read to 0.001
mercury thermometers,
ually measured with differential
-

•g. with the aid of a microscope.

393 The essential details of procedure for a proximate analysis
in a shallow pan and air-dned
as follows- (1) The whole sample is placed
•e
•

a special oven at 10 deg. or 15 deg. cent,

above room temperature until
.e weight is practically constant
(from 2 to 4 hr.) The loss in weight is the
irface moisture or "air-dry" loss. The sample is then ground in a
.ffee mill until it will pass through a
20-mesh sieve;* it is next quartered
id then about 100 g. are ground in a mortar
or ball mill to 80 or 100 mesh.

'
(2) Total moisture is obtained by heating
5en porcelain or platinum
:3ting the loss in weight.
(S) Volatile matter is
crucible

obtained
in

by
an oven
heating
latinum crucible at a bright red heat in a Bunsen
the volatile matter
,,,
1 g. of the final sample in an
at 104 to 107 deg. cent., and

1 g. in a special, covered

plus
flame for 7 mm.
the moisture.
i a
1 he
•

)tal loss in weight is equal to

(4) Ash is determined by burning 1 g.
of the sample in an open crucible
ntil the weight is constant (1 to 2 hr.).
The highest temperature of the
.upsen flame is utiUzed. Sometimes a small stream of oxygen at low pres-
jre is injected into the crucible to hasten combustion. _ , , .

calculation, that is, faxed carbon =»

(5) Fixed carbon is determined by
00- (moisture +
volatile matter +
ash), all expressed in per cent.
'

is determined as follows: 1 g. of the

Sulphur coal is mixed with suit-
(6)
ble chemicals (such as magnesium oxide and sodium carbonate) and burned,
•he residue is extracted with water, filtered, and the sulphur precipitated
-om the solution with barium chloride, coming down as barium sulphate,
•rom the weight of this precipitate, the percentage of sulphur in the original
ample is calculated.
394. The Junker calorimeter is the best known example of the con-
inuous class. It is used extensively for gas fuels and can also be used for
Fig. 137 shows the calorimeter set up for gas testing. 1 he
quid fuels
as flows through the meter M
and a pressure regulator R to a special Bunsen
chamber surrounded
umer inside of the calorimeter C. The combustion is

y a chamber through which water flows at a constant rate. The heating

alue in B.t.u. per cubic foot of gas is calculated from the rate of gas con-
umption, rate of flow of the water and the difference between the average
ilet and average outlet water temperatures. For liquid fuels, a weighing
(vice and a special burner are provided.
395. Other types of calorimeters of the discontinuous class differ
-piUially from the Berthelot only in the method of supplying the oxygen.
alorimeters of the C arpenter and the Favre and Silherman type, oxygen
:

' 20 clear spaces per linear inch.

213
Sec. 3-396 MEASURING APPARATUS
gas is supplied at atmospheric pressure. In instruments of the Parr class ;

the oxygen is supplied by chemicals with which the sample is mixed.

396. Fuel oils are, in addition to the foregoing. Par. 394, frequently .

tested for flash-point, or temperature where the vapor given oS will ig- j

Fia. 137. —Junker gas calorimeter.

nite but will not continue to burn; fire-point, or temperature where
combustion will continue if the vapors are ignited; viscosity; chill-point,
or congealing temperature; per cent, of asphaltum.
397. Reports of proximate analyses and heating value (in B.t.u. per
pound) usually give the results calculated on
at least two bases, "as received" and "dry."
The former are of most interest to the users of J"^^
the fuel, but the results must be reduced to
the latter basis when comparisons are to be
made.
398. Fuel or illuminating gases are
analyzed for the following components in
per cent, by volume; carbon dioxide
(CO2), carbon monoxide (CO), oxygen
(Oj), methane (CH4), ethylene (C!H4),
hydrogen (Hj) and nitrogen (N). CO,
COj, Oi and CjH* are usually determined
by passing a known volume of the gas through
a series of reagents, one at a time, each of
which will absorb one, and only one, of the
components. The diminution of the volume
is noted after each absorption. Hj and CH*
are obtained by combustion in a glass tube
with a known volume of air, the products of
combustion being measured by absorption as
in the case of the other constituents, and the
original volume calculated. N
is obtained by
difference.
399. Orsat apparatus. The various
Fig. 138. —Orsat apparatus.
forms of apparatus which employ the ab-
sorption method are based on the principle of the Orsat apparatus shown
in Fig. 138. A given quantity of gas, usually 100 c.c, is drawn into the
214

t
 MEASURING APPARATUS See. 3-400

^
easuring tube, T, by means of the water bottle, B, and carefully measured.
'
he gas is then forced into the COj reagent bottle, d, drawn back into T
id the decrease in volume noted. The process is repeated with each
the tubes, c, b and a, giving the percentages of O2, CO, and Hj re-
)ectively. The usual reagents are caustic potash solution for COj,
mmoniacal cuprous chloride solution for CO and alkaline pyrogallic acid
)lution for Oi, H2 being obtained by combustion.
400. Flue gases are analyzed for carbon dioxide (CO2), carbon mon-
dde (CO), oxygen (O2), hydrogen (H2) and nitrogen (N), in the manner
idicated for fuel or illuminating gas.
401. COj recorders are instruments which automatically and continu-
usly remove samples of flue gas and indicate with a pointer or record on a
:0ck-driven chart the percentage of COj in each sample. Various principles
re employed, among which are the variation in the refraction index with the
ercentage of CO2, the variation in density compared with air as a standard,
nd the variation in the position of a float with the volume remaining after
he CO2 has been removed with caustic potash, the usual reagent.

—
402. Selected list of reference literature on fuel and gas analysis.
Lewes, V. B. "Liquid and Gaseous Fuels." D. Van Nostrand Co., New
.^ork.
Gill, A. H. — "Gas and Fuel Analysis for Engineers." John Wiley & Sons,
^ew York.
Kershaw, J.
—"The
B. C. Value
CalorificFuels." D. Van Nostrand
of Co.,

SoMERMEiRER, E. E. — "Coal,
•Jew York.
Composition, Analysis. Utilization and
Its
/^aluation."
— "Purchasing
McGraw-Hill Book New York.
Co.,
MoTEH, A.
J. Coal by Specification."
Jour. Engineering
iociety of Pennsylvania, Aug., 1913.
Fuel Technology Publications, U. S. Bureau of Mines (Formerly U. S.
jieological Survey).
Bulletin No. 12. Apparatus and Methods for the Sampling and
•
Analysis of Furnace Gases, 1911.
Bulletin No. 23. Steaming Tests of Coal, 1912.
Bulletin No. 63.
I

i Sampling Coal Deliveries and Types of Government

L Specifications, 1913.
Technical Paper 3. Specifications for Fuel Oil for the Government, 19H.
Technical Paper 8. Methods of Analyzing Coal and Coke, 1912.
Technical Paper 26. Methods of Determining Sulphur in Fuels,
Especially Petroleum Products, 1912.
Technical Paper 49. Flash-point of Oils, Methods and Apparatus, 1913.
Bulletins, University of Illinois Experiment Station:
No. 15. How to Burn Illinois Coal without Smoke, 1908.
No. 31. Fuel Tests with House Heating Boilers, 1909.
No. 37. Unit Coal and Composition of Coal Ash, 1909.
No. 38. Weathering of Coal, 1909.
No. 46. Spontaneous Combustion of Coal, 1911.

WATER, GAS, AIR AND STEAM METERS

BY REGINALD J. S. PIGOTT
WATER METERS
403. Classification. Water meters are of three classes: weighing, volu-
metric and kinematic.
404. Water weighers are not affected by variations in temperature and
allow, approximately, 2 per cent, error. All weighers must be fed with
a gravity flow. The various methods employed by concerns manufacturing
water weighers are described in Par. 405 to 408.
406. Worthington weigher. In this device two counterweights are
mounted on trunnions, water flowing into one tank while the other empties
As the water rises the centre of gravity of the tank and water is shifted, finally
reachmg a point where the tank upsets and empties. This movement auto-
JJjat'cally throws the water deflector over to fill the other tank. See Fig. 139.
1 his device will, of course, weigh only in units corresponding to the weight
contained in one tankful; the number of trips of the tanks being auto-

215
Sec. 3-406 MEASURING APPARATUS
matically taken by a counter and multiplied by the tank unit weight. Thi
accuracy approximates 2 per cent. See Pai 404..

Fig. 139.^Worthington recording liquid weigher.

406. The Kichardson weigher, Fig. 140, uses a single weighing tank
mounted on knife-edged scale beams directly counterbalanced. The over-
balancing of the weighing tank trips the feed valve from the upper reservoir
and opens the discharge. By a system
utilizing two toggles and dead-centres,
the upper valve does not open till the
outlet valve is again entirely closed.
See Par. 404.
407. The Wilcox weigher operates
as a single tank with a syphon outlet.
The bell float and standpipe (which is
open top and bottom), are down nor-
mally, so that the standpipe seals the
opening in the diaphragm between up-
per and lower tanks. Water accumu-
lates in the upper section until it
overflows the top of the standpipe and
runs down into the lower compartment,
trapping air in the bell and inner legs of
the two siphon , and raising the bell.
As the water rises, the trapped air is com-
pressed until finally it breaks through the
trip seal and starts the main siphon.
The release of air pressure allows the
bell and standpipe to drop, and the cycle
begins again. See Par. 404.
408. Volumetric meters include
measuring-tank meters (other than
weighers), piston meters and disc meters.
Variations in temperature affect all
these types, so that they must be cali-
brated for the average temperature on
which they are to be used. Accuracy
of piston and disc meters should be
1.0 to 1.5 per cent, average error, pro-
vided they are properly used and not
worn. Wear of piston meters or
disc meters, causing leakage, may in-
crease the percentage of average error Fig. 140.
to 5 />r 10 per cent. The various typos
— Richardson weigher,

of volumetric meters are described in Par. 410 to 412.

216
 MEASURING APPARATUS SeC. 3-408

^M\ ^ uJiwiJi-MiiwiJj

Fig. 141. —Hammond water meter.

217
Sec. 3-409 MEASURING APPARATUS
409. Space occupied by Richardson weigher.
SIZES AND DIMENSIONS (IN.)

H J N P Q R
< S

25 38.5 22 '25 2i:i5 33 187.25 151.5 |19 2013 1,05.=

43.5 2810 232.2523 3020 2,80<

76 54 3835 36.5 41 10
1 354 I35 4230 6,40(

76 38,35 36.5 4110 354 42^30 6,9(K

I

76.25:f 4848 24 56:15 34|4 48|37: 10,4CK

3000 420 76.25:69 48:48 24 56115 161344 4837 11,000

Fig. 142. —-Worthington disc meter. I

410. The Hammond measuring-tank meter, Fig. 141, consists of twol

tanks, Bi and fij, into one of which the inflowing water is directed by the
baffle G, while the other is emptying through the valve Dt. When the water
level in Bi rises high enough to lift float ii, latch Hi releases, the weight of
water on valve Di throws the wrist plate over, opening Di and closing Di, and

J
MEASURING APPARATUS Sec. 3-410

219
Sec. 3-411 MEASURING APPARATUS
changing the deflector G to fill Bt. The action is very rapid at the relea '

period, preventing loss of water during the change period. A gage, X

included for accurately setting the meter. This device, as with all
volumetric meters, is affected by change of temperature. For variatij^
approximately 50 deg. fahr. (28 deg. cent.) the error is not great, the avera; :

being 2 per cent, to 3 per cent. It is operated on gravity flow. '

|

411. Disc meters of the general type in Fig. 142, operate by the gyratici
of a disc in a spherical chamber. The stem attached to the disc describes; ]

circular path and operates the counter. These meters are used on clos< !

lines under pres.sure. j

Disc meters vs. piston meters. Disc meters are used chiefly for smE;
lines, up to about 3 in. diameter. Piston meteis for sizes from 2 in. to 8 i ,

For larger flows, tank, Venturi or turbine meters are generally employed. '

SECTION THROUGH VERTICAL CENTRE LINE

Fig. 144. — Worthirigton turbine meter.
412. Piston meters of the general type shown in Fig. 143, operate like i

duplex steam pump, the movement of the pistons measuring off definit'
volumes of water per stroke. The strokes are recorded by the counter'
usually in units of cubic feet. These meters are used on closed lines unde
pressure, and necessitate, for their operation, a pressure drop of from 2 t<
6 lb. per sq. in., depending on the flow.
413. The Venturi meter is widely used, both for large and small flow, ol
pumping seivice and boiler feed. It occupies practically no space outside o:
the pipe line; has no moving parts in the meter proper, and operates oi
closed pressure lines. The accuracy is from 1.0 to 1.5 per cent, if used ot
reasonably steady flow. If used on rapidly fluctuating flow it becomes verj
inaccurate. If kept clean, the accuracy is substantially constant during thi
life of the meter.
A slight pressure drop, 0.2') to 3 lb., occurs through the meter, depending ir
amount on the flow and ratio of upstream to throat areas. For theory ol
the Venturi tube, see Sec. 10.
414. The Pitot meter is not satisfactory for general service, as the head
differences are much less than those developed in the Venturi, consequenUj

220
 MEASURING APPARATUS See. 3-415

t registering apparatus is much more delicate and sensitive to leakage in the

Tissure lines leading from the main to the recordinp instrument. It is also'
\ y sensitive to
eddies in the pipe lines in which the Pitot tube is inserted.
J' the theory of the Pitot tube, see Sec. 10.
The turbine meter, Fig. 144, is used to some extent for large-size
16.
1 and large flow. It operates like a hydraulic turbine, and as the meter
's
iSoses practically no friction or pressure loss to flow, the speed of the meter
;nhatantially proportional to the flow._ It is called a "velocity meter," but
speaking, this meter is volumetric: t is affected in accuracy by tem-
'
i

,ie changes. The accuracy is practically the same as the weighers and
.,. meters (Par. 404).

116. Weirs, usually of the V-notch type, are in considerable use, in con-
;tion with indicating and recording mechanisms for water measurement.
•e Sec. 10.) In the Lea type, a float in a chamber above the weir, operates
drum in such a fashion that the recording and integrating appara-
rooved
, move over equal increments of space for equal increments of flow.
in the Hoppes type, a conoidal float is suspended by a coil spring, and is so
iped that the descent of the float by the weight of water forced over by the
e of the weir, is proportioned to. the flow. Very good accuracy is claimed
these weir meters, from 0.5 to 1.3 per cent, over all ranges of flow,
mperature changes are approximately compensated in both types, by
3behavior of the float and the conoidal chamber respectively.

QAS METERS AND AIR METERS

417. available for gas and air measurement are: (a)
The meters
MIows-type, for low pressure chiefly; (b) Thomas electric, for high or low
jessure; (c) Venturi-tube, Pitot tube, and disc orifice types for high or low
jessures; (d) wet types for low pressure; (e) rotaries.
418. The bellows type "dry" meter has usually a pair of leather bellows
K-rating two diaphragms, after the manner of a piston in a reciprocating
igine. The valve operation
exactly likeis that of a two-oylinder double
ting engine with quartering cranks. The movement of the diaphragms
easures off volumes of gas. The pressure and the temperature must be
,!pt reasonably constant, as the accuracy of the meter is affected by both.
:he error may range from 3 per cent, "slow" to 2 per cent, "fast."
• 419. The wet meter is now used chiefly for large gas-works service, and
s operation is somewhat like that of a rotary engine. The average error
usually from 3 per cent, slow to 2 per cent. fast. The obtainable accuracy
ith large wet meters is within 0.1 per cent.

480. The Thomas

electric gas meter consists of an electric resistance
eater coil in the gas main, a wattmeter and two screen-resistance thermom-
ters. An amount of current is passed through the heater such that the
ifference of temperature of the gas before and after passing the heater is a
efinite amount as measured by the screen thermometers, which automatic-
lly average the temperature.
The relation between the temperature, watts input and flow is then
^
= 0.05686 JS
W _,
(lb. gas per min.)
. .
.,,^
(51)

There t = temperature difference, inlet and outlet, deg. fahr. s specific ; =

eat at constant pressure of air or gas measured; E=
watts input. The
'homas meter is used as a substitute for the huge wet meters formerly em-
loyed at gas houses for the main-flow measurement. Its accuracy is higher
lian that of any other device now in use for air or gas flow, the error being
•om +0.05 to +0.2 per cent. In small sizes it is too expensive to compete
Tth other types of meter, but in large sizes it is much less expensive in pro-
ortion, and has the additional advantages of indicating and recording as well
3integrating. In commercial service it is generally equipped with an auto-
laticregulator arranged to keep a constant temperature difference between
iletand outlet; the electric instruments can then be graduated directly in
ounds or cubic feet, as the flow is directly proportional to the watts input.
221
Sec. 3-421 MEASURING APPARATUS
421. Venturi meters are in some use for large gas-flow measurement
the device is accurate, but the formula for its use is complicated.
The formula for air and gas service is

W=CAi {9)' ^j^'^^i""'

'-
(lb.
mi9>-
per
gas or air sec.) (51
Where .A = upstream area, sq. ft.; jl2 = throat area, sq. ft.; P = ui
stream pressure, lb. Pj = throat pressure, lb. per sq. ft. -y =rat
per sq. ft.; ;

sp. heat at constant pressure to sp. heat at constant volume; = 1.408 for ai
= 1.266 for natural gas; 6i = density, lb. per cu. ft. at upstream sectioi
C = 0.98, coefficient of flow; g = gra^^tation constant, 32.2.
For differences of pressure less than 20 in. of water, the hydraulic formul
may be employed without error in excess of 1 per cent.

iH
Ai 'ipy
(cu. ft. per sec.)
Q= 18.3 (52

^'~m
where Q — cu. ft. per sec (= W/Si); ft = difference of pressure, upstream an
throat in in. of water [ = (Pi-Pi)(12/62.35)].
422. The Pitot-tube formula for gas and air

Q = 218.44£;d»p,
''•
V/hP
j^Ccu. ft. gas or air per hr.)(64

where E «= flow factor of the tube expressed as a decimal d = internal diam. c ;

tube (in.); T, = absolute fahr. temperature of measurement base; P^abac

lute pressure of measurement base, lb. per sq. in.;_G'=sp. grav. of gas referre
to air; if air is measured, G<= 1; P=> absolute static pressure of flowing gas i
meter, lb. per eq. in.; 2" = absolute temperature fahr. of flowing gas; A =
velocity head of flowing gas (in. of water) Q = cu. ft. of gas per hr. at T andJ
;

The value of E is 0.8530 for smooth tubes, 2-in. to 5-in. diameter, with th
Pitot tube placed exactly in the centre of the pipe. The velocity is a maxi
mum at the centre of a pipe, decreasing to a minimum at the pipe gurfaot
This accounts for the fact that E is less than unity when the Pitot tube is a
the centre of the pipe. The coefficient of flow for the Venturi meter approxi
mates from 0.97 to 0.98 for properly designed meters.
423. Thin disc orifices operate on the same formula as the Ventiu
meter, except that the coefficient of discharge C varies with the ratio c
orifice diameter to pipe diameter. The simplified formula allowing fo
the orifice ratio is
TF = 360Xd>XCX\/Aw/ (55
Where W equals pounds per hour,d equals the diameter of the orifice ii
inches, C
equals coefficient of discharge, hg equals the differential head ii
inches of the fluid at the conditions of measurement, y equals the density
CoefBcient C has the following values:
Ratio of orifice diameter
to pipe diameter Value of coefficient
0.10 0.598
0.20 0.600
0.30 0.604
0.40 0.612
0.501 0.627
0.60 0.667
0.70 0.707
These coefficients are affected to some extent by the positions of the pip
connections up-stream and down-stream for obtaining the difi'erentia
pressure.

222
 MEASURING APPARATUS Sec. 3-424

STEAM METERS
24. Steam meters. of the steam-flow meters such as the St. John,
Most
I ley, Republic, and General Electric, etc., can be used on compressed-air
S 7ice if desired. See Par. 423. Steam meters are divided into area
r ers (Par. 426 and 426) and so-called flow meters (Par. 427 and 428).
I ssure and quality variation affect the accuracy of all area and flow
I crs, so that the meters are
only correct for the calibration conditions
c )ressure and quality, unless fitted with
compensating devices.
25. "Area" steam meters. In this class are those in_ which a disc or
( partially closes an opening through which steam is passing.
I
The shape
( ;he passage or of the cup is so arranged that as it rises from zero position,
f free area for passage of steam is increased. As demand for steam is in-
I ased, the increase of pressure drop past the disc or cup, causes it to move
I ther up the passage, enlarging the area till the pressure drop is reduced
: i the cfisc again in equilibrium. The rnovement of the disc is communi-
ed to an indicator and chart graduated in lb. per hr. flow. The passage is
designed that the movement of the di8c_ or cup is directly proportional
the flow, giving an equal increment reading.
126. The St. John meter is an example of the area type. It has a
lieal plug floating vertically in a circular seat. As the stream flow is in-
,ased, the plug rises, exposing more area for flow between plug and seat,
the weight of the plug and stem is the only load, the pressure difference is
astant.

.427. Pressure indicating

'vices for use with veloc-
r steam meters. All the
w meters (Vcnturi, Pitot
d orifice types), require
I
me form of sensitive differ-
.tial gage which will accu-
tely measure a
'

small dif-
irence between two high
"itial pressures.
The simplest indicating
)paratus consists of a glass
iater or mercury
o this class belong the
—
U tube. —
iebhardt, Gehre and Gen-
^al Electric testing type.
428. The Gebhardt
^am meter, Fig. 146 is
ven as an example of the
ige-glass type of velocity
ueter and reads directly
:y water column on a
a
aart graduated in lb. per
lin. or per hr., and for a
pmplete range of pressures,
'o read the meter correctly,
. is necessary to know the
ressures and quality. By
leans of a small condensing
hamber this meter is made
uitable for use with super-
eated steam. Accuracy of
he Gebhardt meter (also the
}. E. type TS« and Gehre) is
: per cent, on careful hand-
1 Fia. 140.— Gebhardt steam meter.
ng, but more usually + 1.6
o3 per cent, in ordinary ser-
ice without constant pressure and quality check.
The Thomas electric meter can be used for measuring steam very
iCCUrately, but it cannot be commercially employed as the amount of
urrent required becomes excessive (on account of the high specific heat of
team) and especially for wet steam where moisture must be evaporated.
Sec. 3-429 measuring apparatus
429. Steam-meter costs. At the present time there are available
least three meters, suitable for general testing, and for the boiler or engi
room as permanent instruments. Of the recording instruments, while c
or two are satisfactory in operation, the price of all is still too high :'

general adoption. There is nothing about these instruments which shoi

prevent their manufacture and sale in the same manner and at about t
same price as high-grade recording gages, provided their construction
standardized and put on a production basis.

PRECISION OF MEASUREMENTS
BY WILLIAM J. DRISKO
430. Classification of measurements. For convenience of treatme
all measurements are classified as either
direct or indirect. dire A
measurement consists in determining the numeric which expresses t
magnitude of the quantity in terms of some arbitrary unit. Thus lengt
determined by means of a graduated scale, time by a clock, volume of a liqu
by a graduated flask, etc., are illustrations.
Measurements are indirect when the numeric is obtained by sot
computation making use of some functional relation expressed by a forma
e.g., the density of a sphere expressed by the relation d = M/dirD'), whe
M is the mass obtained by means of an equal-arm balance and D the diai
eter measured by a micrometer caliper; or the horse power of an engir
h.p. = p.l.a.n./33,000, where p is the mean-effective pressure found by met
urement, I the length of stroke, a the area of the piston found by me:isuri>
its diameter and n the number of strokes per minute found by countii
them. In general these expressions take the form,
X=F(a, h,c . . . A,B,C . . .
)
where o 6, c . .
. represent measured quantities, while A, B, C .re . .

resent constants (like 3.3,000 and ir in the above formulse) and F repr
sents that there is some functional relation between measurements, constan
and the indirectly measured quantity X.
431. Every measurement has a definite precision. Thus the leng
of a building might be reliable to the nearest quarter inch, the current in
certain circuit to the nearest tenth of an ampere, or the time of vibration
a pendulum to the nearest hundredth of a second. To determine th
reliability it is necessary to make a very careful study of all the instriimen
used, the care with which they are made, graduated, calibrated, adjust!
for change of temperature or of position, etc., etc. It furthermore is nece
sary to know not only the skill of the observer, but also whether any constat
errors may be due to his "personal equation." If for instance one dcsif;
to calibrate a voltmeter at 110 volts by means of a standard Weston cc
the following points must be considered: How closely must the electr
motive force at standard temperature be determined? How closely must tl
temperature coefficient be determined? If the temperature of the col'
used is determined by means of a mercury thermometer, how closel\
the thermometer be calibrated and read? How closely must the resi
of the voltmeter be known and is it necessary to take any precautions r
garding its temperature; and lastly, what must be the precision of the variab,
resistance used for the balance? After an examination of nil these probab
sources of error the final question is. What is the most probable value of tl;
combined effect of all these separate deviations or errors? (See Par. 1-6.)/
432. The general problem. Given the functional rel.ation,
X=F(a, h,c...) (5(
the problem in general is as follows: First case if o, 6, c can t. . .

measured each with a definite degree of precision, what is the best r"-"
sentative value of the resultant precision in A'? Second case: if if
sired to determine X to a certain definite precision, how precisely
each of the components be measured so that the combined effect of u.. i.
deviations may not produce a resultant deviation in X
greater than th
assigned limit?
Unless it is po.ssible to assign some numerical estimate to the precisio
attained in determining any measured quantity, X, the result is of littl
practical value. Hours of valuable time are often wasted in deterininin
some unimportant component of an indirect measurement with excessiv
precision, while at the other extreme we often find final results absolute.

224
 MEASURING APPARATUS Sec. 3-433

irthless as the result of failure to measure some important component

'th the necessary precision.
433. Determination of precision in final result with known pre-
sion in the measured components. Referring to Eq. 56, let Sa, Sb, Sc
be the numerical deviations or precision measures of the direct measure-
. .

?nts o, b, c Aa, At, Ac be the deviations in

. . . ; due to the X
jViations in the separate components, and A the combined effect of
e separate effects Ao, As, Ac ... Then A/X is the fractional deviation or
.

ecision measure of and Sa/a, Sb/b, Sc/c X

are the fractional de- . .

ations of the components a, b, c and 100 times the fractional . . .

viation is the percentage deviation. We first find the separate efi'ect

'

each of
'
these deviations Sa, Sh, Se on and then find the . X
;
mbined effect of these separate effects. The change in due to a slight X
;,.ange in a (6, c remaining constant) is found by differentiating the
. . .

nction with respect to a, i.e.,

ax
A„ = ^6a (57)
id a similar slight change in any component k would give
If 3-Y ,

!j ^TbT"' (58)
^; can be shown that the most probable value of^ the resultant effect. A, of
;ie separate effects, Ao, Aj, Ac .is . .

-
A = VAa^+Ab^+Ac^+ . . .
(59)
.
Example. The value of the acceleration due to gravity is to be deter-
"lined by means of a pendulum whose length and time of vibration are to be
loasured and used in the formula g=-rH/t^. Here X isg, a is /, b is < and
is a constant. Measurements gave /= 101.42 cm., reliable to 0.05 cm. and
1= 1.0094 sec, reliable to 0.0008 sec. How precise is the value of g when
lomputed from this data? Differentiating with respect to /, we have, Ai=»
'r5ZA2 = 9. 9/ 1.0X0.05 = 0.50 cm. per sec. per sec. Differentiating with respect
t we get, A,= -ff2;x2X«(/<» = 9.9X 100X2X0.0008/1.0= 1.6 cm. per
fi<i. per sec. This means that a deviation of 0.05 cm. in the length of
ihe pendulum affects g by only 0.5 cm. per sec. per sec. while a deviation
,f 0.0008 sec. in the value of t affects the value of g by 1.6 cm. per sec.
per
ec. The combined or resultant effect would be A = \/A(=+A(' = v'o. 52+1.6'
!=1.7 cm. per sec. per sec. and we might write the final result as = 981.5
t 1.7 cm. per sec. per sec. which means that the value of g, as determined
'3 probably reliable to the nearest 1.7 cm.
per sec. per sec. It should be
loted m the above computation for A;, At and A that not more
than two
'iRures are used in any of the quantities, i.e., t= = 9.9, < =
1.0, ?=100, etc.,
•^e reason being that deviation measures always represent
doubtful places!
lience, smce more than two doubtful places would be useless,
there is no
leed of ever keeping more than two figures in each quantity
entering into a com-
nitation of a deviation measure.
Determination of necessary precision in measured components
434.
';o secure desired precision in final result. The second or converse
jroblem IS as follows: X is to be measured to a certain degree
of reliability
sipressed by A = some definite number. What are the allowable deviations
'a, Sb, Sc, in each of the measured components a, b, c
. . .
such
combined effect. A, of their separate effects, Aa, As, Ac
'k n
mall not exceed the prescribed limit? From the law of errors (Eq. 59) an
nfinite number of solutions is possible. The best solution would be that
3ne which, with the least effort on the part of the investigator,
would give
the assigned precision. The easiest solution and the one that has been found
latisfactory, at least as a preliminary adjustment of
deviations among the
various components, is to assume that each of the components
in equal effect on the final result. I.e., to let Ao = A6
may produce
this and Eq. 58 it follows that
=Ac= A«
ii». From .
. .

Aa = A6=Ac= . . .A„=—: :.
(60)
,
jtiere n represents the
number of measured components. The allowable
Vn
leviation inany component can then be determined from Eq. 58 and Eq 60
^* IS desired to find the heat developed by an electric heater!
•n5*^?^-
vithin three parts m a thousand (0.3 per cent.), by measuring
the current
15 225
 Sec. 3-435 MEASURING apparatus
used, the voltage at the terminals and the time that the current is flowing,
the pressure is about 110 volts, the current about 0.8 amp. and the tii
10 min., how precisely must each component be measured? The formula
H = I.E.t, where H
is in joules, or // = 0.8X 110X600 joules = 52.800 joul.
If His to be reliable to three parts per thousand, it must then be determin
to the nearest 158.4 joules, or keeping two figures only, to the nearest 1
joules. Since there are three components, n = 3 and we have

Aj = A^ = Ai= —— = —T^ = 94 joules. Differentiating, we get,

Vn V3
94
Aj==94=E,Sl .-. 5^= —^^^ = 0.0014 amp.
oi
A^ = 94=/,«i? .-. 5£ = ^-^^^ = 0.19 volts

A, = 94=7£«.-. 5,= — 94
^-^=l.lsec.
This means that if we assume equal effects and wish to know the heat to t'
nearest 160 joules, the current must be measured to the nearest 0.0014 amj'
the voltage to the nearest 0.19 volts and the time to the nearest 1.1 sec.
would be very easy to reach this precision in the time measurement if a goi
stop watch were used; in fact this interval could be determined to within
sec. and therefore the time might be treated as a constant, in which case;
would be two instead of three and therefore it would not be necessary
measure I and E quite so accurately as indicated above.
435. Two classes of formulss in indirect measurements. The t«
methods shown above for the direct (Par. 432) and the indirect (Par. 43
methods respectively are perfectly general; consequently by their use ai
problem may be solved provided all deviation or precision measures are e
pressed as actual numerical deviations and not as fractional or percental
deviations. It is found in practice that nearly all formulae used in indire^
measurements fall in one or the other of two general groups. Those of tl
first class include all tlio.se functions which contain sums or differences ;J

terms, each of which may involve either measured components, or OO-

Btants, or both. The general form would be
X = Aa'±Bb''±Cc«± ... (6
where A, B, C . are constants and a, h, c
. . are measured quantiti'
. . .

entering to the I"', wi<*, and n"> powers respectively. Examples of formulae
this sort are the expressions for the electromotive force of a standard Clai
cell, £;= 1.4.340 [1-0.00078 «°-15°)], or the resistance of a standard V
ohm coil, /? = 10(1 +0.00388 (<°-15°)].
Those of the second class include all those functions which involi
products, quotients or powers of the measured components and constan
and do not involve either trigonometric or logarithmetic functions. Tl
general type would be
X = Aai-bm-cn . . . (61
where A, n, m, and k are constants (positive, negative, fractional or integral
An example of formulae of this type is the expression for the modulus of elaf
ticity for bending, given as E ^WV/iahd*, where is the load at tlW
centre, I is the length between supports, a is the deflection, h the breadtli an
d the depth of the beam; the formula given above for density (Par. 4S(
is another example.
436. Percentage method of computing precision. Problems (
the second class (Par. 436) may be solved much more easily by the fraction!
or percentage method than by the general method, as will appear from tb
following. Taking the general form of the function as
X = A.a'-6'"c" ... (68!

and differentiating with respect to each of the variables, and then dividiBi
each of these results by the general formula gives,
Aa ISa Ah mSb Ac n'6e .^
X'^a'
~b X" '
5"r""
This shows that a fractional deviation Sa/a in a produces a fractional devia
tion in X which is n times as great, or in per cent, it means that if a is un

226
 MEASURING APPARATUS See. 3-437

ftikble by 1 per cent., X

will be unreliable n times 1 per cent, and it is
£i 6 noted that the remaining factors in the formula have no effect whatever
B n this relation. This enables us to state at once the separate effect of
M percentage deviation of a given component and by using the relation

1 1 ts eqmvalent, _____^_

I- ^('?r+(4)'+( »?)'+••• <™

1 can therefore express the final resultant effect as a percentagb deviation.
The percentage
37. method
is illustrated by the following prob-
1 Measurements for the modulus of elasticity using the above formula
1.
as follows.
I The weight is 10 kg., reliable to the nearest gram; the length
i ,000 mm., reliable to 0.5 mm.; the deflection is 6.983 mm., reliable to 0.007

Ji; the breadth is 4.675 mm., reliable to 0.005 mm.; and the depth is 15.069
la., reliable to 0.008 mm. The problem is to determine the reliability of
t modulus when calculated from the formula S=
pr'Z'/4 a.b.d'. The first
»p is to express all the deviations in per cent. Inspection shows that W
Jeliable to 0.01 per cent., I to 0.05 per cent., a to 0.10 per cent., 6 to 0.10
} cent, and d to 0.05 per cent, and by Ekj. 71 we get 100 Aw/J5 0.01 per =
-it; 100 Al/E = =
Q.15 per cent.; lOO Aa/E 0.1 per cent.; 100 Ab/E"
I
percent.; and 100 Ad/£ = 0.15 per cent. Substituting these values in
65 or Eq. 66 we get for the percentage reliability of E: 100 A/i5 =
jher Eq.
|6.01« + 0.1524-0.10»+0. 102+0. 152 = 0.25 per cent., i.e., the combined effect
.all the deviations amounts to 0.25 per cent, in the value of the modulus,
len £ = 22,420*56 kg. per square millimeter.
The converse problem in the percentage method would be as
*138.
Mows. It is desired to measure the modulus to 1 per cent.; how precisely
rMt each of the above five components (Par. 437) be measured, and, sec-
dly, can any of them be measured with negligible precision? An inspection
the above measurements, or a knowledge of measurements, would show
t

at the weight might be measured so precisely as to be regarded as a con-

ciat, and hence n = 4; then we should have, assuming equal effects, Ai/£?"»

i/.B-Aj/jB=Ad/S=A/E\/4 = l/100\/4 = 1/200 = 0,5 per cent. Applying

1^ 71 we find the percentage deviations to be as follows: 100 51/1 = 0.5/3'=
17 per cent,' 100aa/o = 0.5 per cent.; 100 36/6 = 0.5 per cent.; 100«d/d»
i5/3 = 0.17 per cent.
With a
experience one can write the result of either the direct or the
little
nverse problem, by the percentage method, from inspection, or at most
'

i.th a small amount of calculation. It should be noted that the equal-effect

iethod often gives only a first approximation to the best result, for it often
true that one or more components can be measured with negligible preci-
3n if equal effects are assumed, in which case a second solution must be
ade treating such components as constants.
Text-books or reference works on precision of measurements.
r439.
I
—
HoLMAN, S. W. "Precision of Measurements." John Wiley & Sons,
ew York, 1894.
I
—
Goodwin, H. M. "Precision of Measurements and Graphical Methods."
[cGraw-Hill Book Co., New York, 1913.
—
Palmer, A. de F. "The Theory of Measurements." McGraw-Hill Book
New York, 1912.
Bartlett, D. p. — "The Method of Least Squares."
o..

Massachusetts Insti-
Merriman, M.— "Method
ite of Technology, 1900.
Least Squares." John
of Wiley & Sons, New
ork.

I 227
i
 SECTION 4

PROPERTIES OF MATERIALS
BY FRANK F. FOWLE, S.B.
niulting Electrical Engineer, Member American Institute of Electricil
Engineers

CONTENTS {
CONDUCTOR MATERIALS
ineral 1 Bronze 132
ire Gages 10 Miscellaneous Metals 138
jpper 31 Resistor Materials 148
uminum 79 Carbon and Graphite 153
3pper-clad Steel 100 Skin Effect 160
on and Steel 114 Bibliography 167
MAGNETIC MATERIALS
lassification 168 Sheet Gages 213
omposition and Properties 172 Commercial Sheets 217
ore Losses 206 Magnet Steel 226
Bibliography, 232

INSULATING MATERIALS
hissification 233 Rubber and Its Derivatives 330
iLscussion of Properties 238 Varnishes and Compounds 345
alid Natural Materials 254 Insulating Oils 358
itrified Materials 273 Gases 366
ibrous Materials 281 Thermal Conductivities 369
lolded Compositions 309 Bibliography 370
STRUCTURAL MATERIALS
ast Iron 371 Non-Ferrous Metals and Alloys 399
t'^rought Iron 378 Concrete, Brick and Stone 400
teel 383 Timber 410
teel Wire and Cable 395 Rope and Belting 428
Bibliography, 431

PROPERTIES OF THE ELEMENTS, 432

229
 SECTION 4

CONDUCTOR MATERIALS
aENEEAL
1. Conductors and non-conductors. All materials possess, in som
degree, the property of electric conductivity and the question whether

) given material shall be classed as a conductor or a non-conductor is entire!

one of degree. Certain materials are readily classified in these two gener:
groups; metals, for instance, are easily classed as conductors, whereas sue
substances as mica, glass, rubber and mineral oil are classed as non-cor
ductors. Certain other materials are not easily classified, because thei
properties undergo extreme changes with their degrees of purity, treatmen
and temperature. In general, all materials which are used commercial!
for conducting electricity can be classed as conductors; and those materia!
used commercially for obstructing the flow of electricity can be classed a
non-conductors, a better term being insulators or dielectrics. Substance
which are neither good conductors nor good insulators can be termed semi
conductors. i

3. Solid conduction, or the property of coDduction through bodies i'J

the solid state, is explained in Sec. 2. This type of conduction is th '
only one considered at length in this section (Sec. 4).
3. Liquid conduction, while refers mainly to the conduction o|
it
electrolytes (Sec. 19), also includes liquids of elements in the pure state-
as distinguished from chemical solutions, acid or basic. The property o',
liquid conduction is treated at length in Sec. 19, on "Electrochemistry'
(also see .Sec. 20, on "Batteries)".
4. QaseouB conduction, or the conducting power of gases, usuall;
in a rarefied state, is also outside the scope of Sec. 4 and is taken up ii
Sec. 19.
6. The theory of conduction is briefly explained in Pec. 2. Thi'
electron theory, or modern view of conduction phenomena, is treated mon
fully in Sec. 22.
6. Effect of temperature. The resistivity of most metals becomet
greater as the ternperature rises. These materials are said to have positive
temperature coefficients of resistance. Carbon and electrolytes, on th<
opposite hand, have negative temperature coefficients; that IS, their resistivitj
becomes less as the temperature rises. The coefficients of alloys are usuallj
variable and change sign at some temperatures. There are certain alloys
such as manganin, which have very small temperature coefficients, but sucl
materials form the exception. It has also been found, in the case of copper
that the temperature coeflBcient of resistance varies directly as the percent-
age of conductivity with respect to the annealed copper standard (Par. 41).
7. Temperature coefficient of resistance. The resistance of anj
conductor, over at least a limited range, can be expressed by the linear equa-
tion,
R, = «o(l + aot) (ohms) (1)

where Rt is the resistance at any temperature t, Ro is the resistance at

deg. cent, and at is the temperature coefficient per deg. from and at zero deg.
At some other reference temperature ti, the resistance is
Ri = Ri[l + ai(t - ti)] (ohms) (2)

where Rt is the resistance at ti deg. and ai is the coefficient from and at the
temperature (i deg. These formulas take no account of the change of di-

230
 PROPERTIES OF MATERIALS See. 4-8

tnsions with change of temperature and therefore apply to the case of con-
dors of constant mass, usually met in engineering work. For a full
icussion of this subject see Bellinger, J. H.
" The Temperature CoeflBcient
Copper," Bulletin of the Bureau of Standards, 1911, Vol. VII, No. 1, p.
and "Copper Wire Tables," Circular No. 31, 3rd edition, 1914, Bureau of
;

mdards.
8. Effect of chemical composition- The resistivity of most metals
very sensitive to slight changes in chemical composition. Particularly is
is true of copper; when all yed, for example, with 1 per cent,
of another
ital, its increase in resistivity, measured in per cent., is many times 1 per
;

at.,
See Par. 63 and 64. Therefore it is very essential when stating a value
resistivity for a given substance to state also what the substance is com-
sed of. or if it be so nearly pure that there are no more than small traces of
-eign. substances, to state its percentage of purity.

9. Effect of mechanical treatment. When ductile metals are sub-

3tedto cold rolling, drawing, hammering, or to cold working of any kind,
'ey become harder, stronger and slightly more dense. At the same time
e resistivity increases, sometimes markedly, and the initial properties can
My be approached again by means of the annealing: process. While
,is process will sometimes restore the initial properties, at least for most
{
'actical purposes, it does not always do so.

WIRE GAGES
10. The sizes of wire have been for many
years indicated in commercial
actice almost entirely by gage numbers, especially in America and Eng-
nd. This practice is accompamed by some conlusion because numerous
are in common use.
riges the most commonly used gage for electrical
America, is the American wire gage described fully in Par. 13.
ires, in
he most commonly used gage for steel wires is the Steel Wire gage briefly
lentioned in Par. 16.
There is no legal standard wire gage in this country, although a gage for
'

loets was adopted by Congress lU 1893 (see Par. 214). In England there is a
gal standard known as the Standard wire gage, mentioned in Par. 17.
1 Germany, France, Austria, Italy and other continental countries prac-
cally no wire gage is used, but wire sizes are specified directly iij milli-
leters. This system is sometimes called the Millimeter wire gage (see
ar. 23). The wire sizes used in France, however, are based to some extent
a the old Paris gage ("jaug3 de Paris de 1857"). For a history of wire
iges see Circular No. 31, "Copper Wire Tab'es," Bureau of Rtandards,
rd Edition, Oct. 1, 1914. Also see Circular No. 67, "Wire Gages," 1918.
There is a growing tendency to abandon gage numbers entirely and
Mcify wire sizes by the diameter in mils (thousandths of an inch). This
Tactice holds particularly in writing specifications, and has the great ad-
antages of being both simple and explicit. A number of the wire manufac-
jrers also encourage this practice, and it was definitely adopted by the
'fnited States Navy Dept. in 1911.

11. The mills a term imiversally employed in this country in connection

,ath wire gages and is a unit of length equal to one thousandth of an inch.

12. The
circular mil is another universal used term, being a unit of
^rea equal to the area of a circle 1 mil in diameter. Such a circle, however,
I
as an area of 0.7854 (orir/4) sq mil. Thus a wire 10 mils in diameter has
cross-sectional area of 100 circ. mils or 78.54 sq. mils. Hence, 1 circ. mil
quals 0.7854 sq. mil.

The American wire gage, also known as the Brown & Sharpe
13.
age, was devised in 1857
by J. R. Brown. It is usually abbreviated A. W.G,
gage has the property, in common with a number of other gages.
^his
,hat its sizes represent approximately the successive steps in the process of
/ire drawing. Also, like many other gages, its numbers are retrogressive,
larger number denoting a smaller wire, corresponding to the operations of
''^^6^6 gage numbers are not arbitrarily chosen, as in many gages,
"^*^"ii^'
-lut follow the mathematical law upon which the gage is founded. The gage
iiumbers and sizes are given in Par. 30.

231
 Sec. 4-14 PROPERTIES OF MATERIALS

The theoretically exact diameters in this gage, as given in the second oo

umn of Par. 30, contain more significant figures than there is any commercii
need for, and hence the largo companies have standardized the sizes given i

the third column, using the nearest mil for large sizes and the nearci'
tenth of a mil for the smaller sizes. These commercial sizes were adopte
as standard by the United States War Dept. in 1911.
14. Tbe basis of the American wire gage is a simple mathemattcii
law. The gage is formed by the specification of two diameters and the la
that a given number of intermediate diameters are formed by geometric:
progression. Thus, the diameter of No. 0000 is defined as 0.4600 in. and <

No. 36 as 0.0050 in. There are 38 sizes between these two, hence the rati
of any diameter to the diameter of the next greater number is given by th
expression
39/0 4600 39/

The square of this ratio = 1.2610. The sixth power of the ratio, i.e., th
ratio of any diameter to the diameter of the sixth greater number = 2. 005(
> The fact that this ratio is so nearly 2 is the basis of numerous useful relatior
or short cuts in wire computations.
16. The steel wire gage, also known originally as the Washburn i
Moen gage and later as the American Steel &
Wire Co.'s gage, wa
established by Ichabod Washburn about 1830. This gage also, with
number of its sizes rounded off to thousandths of an inch, is known as th
]

Roebling gage. It is used exclusively for steel wire. See Par. 30.
16. The Birmingham wire gage, also known as Stubs' wire gage an
Stubs' iron wire gage, is said to have been established early in the eighteent
century in England, where it was long in use. This gage was used to desif
nate the Stubs' soft wire sizes and should not be confused with Stubs' stei
wire gage mentioned in Par. 19. The numbers of the Birmingham gage wcr
based upon the reductions of size made in practice by drawing wire from rolle
rod. Thus, a wire rod was called No. 0, first drawing No. 1, and so on. Th
gradations of size in this gage are not regular, as will appear from its grapl
This gage has been used to a considerable extent for designating iron and stet
telegraph wires and the Bell telephone system has standardized No. 8 bar
•copper. See Par. SO.
17. The Standard wire gage, which more properly should be designate
(British) Standard wire gage, is the legal standard of Great Britain for ai
wires, adopted in 1883. It is also known as the New British Standar(
gage, the English legal standard gage and the Imperial wire gage
It was constructed by so modifying the Birmingham gage that the difference
between consecutive sizes became more regular. While this gage is the on
most largely used in England, there is a tendency there, as here, to drop gag
numbers and specify sizes by the diameter in mils. This gage has neve
been extensively used in this country, except by the Bell telephone systen
which has standardized No. 12 bare copper. See Par. 30.
18. The Old English wire gage, also known as the London wire gage
differs very little from the Birmingham gage. It was formerly used to sonn
extent for brass and copper wires, but is now nearly obsolete. See Par. 30
19. The Stubs' steel wire gage has a somewhat limited use for too
steel wireand drill rods. It should not be confused with the Birmingham o
Stubs' iron wire gage mentioned in Par. 16. The numbers and sizes an
given in Par. SO. In addition there are twenty-six larger sizes, Z to A, an<
thirty smaller sizes, No. 51 to No. 80, besides those given in Par. SO (see too
catalogue of Brown & Sharpe Mfg. Co., or The L. S. Starrett Co.).
20. The Trenton Iron Co.'s gage, of which the numbers and sizes ar
given in Par. 30, is used only to a very limited extent. It differs but slightl;
from the steel wire gage mentioned in Par. IS.
21. The French wire gage is an exception to the other gages given ii
Par. 30 in the respect that its sizes are progressive, instead of retrogres.siv«
as the numbers advance. The sizes there given were taken from the Aineri
can Steel and Wire Co.'s handbook, "Electrical Wires and Cables," 1910.

232
 PROPERTIES OF MATERIALS Sec. 4-22

2. The Edison standard wire gage was proposed some time before
,7 and was based upon the simple principle that the area of cross-section

Freased proportionately with the gage numbers. Thus No. 5 = 5,000 circ.
:-!s, No. 10 = 10,000 cir. mils, etc. This gage never came into general use.
13. The Millimeter wire gage, also known as the Metric wire gage, is
;pd on giving progressive numbers to the progressive sizes, calling 0.1
1. diameter No. 1, 0.2 mm. No. 2, etc.
i4. The German gage, in which the diameters or thickness are ex-
issed in millimeters, is retrogressive and contains 25 sizes. The gage
,mbers and sizes are given in Par. 29. .

'16. Large sizes of wire, above No. 0000 A.W.G., are specified by the
al cross-section in circular mils. This applies in particular to large
Aes.
26. The United States standard sheet gage, for sheet and plate iron
d steel, was adopted by Congress on March 3, 1893 (see 27 Stat. L., 746)
d established a uniform legal standard for the United States. The num-
rs and thicknesses in this gage are given in Par. 30, for comparison with
re gages. A full table of gage numbers, thicknesses and weights is given in
r. ai6.
,27. The standard decimal gage for sheet metals, designating the
ickness in mils,was recommended in 1895 by the Association of American
[eel Manufacturers, the American Railway Master Mechanics' Association
d the American Society of Mechanical Engineers. There are 38 sizes,
nging from 2 mils to 250 mils. See Par. 216 for a full table of sizes and
!ights.

28. The measurement of wire diameters maybe accomplished in three

by means of a micrometer caliper, by means of a wire gage such
lys, viz.,

J
shown in Fig. 1, or by means of a V-gage. The most accurate
that
|eans a micrometer caliper, which reads directly to mils, and, by estimate
is
g tenths of the smallest scale division, to tenths of a mil. The most accu-
Ltetype of micrometer is one equipped with a miniature friction clutch, which
laufttes errors caused by gripping the wire too firmly between the jaws.

FiQ. 1. —Gage for testing the sizes of wires.

29. German wire gage table

Diameters in millimeters

,No.
Sec. 4-30 PROPERTIES OF MATERIALS

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234
 PROPERTIES OF MATERIALS Sec. 4-30

Gage No.
 Sec. 4-31 PROPERTIES OF MATERIALS
COPPEB
31. Oeneral properties. Copper, which is by far the most importan
metal in the electrical industry, is a highly malleable and ductile metal, of i,

reddish color. The density varies slightly, depending on the physical state
an average value being 8.9. Copper melts at 1,083 deg. cent.* (1,981 deg
fahr.), and in the molten state has a sea-green color. When heated to a ver\
high temperature it vaporizes, and burns with a characteristic green flame
Copper boils at 2,310 deg. cent. (4,190 deg. fahr.).t Molten copper readilj
absorbs oxygen, hydrogen, carbon monoxide and sulphur dioxide; on cooling
the occluded gases are liberated, tending to give rise to blow holes and porous
castings. The presence of lead in molten copper tends to drive off both
carbon dioxide and water vapor.
Copper when exposed to ordinary air becomes oxidized, turning to ai
black color, but the coating is protective and the oxidizing process is not
progressive as with iron and steel. When exposed however to moist aii
containing carbon dioxide, it becomes coated with green basic carbonate,
It is also affected by sulphur dioxide. It resists the action of hydrochloric,
sulphuric and strong nitric acids, at ordinary temperatures, but is acted
upon by dilute nitric acid.

> The electrical conductivity of copper depends most critically on its degree
of chemical purity (see Par. 63) and also, in much less degree, upon the
physical state, being reduced slightly (from 2 per cent, to 4 per cent.) by
cold rolling and drawing. The tensile properties depend greatly upon the
phy.sical state, being much improved by cold rolling and drawing.
The alloys of copper are exceedingly numerous, both for electrical and
mechanical purposes. Among the most important for electrical purposes
are German or nickel silver, bronze and brass. Copper solders readily with
ordinary low- temperature solders; solder alloys with copper at about 238,
deg. cent. (460 deg. fahr.). Also see Bur. of Standards Circular No. 73, on
"Copper."
32. Commercial grades of copper. In the copper trade there are
three recognized grades of copper known as electrolytic, Lake, and cast-
ing.:!: The first, electrolytic, is that refined by the electrolytic method and
is highly pure (see Par. 34). The second. Lake, is also highly pure, in its
natural or mineral state, and requires simply to be melted down to bars,
for convenient handling (see Par. 36). The third kind of copper, known as
casting copper, contains more impurities and consequently runs lower in
conductivity. It is, as its name implies, more suitable for mechanical than
electrical applications (Par. 38).
33. Density of copper. The internationally accepted density of
annealed copper, § expressed in grams per cu. cm. at 20 deg. cent., is
8.89; this of course is also the specific gravity at 20 deg. cent., referred to
water at 4 deg. cent. The American Society for Testing Materials has
accepted this value, on account of its internatioiial endorsement, but con-
siders that a value of 8.90 is probably nearer the exact truth. A density of
8.89 at 20 deg. cent, correspond.s to 8.90 at deg. cent. In English units
the international standard equals 0.32117 lb. per cu. in. Also see "Copper
Wire Tables," circular No. 31, Bureau of Standards, Washington, D. C; and
"Smithsonian Physical Tables," Washington, D. C, 1920, 7th rev. ed., p. 334.
34. Electrolytic copper. The electrolytic refinement of copper ||

(see Sec. 19) not only produces metal of the highest purity, but it is eco-

• "Tables Annuelles de Constantes Et Donn^es. Num^riques, de Chimie,

de Physique et de Technologie;" University of Chicago Press, 1912; Vol.
I (1910), p. 48.
H. " Principles of Metallurgy;" McGraw-Hill Book Co.,
t Fulton, C.
New York, 9111; p. 74.
X See report of Committee B-2, on Non-ferrous Metals and Alloys;
American Society for Testing Materials, 16th annual meeting, June 24-28,
1913.
§ Ratified at the meeting of the International Electrotechnical Commission
held in Berlin, Sept. 1 to 0, 1913; see Trans. A. I. E. E., Vol. XXXII, p.
2148.
Addicks, L.
I]
"Electrolytic Copper;" Journal of the Franklin Institute,
Philadelphia, Pa., Dec, 1905.

236
 PROPERTIES OF MATERIALS Sec. 4-35

mically necessary when precious metals are present in the ore. This
ide of copper should run higher than 99.88 per cent, of pure metal. An
salysis of average electrolytic copper, representing neither the best nor the
'

->t, was furnished by Mr. Lawrence Addicks and appears in Par. 36.
minute quantities of impurities there ^hown of course fluctuate from
to time in any given refinery, and there are usually certain typical
i.rences among the refineries, owing to individual characteristics of the
llion supply. Wire bars of electrolytic copper are made by melting down
e cathode copper in a furnace and casting in the desired form and size.

35. Averag'e analysis of commercial electrolytic copper

(L. Addicks)
Conductivity 100 per cent.
 Sec. 4-40 PROPERTIES OF MATERIALS

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O V Q>
 PROPERTIES OF MATERIALS Sec. 4-41

,1. The International Annealed Copper Standard is the inter'

i.ionally accepted value* for the resistivity of annealed copper of 10() per
( conductivity.
it. This standard is expressed in terms of mass-resistivity
{0,15328 ohm
(meter, gram), or the resistance of a uniform round wire
a. long weighing 1 gram, at the standard temperature of 20 dejf cent. .

'
uivalent expressions of the annealed copper standard, in various units of
ss resistivity and volume resistivity, are as follows:
0.15328 ohm (meter, gram)
875.20 ohms (mile, lb.)
1.7241 microhm-cm. at 20 deg. cent.
.67879 microhm-in.
10.371 ohms (mil, ft.)
0.017241 ohm (meter, nim.^)
:
It may be convenient to note that a value of 0.017241 ohm (meter, mm.')
'

exactly g^ ohm, so that the volume conductivity at 20 deg. cent, can be

pressed 58 mho (meter, mm.').
It is important to observe that weight-measure rather than volume-
sasure is commercially the more important in wire calculations, since
.re is sold by the pound. Therefore the most attention should be given to
ass-resistivity and mass resistance.
42. Temperature coefficient of mass resistance. This coefGcient,
.hieh applies to resistance calculations when a conductor is defined in terms
i
its mass, is the one commonly employed
in engineering calculations; that
; to say, in common practice, the mass of a conductor remains the same
j; all temperatures, ana changes of volume, length, or sag are disregarded.
.
; is important to note that it does not apply to a conductor defined in terms
!f its volume.
The temperature coefficient (for constant mass) of the annealed copper
•andard, 100 per cent, conductivity, is 0.00393 per deg. cent., at 20 deg.
,
mt. The coefficient changes with the temperature of reference, as given in
j'ar. 40, column 8.
The
coefficients for copper of less than standard (or 100 per cent.)
onductivity is proportional to the actual conductivity, expressed as a
I
^ecimal percentage. Thus if n is the percentage conductivity (95 per
ent. = 0.95), the temperature coefficient will be a'l = nai, where ai is the
oeflScient of the annealed copper standard.
The coefiBcients given in the table in Par. 43 were computed from the
ormula
«, = -, (3)

n (0.00393)
+ «i-20)
The quantity —T given in the last column (Par. 43) is the inferred absolute
jero of temperature, assuming a linear relationship between resistance and
temperature. At the absolute zero of temperature the resistance would be zero.
13. Table of temperature coefficients of copper for different initial
temperatures (centigrade) and different conductivities
Ohms
(meter,
gram) at 20
deg. cent.
 Sec. 4-44 PROPERTIES OF MATERIALS

44. Reduction of observations to standard temperature. A

tabl
of convenient corrections and factors for reducing resistivity and resistanc
to standard temperature, 20 deg. cent., will be found in "Copper Wir
Tables," Circular No. 31, Bureau of Standards.
45. Calculation of per cent, conductivity. The per cent, con
ductivity of a sample of copper is calculated by dividing the resistivit:
of the International Annealed Copper Standard at 20 deg. cent, by th
resistivity of the sample at 20 deg. cent. Either the mass resistivity o
volume resistivity may be used. Inasmuch as the temperature coefficien
of copper varies with the conductivity, it is to be noted that a differen
value will be found if the resistivity at some other temperature is used
This difference is of practical moment in some cases. In order that sucl
differences shall not arise, it is best always to use the 20 deg. cent, value o
resistivity in computing the per cent, conductivity of copper. When th(
resistivity of the sample is known at some other temperature, t, it is verj
simply reduced to 20 deg. cent, by adding the quantity (20 — multipliec
by the "resistivity-temperature constant," given in Par. 46.
46. Resistivity-temperature constant. The change of resistivity pei
degree may be readily calculated, taking account of the expansion of the meta!
> with rise oftemperature. The proportional relation between temperature
coefficient and conductivity may be put in the following convenient form foi
reducing resistivity from one temperature to another: The change of resistivity
of copper per degree cent, is a constant, independent of the temperature of refer-
ence and of the sample of copper. This "resistivity-temperature constant" may
be taken, for general purposes, as 0.00060 ohm (meter, gram), or 0.0068
microhm-cm. For further details, sec "Copper Wire Tables," Circular No 31,
Bureau of Standards, Washington, D. C.
47. Complete copper-wire tables, based on the International
Annealed Copper Stanclard, are given in Par. 60, and represent approxi-
mately an average of the present commercial conductivity of copper. For
annealed wires, the resistivity is independent of the size. These tables are
reproduced directly from Circular No. 31, 3rd Edition, issued by the Bureau
of Standards. The quantities were computed to five significant figures and
rounded off to the fourth place, being therefore correct within 1 in the fourth
significant figure. The volume resistivity at 20 deg. cent., used in calculating
these tables, was 0.67879 microhm-in. and the density, 8.89 at 20 deg. cent.
or 0.321,17 lb. per cu. in. The tables in Circular No. 31 contain additional
columns for deg., 15 deg., 25 deg. and 75 deg. cent. What the tables show is
the resistance at various temperatures, of a wire which at 20 deg. cent, is
1,000 ft. long and has the specified diameter, and which varies in length and
diameter at other temperatures.
48. Explanatory notes on copper wire tables.
Note 1. The fundamental resistivity used in calculating the tables is the
International Annealed Copper Standard, viz., 0.15328 ohm (meter, gram)
at 20 deg. cent. The temperature coefficient for this particular resistivity
is 020 = 0.00393, or ao = 0.(X)427. However, the temperature coefficient la
proportional to the conductivity, and hence the change of resistivity per
deg. cent, is a constant, 0.000597 ohm (meter, gram). The "constant
mass" temperature coefficient of any sample is
0.000597+0.000005 „.
resistivity in ohms (meter, gram) at t deg. cent.
The density is 8.89 g. per cu. cm.
—
Note 2. The values given in the tables are only for annealed copper
of the standard resistivity. The user of the table must apply the proper
correction for copper of any other resistivity. Hard-drawn copper may be
taken as about 2.7 per cent, higher resistivity than annealed copper.
—
Note 3. This table is intended as an ultimate reference table, and ia
computed to a greater precision than is desired in practice. The practical
user of a wire table is referred to the "Working Tables," Par. 51.

49. Working copper-wire tables, based on the International An-

nealed Copper Standard, are given in Par. 51. This table is carried only
to three significant figures, and is more convenient for most practical work.
The table itself is adapted from Circular No. 31, 3d edition, issued by the
Bureau of Standards, and amplified by the addition of values based on the
mile unit.
240
 PROPERTIES OF MATERIALS Sec. 4-50

60. Complete wire table, standard annealed copper

American wire gage (B. & S.). English units

Diame- Cross-section at 20 deg.

Ohms per 1,000 *
ft.
ter in cent.
mils at 20 deg. cent. 50 deg. cent
20 deg. Circular Square
( = 68 deg. (=122 deg.
cent. mils inches
fahr.) fahr.)

460.0 211,600.0 0.1662 0.04901 0.05479

409.6 167,800.0 0.1318 0.06180 0.06909
364.8 133,100.0 0.1045 0.07793 0.08712
324.9 105,500.0 0.08289 .09827 0.1099
289.3 83,690.0 0.06573 0.1239 0.1385
257.6 66,370.0 0.05213 0.1563 0.1747
229.4 52,640.0 0.04134 0.1970 0.2203
204.3 41,740.0 0.03278 0.2485 0.2778
181.9 33,100.0 0.02600 0.3133 0.3502
162.0 26,250.0 02062
, 0.3951 0.4416
144.3 20,820.0 0.01635 0.4982 0.5569
128.5 16,510.0 0.01297 0.6282 7023
.

114.4 13,090.0 0.01028 0.7921 0.8855

101.9 10,380.0 0.008155 .9989 1.117
90.74 8,234.0 006467
. 1.260 1.408

80.81 6,530.0 0.005129 1.588 1.775

71.96 5,178.0 004067
. 2.003 2.239
64.08 4,107.0 0.003225 2.525 2.823

57.07 3,257.0 0.002558 3.184 3.560

60.82 2,583.0 002028
. 4.016 4.489
45.26 2,048.0 0.001609 5.064 5.660
40.30 1,624.0 0.001276 6.385 7.138
35.89 1,288.0 0.001012 8.051 9.001
31.96 1,022.0 0.0008023 10.15 11.35
28.46 810.1 0.0006363 12.80 14.31
25.35 642.4 0.0005046 16.14 18.05
22.57 509.5 0.0004002 20.36 22.76
20.10 404.0 0.0003173 25.67 28.70
17.90 320.4 0.0002517 32.37 36.18
15.94 254.1 0.0001996 40.81 45.63
14.20 201.5 0.0001583 51.47 57.53
12.64 159.8 0.0001255 64.90 72.55
11.26 126.7 0.00009953 81.83 91.48
10.03 100.5 0.00007894 103.2 115.4
8.928 79.70 0.00006260 130.1 145.5
7.950 63.21 0.00004964 164.1 183.4

7.080 50.13 0.00003937 206 . 231.3

G.305 39.75 0.00003122 260.9 291.7
5.615 31.52 0.00002476 329.0 367.8
5.000 25.00 0.00001964 414.8 463.7
4.453 19.83 0.00001557 523.1 584.8
3.965 15.72 0.00001235 659.6 737.4
39 3.531 12.47 000009793
. 831.8 929.8
40 3.145 0.000007766 1,049.0 1,173.0
*Resistance at the stated temperatures of a wire whose length is 1,000 ft.
20 deg. cent.
 Sec. 4-50 PROPERTIES OF MATERIALS

50. Complete wire table, standard annealed copper.-

)
PROPERTIES OF MATERIALS Sec. 4-50
Sec. 4-50 PROPERTIES OF MATERIALS
 PROPERTIES OF MATERIALS Sec. 4-51

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 Sec. 4-61 PROPERTIES OF MATERIALS

)
 PROPERTIES OF MATERIALS SeC. 4-52
I I.Reference to copper-wire tables in other gagres. For copper-
w tables in the British Standard Wire Gage and in the Millimeter Gage,
b; d on the International Annealed Copper Standard, see Bulletin No. 31,
3< dition (Oct. 1, 1914), issued by the Bureau of Standards.
I. Conductivity of hard-drawn copper. The conductivity of hard-
d copper, expressed as a percentage of the conductivity of the annealed
*'n
cc standard,
jer varies with the size of wire, becoming smaller as the wire
b )nies smaller. It is impracticable, however, to state any general rule,
b luse of differences in manufacturing practice, as to the number of draw-
ii between annealings, amount of reduction to each drawing, etc. The
I eau of Standards found that the cdnductivity of No. 12. A.W.G. hard-
divn copper was 97.3 per cent. The copper-wire specifications of the
^ erican Society for Testing Materials, call for resistivities which correspond
t ;he following percentage conductivities, based on the annealed copper
B idard.
Per cent.,
conductivity
J lealed copper 98.

I dium-hard drawn, above 0.325 in 97.7

] dium-hard drawn, below 0.325 in 96.7
J rd-drawn, above 0.325 in 97.2
] rd-drawn, below 0.325 in 96 .

'
e density of all these grades of wire is taken as the same, or 8.89 at 20
I ;. cent.
!4. Temperature coefficient of expansion. The temperature
.efficient of linear expansion of copper is approximately 0.000017 per
'?. cent. The values given in the "Tables Annuelles de Constantes et
inn6s Numfiriques," for 1910, are as follows (p. 44 and p. 45): Between
190 deg. and 17 deg. cent., 0.00001418; between 17 deg. and lOOdeg. cent.,
0001636; and by St6phan's determinations (1910),
Z( = ;„[l+0.00001607<+0.00000000403t2i (5)
Matthiessen's mean coefficient* between deg. and 100 deg. cent., was
iKKX)1666 and Fizeau found the value* at 40 deg. cent, to be 0.00001678.
' computation from St^phan's results the mean coefficient between
g. and 100 deg. cent, is 0.0000165. The mean of these four results is
)000166 per deg. cent. The corresponding value in the fahrenheit scale
0.00000922 per deg.
'65. Concentric strand, or cable, is a conductor made up of a straight
;ntral wire (or group of wires) surrounded by helical layers of bare wires
.r groups of wires), the alternate layers having a twist in opposite direc-
•)ns. The term "concentric-lay" applies when the strands are composed
•single bare wires; the term "rope-lay" applies when the strands are made
) of groups of wires, each group in concentric lay. All the individual
r.'inds are of the same size. If there are n layers over the core of a con-
ntric-lay cable, not counting the core as a layer, the total number of
<rands or wires will be
N==3n(,n + 1) + 1 (6)
The diameter of such a cable is the diameter of the circumscribing
rcle, or
D = d(.2n + 1) (7)
here d is the diameter of any strand or individual wire. In a rope-lay
ible, such as some forms of extra flexible cable, where instead of individual
ngle wires there are groups of wires, each group consisting of a concentric-lay
ible, the total number of wires N
in the entire cable will be that given
/ Eq. 6 for concentric-lay cable multiplied by the number of wires
each component group. Thus a rope-lay cable comprising 1 layer,
ith 7 wires in each group, would have 7X7 = 49 wires, and is sometimes
illed a 7X7 rope. Such an expression as a 19X7 rope strand means 19
rands, each composed of 7 wires. A 7X7 rope strand is not economical
r large conductors and is usually confined to sizes like No. 4 A.W.G. or
nailer. For large sizes a 19X7 or 37X7 rope strand is moi'e compact and
•
esents a smoother exterior.
• "Smithsonian Physical Tables;" Washington, D. C, 1920; 7th rev. ed.,
218.

247
 Sec. 4-56 PROPERTIES OF MATERIALS
The number of circular toils in a cable composed of A'^ wirea is
C.M. = Ndi
where d diameter of each wire in mils (thousandths of an inch).
is tlie
The equivalent solid conductor is one having the same nuniber
circular mils, or its diameter is

It is not equal to the normal cross-section of the cable, because in the 1;

case the strands are cut at a slight angle (due to their pitch) and such
section is therefore larger than the true section, equal to the sum of the norii
sections of all the strands, each tak^n normal to its own axis.
The ratio of the diameter of concentric strand to the diameter ,

equivalent solid conductor is given by {

D' Vn 3n2 +371 + 1 '''

Substitution in this formula from n = to n = 8, gives the following vali

of the ratio.

I
 PROPERTIES OF MATERIALS Sec. 4-58

B idard pitch used by all cable manufacturers. Also see "Electrical Wires
a Cables," Amer. Steel & Wire Co., 1910, pp. 27 to 35; and Se*. 24, Par.
9 4.
'8. Increase in mass and resistance due to stranding. The Bureau
c Standards has shown in Circular 31 (3rd Edition, 1914, p. 71) that the
I cent, increase of resistance of a cable with all the wires perfectly insulated
I n one another, over the resistance of the
"equivalent solid rod," is exactly
6.al to the per cent, decrease of resistance of a cable in which each wire
j-kes perfect contact with a neighboring wire at all points of its surface.
''
at is, if R, is the resistance of the equivalent solid rod or wire, Ri\s the re-
tance of the cable with perfectly insulated wires and Rt is the resistance of
1 cable in which all the wires make perfect contact with their neighbors,
» niJi
= \{Ri Ri).+ In general, 7?i>/fj>if J. The resistance of a cable is
Jierally somewhat less than Ri, which is shown by the fact that the actual
( istance of a cable increases slightly with age, probably due to the formation
loxide on the contact surfaces.

59. Copper cable tables. The table in Par. 62 gives the properties of
"e concentric-lay copper cables, based on the International annealed
pper standard (see Par. 41). The column headed "Diameter of Wires"
i 3 calculated in each case from the total cross-section. The values given
^- "ohms per 1,000 ft." and "lb. per 1,000 ft." are 2 per cent, greater
Un for a solidrod of cross-section equal to the total cross-section of the
ires of the cable. This increment of 2 per cent, means that the values are
r.-rect for cableshaving a pitch of 15.7. If the pitch is different, the resist-
and the mass may be calculated by multiplying the values in the table
il'ce
the factor

l)rexample, if the pitch is 12, the resistance and the mass given in the table
[ould be increased 1.4 per cent.; if the pitch is 30, the values should be de-
I
erased 1.5 per cent. Also see Sec. 24, Par. 9403.
60. Hemp-centre cables. If the core of a concentric strand is replaced
hemp, the characteristics of the cable are altered in several respects. The
'

ameter of the cable, for a given cross-section, is greater than the diameter
r an all-metal cable; the flexibility is slightly greater, for the same size,
[:ing more marked in the case of 7 wires than a greater number; and the skin
liect, for equal sizes, is slightly diminished. The tensile strength of a
;
;mp-centre cable would be computed on the basis of the cross-section of
etal, disregarding the hemp. Such cables are not in general manufactured
standard sizes, but made up to order. See article by D. B. Rushmore in
•neral Electric Review, June, 1912, discussing objections to cables of this
•pe.

61. Weight of hemp-centre, concentric-lay, copper cable*

Made of six wires around a hemp centre
(The American Brass Co.)
li
; Size of
 Sec. 4-62 PROPERTIES OF MATERIALS

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ICMO!
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mmm coco t~r~oo 0)00
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 PROPERTIES OF MATERIALS Sec. 4-62

lis ooi^t» ocom io<«<T)i

t-.co
coco
»to
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coo
MM 00«'*
-Hi-li-H
5 o8 a

10050 t-rtO OCOO -^tO '-'to Oit- M f-i "5

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050000 wt^to O °3

05 05 05 05 05

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 Sec. 4-63 PROPERTIES OF MATERIALS

63. Effect of impurities on the conductivity of copper. It i.-

known that the conductivity of copper is highly sensitive to slight impuriti •

A series of progressive tests on the effect of the presence of very small qua,,
ties of foreign elements, with respect to electrical conductivity, was made r

Mr. Lawrence Addicks. In order to obtain a comparative figure, '.

Addicks divided the percentage decrease of conductivity by the percentage
impurity added, and obtained the results given in Par. 64, which are strio
true only for an infinitely small lowering of conductivity. The factor isH i

to bear a general relation to the periodic arrangement, becoming smaller Vi

increasing atomic weight within any one group, though there is no evid
relation between one group and another. This factor is of use when exan
ing the analysis of a copper which shows low conductivity, as a means!
indicating the probable cause of the trouble. Commercial copper wli
examined under a microscope reveals a structure made up of grains of p:
copper enclosed in matrices of impurities, thus forming a complicated chaii '

two substances. By adding certain impurities the conductivity of i

impure portion of the chain may be increased without changing that of

'

copper itself, thus showing an increase in the total conductivity of the cha
Relation between percentage impurity and percentage chani
I 64.
in conductivity
(Lawrence Addicks, Proc. A. I. M. E., Vol. XXXVI, p. 18, 1906)
 PROPERTIES OF MATERIALS Sec. 4-66

relationship between tensile strength and conductivity of copper

This shows, among other tilings, that the properties of copper, after it
n oeon through a cycle of hard drawing and annealing, are not completely
r«3red, but nearly so.
'
oncentric strand or
r n should have a total C4000
•ih equal at least to 90
,
at. of the strength of
II. ninponent strands. The
Hcnate strength, however,
i^aeoretically a function of
tj' pitch, and in addition
ti internal stresses in a
C le under load are very
C,iplex, so that a factor of
^jer cent, is approximate.
copper ranges in
(iast
tjsile strength from 20,000
1 to 30,000 lb. per sq. in.
ji! has a crushing strength

( bout 40,000 lb. per sq. in.

The tinning: process,

f )lied to copper wires
'";ch are intended to re-
; ij.e any kind of insulation
f
4 taining rubber as an in-
r /dient, removes some of
I
f temper of hard-drawn
I
e and hence impairs its
ttsile strength. Also see
Miles of tensile strength in
[.fi.T.M. specifications for
'

f iper wire, current issue of

\ ear Book."
 Sec. 4-69 PROPERTIES OF MATERIALS

69. Table of breaking loads of copper wire

(Based on tensile requirements of the American Society for Testing Materia

f
 PROPERTIES OF MATERIALS Sec. 4-71

u being the difference between ab and ae.

ST stress, The test length was
,3. n.and the elongation at rupture was 1.3 per cent. The true elastic
li.t was 27,000 lb. per sq. in. or 44 per cent, (rather low, below average)
©he ultimate tensile strength; Johnson elastic limit, 44,0001b. per sq. in.
o 2 per cent, of the ultimate; ultimate tensile strength, 61,400 lb. per sq.
it modulus (Young's) of elasticity, 17,500,000.
series of stress-strain curves on annealed, half-hard, and hard copper
'

ws was published in 1904 by Mr. F. O. Blackwell in a paper entitled "Con-

dtors for Long Spans," Trans. International Elec. Cong., St. Louis, 1904,
\ II. p. 331.
!ig. 6 shows a stress-strain diagram, from Mr. Blackwell's paper, for
bip-centre, hard-drawn, concentric-lay, copper cable composed of six
iS-in. strands. The curve A is for the cable, and B for one of the strands.
1 elastic behavior is notably different from that of solid wire, since the
;

a lal elongation of a new or previously unstressed cable appears to comprise

t components, one due to tightening or readjustment of the outer strands
8 and the core, and the other to actual stretching of the material.
 Sec. 4-72 PROPERTIES OF MATERIALS

72. Fatigue under load. Under long-sustained loads approaching ;

normal tensile strength, copper has somewhat less strength than the rail
obtained by ordinary test. Mr. F. O. Blackwell, in the paper referred tt^
Par. 70, found that a 0.168-in. hard-drawn wire stressed to 54,000 lb. 1
sq. in., stretched continuously, and broke in 7 days, 8 hours; pieces of 1

same wire afterward broke at 61,000 lb. in the testing machine. He condul
that a hard-drawn wire would stand continuously a stress of about 80
cent, of its normal tensile strength.
73. Young's modulus of elasticity for annealed and hard coppe t

not a very definitely known quantity and the values given for it fiuctu!
over a considerable range. This maybe accounted for, inthecaseof anneal
copper, by the lack of any very definite elastic limit, and the fact that j

initial stress-strain diagram departs at a very early stage from Hooke's L

and as soon as a slight load has been applied the properties commencej
change. In all cases, the final value of the modulus, after stressing i

almost invariably greater than the initial modulus. The following vah
represent the extreme range, and a probable average, drawn from sevtl
authorities,* expressed in in-lb. measure.

I State Range
 PROPERTIES OF MATERIALS Sec. 4-78

inr ill be found in the current issue of the "Year Book." They are too
!Xt, led for reproduction.
7 Standard sections for copper trolley wire are prescribed in the
itions of the A. S. T. M. (see "A. S. T. M. Standards") and are shown
7 and 8. These sections are known respectively as "grooved" and
eight." Copper trolley wires are always hard drawn, in order to
uaximum hardness and strength.
U e.3«---
—O.MS —)

133,200 Cii.Mlls. 168^00 Cir.Mil9. 211,800 Cii:.iliU.

Fig. 7.
—"American Standard" grooved trolley-wire sections.

K 0:362 — •»J
U 0.460 *i

133,200 Cir.Mils. 168,100 Cir.MUs. 211,000 Cli.UllB.

Fig. 8. — Cross-sections of figure-eight trolley wires.

ALUMINUM
t. General properties. Aluminum ranks second to copper in its
nDrtance as an electrical conductor, and in some respects is superior to
( )er. It is one of the softest and most malleable of metals, and is nearly
15.15, or silver-white, in color. The density depends to some extent upon the
ihical state, an average value being 2.7. Aluminum melts at 658 deg.
*.* (1,216 deg. fahr.). Molten aluminum is very fluid and care should be
i:n not to overheat it. In the molten state it readily absorbs gases, but
I a cooling these occluded gases are partially liberated, giving rise to blow
i,s in castings. Aluminum boils at 1,800 deg. cent. (3,272 deg. fahr.).t
ike copper, aluminum can be cast, forged, rolled or drawn, and also be-
\('s hardened by working, although it requires less annealing than copper
i'rass. By cold rolling and drawing it can be given considerable rigidity
• temper, with accompanying increase in tensile strength. The general
ht of cold or hard drawing upon aluminum is quite similar to the effect
,'n copper.
luminum when exposed to dry air is not affected, but in the presence of
st air it tarnishes rapidly, the coating consisting of oxide of aluminum
[lOa) or alumina. This coating is protective, so that the corrosion is not
ijressive; the oxide is also very refractory, which accounts for the difii-
y of soldering aluminum. Hydrochloric acid and alkaline solutions
lily attack aluminum; concentrated sulphuric acid, hot dilute sulphuric
I, and hot nitric acid aflfect it to a less extent. Sulphur and sulphur
Circular No. 7, "Pyrometer Testing and Heat Measurements;" Bureau
Standards, 1910; p. 4.
Fulton, C. H. "Principles of Metallurgy;" McGraw-Hill Book Co.,
, New York, 1910; p. 74.
267
 Sec. 4-80 PROPERTIES OF MATERIALS

dioxide do not affect it at ordinary temperatures; it is not attacked byit

Ehuretted hydrogen, or carbonic acid. It resists the action of sea w)
etter than copper, provided there is no electrolysis, but it is a highly i

tropositive metal. The presence of impurities in considerable quarilj

lowers the resistance to corrosion in marked degree. There is also dai
from electrolytic corrosion if aluminum is alloyed with an electronegs
'

metal.
The electrical conductivity of aluminum, like that of copper, depends oj
degree of chemical purity. The conductivity of hard-drawn aluminuj
about 2 per cent, less than that of soft or annealed aluminum. The tei
properties, in like manner, depend greatly upon the physical state, h
much improved by cold rolling and drawing.
The alloys of aluminum are very numerous. The so-called light alii
containing but small percentages of other metals, are light, hard and strj
but do not resist corrosion from galvanic action. The heavy alloys, or ah
num-bronzes, with but 2 per cent, to 10 per cent, of aluminum, and res'
tively 98 per cent, to 90 per cent, of copper, have high tensile strength \

strongly resist corrosion in air or sea water. A very small proportio

aluminum, about 0.01 per cent., added to iron, steel or brass in castiuf
moves the oxide and prevents blow holes.
) The tinning process, which is applied to copper wires intended to rec
.j

an insulation of rubber compound (sulphur being present), is unneces.

in the case of aluminum.
Aluminum possesses an insulating film which ordinarily has a dielei
strength of about 0.5 volt, and by electrolytic action this value cai
somewhat increased.
80. Commercial grades of aluminum. The impurities most c|
monly found in aluminum are silicon and iron. Silicon in aluminum ezigtl
two forms, one seemingly combined with aluminum as combined oai|
exists in pig iron, and the other as an allotropic graphitoidal modificaiL
Small quantities of copper, sodium, carbon and occluded gases i:-
found in aluminum. The Aluminum Company of America classifii
num commercially in three grades, * as follows:
Extra-pure aluminum, No. 1 grade or so-called pure aluminum, and N2
grade for castings, or structural shapes. The average composition in(
follows

No. 1 J No. I

]
(per cent.' (per cei*

Aluminum. 99.55
Silicon 0.30
Iron 0.15
Pure aluminum (No.l grade or better) is necessary to secure high eleKr-
conductivity, extreme malleability, ductility and maximum rosi.-t
corrosion. For other purposes small amounts of copper, nickel, t
manganese, chromium, titanium, zinc or tin may be advantageously :: .
.

aluminum to produce hardness, rigidity and strength. These metuis »

alloyed with aluminum do not diminish its resistance to corrosion so muclj
silicon or iron. Also see Circular No. 76, "Aluminum and Its Light AUoj,
Bureau of Standards, 1919.
81. Typical analysis. The following analyses of aluminum are typi
Aluminum
Co. of Richar
Amer.f (per cer
(per cent.)

Aluminum. 99.57
Silicon 0.29
Iron 0.14 II IH
Copper
jpe 02
Lea'a. 0.01

* "TProperties of Aluminum;" Aluminum Co. of America, Pittsburgh, I

1909; p. 7.
t Bureau of Standards, Circular No. 31, Third Ed., Oct. 1, 1914; p. 14.

258
 PROPERTIES OF MATERIALS SeC. 4-82

( Methods of working aluminum are described at some length in a

pu! ;ation issued by the Aluminum Company of America. * Sections or
th'< 3 similar to thosein which steel isroHedcanbe made of aluminum andita
II sheets can be rolled commercially as thin as No. 40 A. W.G. Aluminum
-,) be stamped, drawn, beaten, spun, forged, extruded and machined,
-uitable methods, tools, dies and lubricants. Aluminum can be drawn
int i great variety of forms; except for slight differences, the methods used
in iwing copper wire are applicable. Like most other metals it is hardened
an trengthened by working, and softened again by annealing. The anneal-
iiperatures depend on the composition of the metal, but probably lie
a the limits of 343 deg. cent. (650 deg. fahr.) and 482 deg. cent. (900
[, lit.). Also see Circular No. 76, Bureau of Standards.
\'aning or pickling is done by dipping first in benzene and then in hot
08 ic alkali (such as caustic soda or caustic potash), in nearly saturated
so ion. Upon removal the metal should be washed in cold running water
ar next immersed in a hot solution of strong nitric acid, to neutralize the
ca':ic. Finally it should be washed in hot running water and then quickly
dr'l in hot air; small articles should be placed in sawdust.
'le ordinary low-temperature solders, containing lead, are not suitable
fo oldering aluminum, since the surface oxide will not dissolve under the
ac^in of a flux or salt as in the case of copper, tin, or zinc. The temperature
at hich solder alloys with aluminum is approximately 349 deg. cent. (660
d( fahr.). It is first necessary to tin the surface of aluminum by heating it
!d hot flame (blow-torch) and pour over it melted tin or half-and-half solder,
bi Richards solder is the best; meanwhile the solder should be rubbed into
tl iurface with a fine metal brush. In this way the oxide is melted and the
BC?r alloyed with the aluminum.
is After this tinning operation is com-
pl.^d, the usual soldered joint may be made. Joints in bare line conductors
Biiisually made with sleeves or with clamps (see Sec. 11). Clamps are
ai used for joining aluminum conductors to copper or steel conductors;
Belted bushingst are employed, of suitable metal to prevent electrolytic
ciosion in the joint. Also see Circular No. 78, "Solders for Aluminum,"
Beau of Standards, 1919.
luminum rod can be readily butt-welded by merely pressing the ends
t< ther in the flame of a blowlamp. No flux is necessary for this process.
r^ also possible to weld aluminum by the autogenous process and this
rfhod is generally adopted for jointing plate or sheet.
:is easy to obtain quite as good a machined surface with aluminum as any
;

ofjr metal. Lubricants should be used only for drilling and screwing and
t, 1 only paraffin. Filing should be done with a single cut file as cross-cut
fif are readily clogged. Aluminum will take and retain a very high polish,
f'.y equal to that of silver.

r3. The value for the density of commercial hard-drawn

Density.
»-ninum, accepted by the Bureau of Standards, t is 2.70. The Aluminum
fapany of America gives 2.56 for pure east aluminum, 2.66 for annealed
Ti and sheets, and 2.68 for unannealed wire and sheets. The British
f minum Company, Ltd., gives 2.56 to 2.60 for castings, and 2.71 for rolled
:fdrawn aluminum. The Smithsonian Physical Tables (5th rev. ed., p.
? give 2.56 to 2.58 for castings and 2.65 to 2.80 for wrought aluminum.
h Eneyclopsedia Britannica (ed. of 1910, Vol. I, p. 771) gives 2.583 for cast-
h and 2.688 for rolled aluminum at 4 deg. cent. Mr. H. W. Buck§ gives
!^ for aluminum wire.
t.^he best average value from the foregoing authorities seems to be 2.57 for
ftings and 2.69 for sheets or wire. The latter value is in close agreement,
1
engineering purposes, with the value 2.70 used by the Bureau of Stan-
|ds and taken as the basis of the aluminum wire tables in this section (Par.
A density of 2.70 g. per cu. cm. corresponds to 0.09755 lb. per cu. in.
.

li. Resistivity. Much less has been published about the effect of im-
"ities on the conductivity of aluminum than in the case of copper. The
* "Methods of Working Aluminum;" Aluminum Co. of America, Pitts-
rgh, Pa., 1909.
I "Instructions for Installation and Maintenance of Aluminum Electrical
nductors;" Aluminum Company of America.
t Circular No. 31; "Copper Wire Tables"; 1914; Third Edition, p. 14.
5 Buck, H. W. "The Use of Aluminum as an Electrical Conductor;"
ans. Int. Elec. Congress, St. Louis, 1904; Vol. II, p. 313.

259
Sec. 4-85 PROPERTIES OF MATERIALS
ordinary percentage of impurities in commercially pure aluminum, '

grade (see Par. 80), is 0.45 per cent. In terms of the British standiu
hard-drawn copper at 60 deg. fahr. (16.6 deg. cent.) Mr. Burkewood
bourn stated* that a (volume) conductivity of 60 per cent, correspoi,
0.71 per cent, of impurities, and a conductivity of 61.7 per cent, correal
to 0.5 per cent, of impurities.
The Aluminum Company of America statesf that the electrical (vol
conductivity of pure (No. 1 grade) aluminum is about 62 per cent, in the
thiessen standard scale. The British Aluminum Company, Ltd., g
(June, 1914) the following values of resistivity, expressed in microhm-cm.

Hard
AnnealedJ
> 1 I

^raw.

Volume resistivity, microhm-cm. at 60 deg. fahr. . . 2. 770 2.87.

Volume resistivity, microhm-cm. at 32 deg. fahr ... 2.610 2.7(1

The Bureau of Standards! gives the following average values of resistix

for commercial hard-drawn aluminum.
Mass resistivity, ohms (meter, gram), at 20 deg. cent 0.0'
Mass resistivity, ohms (mile, pound) at 20 deg. cent
, 436 .

Mass per cent, conductivity 200 .

Volume resistivity, mierohm-cm., at 20 deg. cent 2.8:

Volume resistivity, microhm-in., at 20 deg. cent 1.1
Volume per cent, conductivity 61.0
Density, g. per cu. cm 2 7(.

Density, lb. per cu. in 0.0!

These values given by the Bureau of Standards are the basis of the alui
num wire tables in Par. 87. Since aluminum is very rarely used as
electrical conductor in the softstate, the foregoing values given by the Burt
of Standards, for hard-drawn wire, have the most commercial significan
Annealed aluminum, however, is used abroad for the conductors of und
ground cables.
86. Temperature coefficient of resistance. On the authority of i

British Aluminum Company, Ltd., the temperature coefficient of resistai

of aluminum, for constant mass, varies from 0.0032 to 0.0040 per d
cent, and from 0.0018 to 0.0022 per deg. fahr.
A determination made in the laboratory of the Westinghouse Electric a
Manufacturing Company, under the direction of Prof. Charles F. Scott, gs
as the average coefficient laetween deg. and 50 deg. cent., the value 0.002
per deg. cent. in the fahrenheit scale the equivalent of this value is 0.002
;

per deg. Prof Scott's determination is quoted by the Aluminum Compa '

of America.
The Bureau of Standards gives 0.0039 per deg. cent, at 20 deg. ce: •

(Circular No. 76, 1919, p. 17.) ,'

86. Aluminum wire tables. The complete tables for aluminum w.(l
given in Par. 87 were taken from circular No. 31, Third Edition, issued f.

the Bureau of Standards, and are based on a volume conductivity, in terms

the annealed copper standard, equal to 61.0 per cent.
Aluminum wire is practically never used in single strands for overhe
construction, but the tables are very useful in computing the resistance
concentric strand. In commercial practice the aluminum delivered imd
contract varies in conductivity from 60 per cent, to 62 per cent, of the forrr
Matthiessen standard, many contracts being placed at 61 per cent.

• Welbourn, B. "Insulated and Bare Copper and Aluminum Cahlt,-. ;

the Transmission of Electrical Energy, with Special Reference to Mini

Work;" Trans. (British) Institution of Mining Engineers; 1913. Giv
bibliography on aluminum wire.
t "Properties of Aluminum;" Aluminum Company of America, Pittsburgi
Pa., 1909: p. 27.
t Circular No. 31, "Copper Wire Tables;" 1914; Third Edition, p. 14.

260
 PROPERTIES OF MATERIALS Sec. 4-87

Table of hard-drawn aluminum wire at 20 deg. cent.

English Units: American Wire Gage (B. & S.)

Cross-section
Ohms Pounds Pounds per
per 1000 per 1000
Circular Square feet feet
ohm
mils inches

[)460. I
212000. 0.166 0.0804 195. 2420.
)410. !
168000. 0.132 0.101 154. 1520.
)365. 133000. 0.105 0.128 122. 957.
1

3325. 106000. 0.0829 0.161 97.0 602.

83700. 0.0657 0.203 76.9 379.

66400. 0.0521 0.256 61.0 238.
52600. 0.0413 0.323 48.4 150.
41700. 0.0328 0.408 38.4 94.2
33100. 0.0260 0.514 30.4 59.2

26300. 0.0206 0.648 24.1 37.2

20800. 0.0164 0.817 19.1 23.4
16500. 0.0130 1.03 15.2 14.7
13100. 0.0103 1.30 12.0 9.26
10400. 0.00815 1.64 9.55 5.83

8230. 0.00647 2.07 7.57 3.66

6530 0.00513 2.61 6.00 2.30
5180. 0.00407 3.29 4.76 1.45
4110. 0.00323 4.14 3.78 0.911
3260. 0.00256 5.22 2.99 0.573

2580. 0.00203 6.59 2.37 0.360

2050. 0.00161 8.31 1.88 0.227
1620. 0.00128 10.6 1.49 0.143
1290. 0.00101 13.2 1.18 0.0897
1020. 0.000802 16.7 0.939 0.0564
810. 0.000636 21.0 0.745 0.0355
642. 0.000505 26.5 0.591 0.0223
509. 0.000400 33.4 0.468 0.0140
404. 0.000317 42.1 0.371 0.00882
320. 0.000252 53.1 0.295 0.00555

254. 0.0002()0 67.0 0.234 0.00349

202. 0.000158 84.4 0.185 .00219
160. 0.000126 106. 0.147 0.00138
127. 0.0000995 134. 0.117 0.000868
101. 0.0000789 169. 0.0924 0.000546

79.7 0.0000626 213. 0.0733 0.000343

63.2 0.0000496 269. 0.0581 0.000216
50.1 0.0000394 339. 0.0461 0.000136
39.8 0.0000312 428. 0.0365 0.0000854
31.5 0.0000248 540. 0.0290 0.0000537

25.0 0.0000196 681. 0.0230 0.0000338

19.8 0.0000156 858. 0.0182 0.0000212
15.7 0.0000123 1080. 0.0145 0.0000134
12.5 0.00000979 1360. 0.0115 0.00000840
9.9 0.00000777 1720. 0.0091 0. 00000528

88.Aluminum cable tables are given in Par. 89. The values of resis-
mce and weight per 1,000 ft. are 2 per cent, greater than for a soUd rod equal
) the combined cross-sections of the wires of the cable; this increment cor-
ssponds to a pitch of 15.7. The component wires are assumed to have the
(ime value of resistivity as the hard-drawn aluminum in Par. 87, temperature
ifferences being allowed for. See Par. 6S to 69 on the general properties of
oncentric strands.

261
 Sec. 4-88a PROPERTIES OF MATERIALS

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262
 PROPERTIES OF MATERIALS Sec. 4-89

9. Table of bare concentxic-lay cables of hard-drawn aluminum

(English Units)
 Sec. 4-93 PROPERTIES OF MATERIALS
Castings 12,000 to 14,C
Sheets 24,000 to 40,C
Bars 28,000 to 40,C
Wire 25,000 to 55,C'
The tensile strength of aluminum wire, in the sizes used commercial
ranges from 14,000 to 33,000 lb. per sq. in., depending upon the size of t
wire and upon its mechanical and heat treatments. Hard-drawn alumim
wire, in the sizes usually employed in the construction of concentric cabl
ranges from about 23,000 to 27,000 lb. per sq. in. It is possible to produ
hard-drawn wire of greater strength than this, but it is likely to be "shor
or brittle and is not satisfactory commercially.
The British Aluminum Company, Ltd., gives the following table showi
the strength of progressive sizes of hard-drawn wire, which is practical
the same as the range stated by the Aluminum Company of America.

Tensile Tensile
S.W.G. Diam. strength
S.W.G. Diam. strengtli
No. (in.) No. (in.)
(lb. per sq. in.) (lb. per sq. ii

\ 0.500
0.400
22,000
23,000
10
12
0.128
0.104
25,000
26,000
0.324 23,000 14 0.080 27,000
0.276 23,000 16 0.064 28,000
0.232 24,000 18 0.048 29,000
0.192 24,000 20 0.036 32,000
0.160 25,000

Soft or annealed aluminum is never used in overhead spans, but is used »

some extent for underground cables.

Concentric cables have a breaking strength somewhat less the sum of tl
breaking strengths of the strands, not usually exceeding 85 to 90 per cen
of the latter. Theoretically the strength of concentric-lay cable is a functic
of the pitch.
93. Elastic limit. Under the definition of Hooke's law, aluminui
has no definite elastic limit, because it stretches under load, if the load is hel
constant for any appreciable length of time. See stress-strain diagrams i
Figs. 9 and 10. Taking as the definition of elastic limit, the maximum loa
under which the material will not continue to stretch, it can be stated the
the elastic limit of hard-draw
24000
84000
KOOO
22000
1

——
I I

—
——
r—i
— ————— —
I I I
1

^^:^-.i^,^s=—.^. — — —.
r I I I I
1

iOOOol I I
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 PROPERTIES OF MATERIALS SeC. 4-95

cate the number of minutes the load was held at each of several points.
ii-

Ts specimen broke at 23,900 lb. per sq. in., with an elongation of 1.25 per

5. Elongation at rupture. The total elongation at rupture, for hard-

d svn wire in commercial sizes, ranges from about 2 to 4 per cent.

6. Youngr'B modulus of elasticity in tension ranges from 8,000,000

t.2,000,000, with an average of 9,000,000 to 10,000,000. F. O. Blackwell
f>s the
modulus for concentric cables as 7,500,000 (Trans. Int. Elec. Cong.,
K Louis, 1904, Vol. II, pp. 331-347).

Specific heat of aluminum at

'7. deg. cent, is 0.2089 and at 100 deg.
0.2226; the mean specific heat between 16 and 100 deg. cent, is 0.2122
C 1. 18
(i rev. ed., "Smithsonian Phys. Tables," p. 228).

'8. Thermal conductivity of aluminum at 18 deg. cent, is 0.504 gram-

i 3rie (cm-cube) per deg. cent, per sec. (Circular No. 76, Bureau of Stand-
j.s, 1919).

•9. Aluminum bars are used in power-plant switchboard connections

1 bus bars, and for carrying very large currents in electrolytic work. Since
h bars are generally designed to have a stated carrying capacity limited
I a stated temperature rise, the comparative cross-sections of aluminum
. i copper are not required in practice to be in inverse ratio to the respective
iductivities, because of the difference in radiating surface.

COPPEK-CLAD STEEL
llOO. Compoundor bi-metallic wires composed of copper-covered
n or steel have been manufactured by a number of different methods, and
re first attempted many years ago. Aluminum-covered steel has also
en tried, on an experimental scale. The general object sought in the
inufacture of such wires is the combination of the high conductivity of
pper or aluminum with the high strength and toughness of iron or steel.
jie resulting conductor is obviously a compromise between copper (or
.iminum) and iron, being inferior as a whole to the former and superior to
e latter,

101. Union between the metals. In the early attempts to produce

•metalUc wires, the two metals were not welded, but merely in physical
ntact. Difficulties were sometimes experienced from electrolytic corrosion
the iron, more particularly at points where both metals were loosely
posed, as might occur at joints. No
great success attended the use of
ch wires until modern processes were developed for effecting a weld or
olecular union between the metals, to give greater stability and strength
the copper coating and prevent electrolysis.

IM. Manufacturing process. Copper-clad steel wire has been manu-

ictured, in this country, by three different methods, known as the Monnot
ocess (formerly used by the Duplex Metals Co.), the Griffith process
polonial Steel Co.) and the Roth process (Copper Clad Steel Co.), the first
which is not present in commercial use.
I The Griffith process consists briefly of coating a mild steel billet with
opper by electrolytic deposition (Sec. 19), then inserting the copper-coated
jllet in a copper tube, closing the ends, and heating the compound billet
ireparatory to rolling; it is then hot-rolled to rods, and cold-drawn to wire.
The Roth process consists of coating a mild steel billet with a special flux,
lacing it in an upright mold closed at the bottom, heating the billet and
lold to_ yellow heat and then casting molten copper around the billet,
fter which it is hot-rolled to rods and cold drawn to wire.
103. Commercial grades of copper-cladsteel wire. It has become
ustomary commercial practice to rate copper-clad steel wire in terms of the
itio of its volume conductivity to copper. Thus one manufacturer makes
wo grades of wire, having respectively 30 per cent, and 40 per cent, con-
uctivity ratio to copper; another manufacturer has standardized a 30-per
ent. wire. These ratios are usually average ratios, and in practice certain
•jrferance limits must be recognized, above and below the average: or else
he rated conductivity can be specified as the absolute acceptable minimum.

Sft6
Sec. 4-104 PROPERTIES OF MATERIALS

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 PROPERTIES OF MATERIALS Sec. 4-105

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 Sec. 4-106 PROPERTIES OF MATERIALS

106. Properties of copper-clad steel wire depend upon the relati

proportions of copper and steel, the constituents of the latter, the mechaiiii
treatment and the heat treatment. The cold-drawing process hardens
steel core to an unpermissible degree and it becomes necessary at int< r

to anneal it before proceeding further with the drawing process. The c i

mercial grades are obtainable either dead soft (annealed) or hard drawn,
desired. The properties of the commercial grades of wire are given
Par. 104 and 106, taken from the manufacturers' tables. In drawing speci
cations it is customary to fix tolerance limits, or else minimum (or maximun
limits. For technical articles dealing with the properties of copper-cli
steel wire, see the following: Electrical World, Vol. LII, pp. 701 and 81
Scientific American, Vol. XCVIII, p. 347; Iron Age, Vol. LXXVII, p. S:
Journal of Industrial and Engineering Chemistry, Sept., 1909; Electric
World, Dec. 22, 1910, Dec. 29, 1910 and Jan. 12, 1911; Telephone Enginee
Oct., 1910 to July, 1911, inclusive. Proceedings A. S. T. M., Vol. X, pj
280-294; Telephone Engineer, Dec, 1911 to Mar., 1912, inclusive. I

107. Temperature coefficient of resistance of the 40 per cent, grade i i

copper-clad steel is approximately 0.0045 per deg. cent., from and at »eri
The coefficient ranges from about 0.004 to 0.005, depending apparently "upc;
r the constituents of the wire and its physical condition. "j

108. Permeability of steel core is about 70, for small magnetizing fore<
at 800 cycles per sec; at power frequencies it is from 100 to 125. Tb
maximum permeability will be from 600 to 800 at roughly 5.000 gausse
The measured hysteresis loss in the core of No. 1 A.W.G. wire, at 10,00
gausses (max.), was 15,000 ergs per cu. cm. per cycle. The resistivity of th
steel will range from 12 to 13 microhm-cm. at 20 deg. cent., approximatel;
For method of calculating internal inductance see Electrical World, 1910, Vo
LVI, p. 1521.
109. Coefficient of linear expansion of the 40 per cent, grade of coppei
clad steel is 0.0000129 per deg. cent.
110. The density or specific gravity of copper-clad steel depends on th'
relative proportions of copper and steel. The 40 per cent, grade has a det
sity of 8.2.
111. Tensile strength of copper-clad steel depends in great measur
upon the kind and condition of steel in the core. The strength of the whol
wire will range as high as 80,000 to 100,000 lb. per sq. in., hard-drawn. Th
typical stress-strain diagram is similar to the curve for hard-drawn coppe
in Fig. 5. The breaking loads are given in the tables. Par. 104 and 101
112. Young's modulus ranges from 19X10« to 21X10* lb. per sq. i^
for hard-drawn wire and 16 X 10« to 20 X 10« for concentric cable. !

113. Specifications for copper-clad steel wire will be found in ih

"Manual" of the Railway Signal Division, American Railway Association
Also see "Handbook of Overhead Line Construction," N. E. L. A.
IRON AMD STEEL
114. General properties of iron and steel are covered in detail in anothe:
portion of this section, under "Structural Materials." The so-called iroi
wire is usually steel, containing carbon, manganese and silicon. The cffec
of these constituents on theresistivity is discussed in Par. 115. In general
those elements which increase the tensile strength of steel also increase it
resistivity; similarly, the mechanical and heat treatments which increasi
the strength, again increase the resistivity.
116. Resistivity of iron. The researches of Barrett, Brown and Had
field (Scient. Trans. Royal Dublin Soc, VII, Ser. 2, part 4, 1900; Jour
Inst. Elec. Eng., 31, p. 674, 1902) on the electrical and magnetic propertiei
of iron and iron alloys are especially important. They found that SwedisI
charcoal iron containing 99.85 per cent, iron had a resistivity of 10.!
microhni-cm.
These investigators abo found that 1 per cent, of any element added U
pure iron increased its specific resistance by an amount approximatel;
proportional to the specific heat or inversely proportional to the atoinii
weight of the alloying element.
Yensen gives the following values for different grades of annealed iroi
(see Bulletin No. 72, Eng. Exp. Sta., Univ. of 111), in microhm-cm. at 20 deg
cent.

268
 PROPERTIES OF MATERIALS Sec. 4-116

-olytic iron melted in vacuo 9. 96

h charcoal iron remelted in vacuo 10. 30
^^ lercial grades:
edish charcoal iron cut from plate 10. 57
mdard transformer steel 11. 09
"icon (4 per cent.) steel 51.15
ipkinson tested and analyzed 35 different samples of iron (Phil. Trans,
p. i3, Part II, 1885) and found resistivities (microhm-cm.) ranging from
13 for wrought iron to 100 for cast iron.
i

io see Boudouard, O. "Electric Resistivity of Special Steels," IX, 6, No.

iCiixth Congress Int. Assoc, for Testing Materials, New York City, 1912.
116. Preece's tests on resistivity of annealed iron wire
(Munroe and Jameson)
Composition I
Ohms
(mile, lb.)
at 60
Fe Mn Si
•

deg. fahr.

S jdish charcoal iron. 99.70 0.10 0.03 Trace 0.022 0.045 4502
f »dish charcoal iron. 99.440.150.234 0.018 0.019 '0.058 4820
^mens-Martin steel. 99.6010.100.324 Trace 0.036 0.034 5308
Tt puddled iron. . . . 99.1110.100.234 0.09 0.03 0.218 5974
rtier steel, soft. . 98.74 0.150.72 0.018 0.092 0.077 6163
Tiier steel, hard. 98.20 0.441.296 0.028 0.126 0.103 7468
cast steel 97.410.62 1.584 0.06 0.074 0.051 8033

17. ESects of difierent alloying: elements upon the resistivity of

I e iron were found Barrett to be by as follows: the values given in the
tie represent the increase in resistivity (microhm-cm.) resulting from the
a ition of 1 per cent, of different alloying elements.

ungsten 2.0 Carbon. . . . 5.0

obalt 3.0 Manganese. 8.0
ickel 3.5 Silicon 13.0
hroinium 5.0 Aluminum. 14.0

..18. Temperature coefficient of resistance. The average coefficient

f.
deg. cent., between and 100 deg. cent., based on the measurements by
war and Fleming, is 0.00622. This value compares with 0.()0635 based on
asurements published by the Bureau of Standards (Scientific Paper No.
>). The mean value between and 20 deg. cent., determined by Dewar
i Fleming, is 0.00527 per deg. cent.
119. Ingot iron. The properties of American ingot iron wire are stated
the Page Steel & Wire Co. as follows, based on a series of tests of wire
nples of different sizes: Resistivity, 4,800 ohms (mile, lb.); density, 7.79;
nperature coefficient of resistance, from and at 20 deg. cent., 0.0055 per
'?. cent.; tensile strength, 55,000 lb. per sq. in.; Young's modulus, 23 X 10»;

nperature coefficient of linear expansion, from and at zero deg. cent.,

'0000116 per deg. cent. The manufacturers guarantee that the total con-
jit of carbon, manganese, silicon and other impurities is not in excess of
1.6 per cent. Also see Par. 379.
120. Resistivity and temperature coefficient of carbon steel. Barus
d Strouhal found that the temper of carbon steel affected its electrical
operties as shown below.

Temper
 Sec. 4-121 PROPERTIES OF MATERIALS

121. Kesistivity of cast iron and cast steel. The resistivity of n

iron is about ten times that of pure iron, owing to both the combined ca n
and the graphite; a value of 74.4 microhm-cm. for soft grades as
microhm-cm. for hard grades is given in the "Smithsonian Physical I

5th rev. ed., 1910, p. 263. This authority also gives 19.1 microhm r
cast steel. The chemical composition, mechanical treatment and
treatment affect the resistivity in a pronounced manner.
f 122. Ohms per mile-pound of galvanized iron (steel) wire
(Telephone and telegraph)
 PROPERTIES OF MATERIALS Sec. 4-125

1 Permeability of iron wire. The permeability of iron or soft steel

! the ordinary commercial sizes, at frequencies of 60 cycles or less, is
H)to 125; at 800 cycles, it is about 70. This applies to small magnet-
rces, such as exist within the wire due to the current flowing through
values hold for the steel core of copper-clad steel.
:,pse
Steel rails. The resistivity of common rail steel varies in considerable
1 .

let depending upon the chemical composition. Special soft steels used
>^-

r'or.iird rails have resistivities ranging from 7.9 to 9 times that of copper;
ri rails, from 11 to 13 times that of copper. In manganese steels the
rnetimes exceeds 30. The effective resistance of rails conveying alter-
i^urrents will be increased somewhat on account of skin effect and
irrents. See "Report of the Electric Railway Test Commission,"
i-Hill Book Co., Inc., New York, 1906. Also see Par. 119.
Density of pure iron is 7.86, which is fairly precise for wrought iron
,1. The National Tube Co. computes the weight of steel at 0.2833 lb.
in. (489.5 lb. per cu. ft.) and iron at 2 per cent less.

Tensile properties of iron and steel wires. The tensile proper-

tii re dependent upon the composition of the metal from which the wire is
dr 11, upon the amount of working the wire has received in the process of
ni: ifacture and upon the heat treatment. For information upon the effect
of the constituents of iron and steel on the
'. x_:
tensile properties, see "Structural Mate-
rials," in another portion of this section.
The tensile strength ranges from about
45,000 lb. per sq. in., for the purest annealed
wrought iron, up to extremely high values
for hard steel, in the neighborhood of
500,000 lb. per sq. in. Carbon, manganese
and silicon are the chief constituents which
impart strength and hardness; they also in-
crease the electrical resistiiaty. Both carbon
and manganese decrease the magnetic
permeability.
The elastic limit and the yield point
occur at about the same relative values as
in structural iron and steel; in other words,
Elongation Per cent the elastic ratio does not change.
y'
typical stress-strain dia-
. 11.—Stress-strain diagram ^'^-
^™:
H ^^"^'^ ""

"^Sf Tm Ik'^^^ '" ""^ "^'^T^^u'

liof
I
galvanized iron wire
^ f V^« at
ana broke 5o, 100 lb. per sq. while the
in.,
[! .
elastic limit was 25,000 lb. per sq. in. and
telongation was 11 per cent, in 60 in. Time was allowed for the wire
t et (see Blackwell, F. O. "Conductors for Long Spans;" Trans. Int. Elec.
Cig., St. Louis, 1904, Vol. II, pp. 331-347).
Uackwell gives Young's modulus as 24X10* lb. per sq. in. for iron wire,
?< 10« for steel wire, and 22 X 10« for iron and steel concentric cable. Also
»: Technologic Paper No. 121, "Strength and Other Properties of Wire
^)e," Bureau of Standards, 1919.
r"29. Coefficient of expansion. Blackwell gives 0.0000064 per deg. fahr.
^iron and steel wire.
-30. Specific heat of wrought iron, from 15 to 100 deg. cent., is 0.115;
1 d-drawn iron, from to 18 deg., 0.0986 and from 20 to 100 deg., 0.115
(>mithsonian Phys. Tables," 1916).
.31. Thermal conductivity of iron in gram-calories (cm-cube) per
i.r. cent, is 0.161 at 18 deg. cent., with a negative temperature coefficient
10.0008 ("Smithsonian Phys. Tables," 1920).

.
BRONZE
:138. Bronze an alloy copper and
tin, with the addition in some cases
is of
zinc and other metals.
There are numerous varieties of bronze, some
by a prefix indicating the special or distinguishing constituent, and
iignated
lers known by trade names.
133. Phosphor bronze is an alloy of copper, tin and phosphorus, contain-
I
from 2 to 6 per cent, of tin and 0.05 to 0.13 per cent, of phosphorus. Its
lume conductivity is not over 35 per cent, of that of copper. Industrial
jnzes carry zinc and lead, a.nd a larger proportion of phosphorus.
134. Silicon bronze is an alloy of copper, silicon and sodium; tin
and zino
l^fc,' 271
 Sec. 4-1.35 PROPERTIES OF MATERIALS

are also added, in some cases. J. Bucknall Smith ("Wire, Its ManufaCf
and Uses," London, 1891) gave the following values of conductivity i
tensile strength.

The grade of silicon bronze used for trolley and span wires has from 2.2
times the resistivity of copper and is from 35 to 70 per cent, stronger.

(
 PROPERTIES OF MATERIALS Sec. 4-138

ono-electric wife, on account of its high tensile properties, has been used for
Hey wire and for long spans in transmission hues and in telephone and
uraph lines.
tensile strength of hard-drawn wire ranges from G8,000 to 84,000 lb.
IP
in.
>i|. The total elongation at ruptvire is about 1 per cent, and Young's
lulus is about 18,100,000. The temperature coefficient of resistance is
i0088 per deg. fahr. and the coeflBcient of linear expansion is 00000149
r deg. fahr.

MISCELLANEOUS METALS
138. Resistivity of various metals
(Compiled from "Smithsonian Phys. Tables," 1916)

Resistivity
Temp. coef. Therm, cond.
per deg. cent., (g-cal.per cm.
Metal at deg. cent, Density
at 20 deg. cube per deg.
(microhm-cm.) per sec.)
cent.

lAotimony 38.6 0.00389 6.62 to 6.69 0.044

lAnenic 35.0 5.73
Bismuth
"E 108.0 0.00458* 9 70 to 9 90
. . oioig'
Boron 8 X 10'» 2 45 to 2 535
. .

6.22'
'
Cadmium 6.2 to 7.0 0.0042* 8.54 to 8.67

.Calcium 7.5 1.54

'Cobalt 9 8 0.00325* 8.71
;Gold 2.04 to 2.09 0.00365 19.3 0.70
Indium 8.38 7.28
Lead 18.4to 19.6 0.00387 11.34

Lithium 8.8 0.534

Magnesium 4.1 to 5.0 0.00381* 1.741 0.37
.Mercury 94.07 0.00072 13.55 0.015
Nickel 6.93 0.0062* 8.60 to 8.90 0.14
Palladium 10.21 00354 *
. 12.16 0.17

Platinum 10.96 0.00367* 21.37 0.16

Potassium 25.1 0.870
Silver 1 468
. 0.0040 10.4 to 10.6 'i!i6"
.
Thallium 17.6 0.00398 11.86
'

Tin 13.0 0.00365 7.30 0.15

> Zinc 5.75 0.0040 7.04 to 7.19 0.26

• Average values, for range from to 100 deg. cent.

139. Tungsten.* The tungsten metal of commerce, prior to the dis-
. overy of ductile tungsten, was a very hard, dark gray powder; in some
ases the metal was heated with low-carbon steel in a crucible furnace,
iroducing the alloy known as ferro-tungsten, containing 80 to 85 per cent.
• if tungsten. The higher-grade alloys are produced in the electric furnace.
'
^ast tungsten is an extremely hard brittle metal, having a specific gravity
if about 18.7. In 1910 a process was announced for the production of
luctile tungsten, by rolling, swaging or hammering a heated body of
•oherent tungsten until it becomes ductile at ordinary temperatures
Electrical World, Jan. 10, 1914, pp. 77, 78). The melting point is 3,100
t 60 deg. cent.
DuctUe tungsten is a bright, tough, steel-colored metal, which
140.
be drawn into the finest wire. The operation of wire-drawing increases
:;an
Fink stated that tungsten wire of 0.0012 in. diam. had a tensile
;he strength;
jtrength from 580,000 to 610,000 lb. per sq. in., and the density increased
rom 18. 81 before drawing, to 19.30 after drawing to 015 in. It retains
ts luster almost indefinitely. Wrought tungsten has been used as a sub-
"stitute for platinum contacts in electrical apparatus, for targets or anti-

> * Baskerville, C. " The Chemistry of Tungsten and the Evolution of the
^Tungsten Lamp;" Trans, of the New York Electrical Society; New Series,
mo. 1; Oct. 29, 1912.

I 273
Sec. 4-141 PROPERTIES OF MATERIALS

cathodes for Rontgen tubes and for the resistor in electric heater elements
of course its most extensive application is in the form of drawn-wire fila
ments for incandescent lamps (Sec. 14). The processes of making ducti'
tungsten are described in British patent No. 2759, issued in 1910; U,
patent No. 1,082,933 issued Dec. 30, 1913 to W. D. Coolidge. The rt^
tivity at 25 deg. cent, is 5 microhm-cm., annealed, and 6.2 microhm-ci,,
hard-drawn. The mean temperature coeffi-
cient of resistance between and 170 deg. 8.00
cent, is 0.0051 per deg. cent. The resist-
ance-temperature curve given
is in Fig. 12.
Coefficient of linear expansion, 20 to 100
deg. cent., 336X10-8.
141. Tantalum is a white lustrous
metal having a specific gravity of 16.6. It
is ductile and workable, and can be drawn
into fine wire, in which form it has a tensile
strength as high as 130,000 lb. per sq. in.
The resistivity at deg. cent, is 14.6 mi-
crohm-cm., and the temperature coefficient
is 0.0033 per deg. cent.

142. Wood's fusible alloy contains 4 parts of bismuth, 2 parts of Iwi

1 part oj tin and 1 part of cadmium. The melting point is 60.5 deg. centl
143. Rose's fusible alloy contains 2 parts of bismuth, 1 part of lead,
1 part of tin. The melting point is 93.8 deg. cent.
144. Composition and melting point of fusible alloys
(Perrine)
 PROPERTIES OF MATERIALS Sec. 4-147

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Sec. 4-147 PliOl'ERTIKS OF MATERIALS

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 PROPERTIES OF MATERIALS Sec. 4-148

ee At zero deg. cent, it has a resistivity of approximately 60,000 ohm-cm.

T! dielectric constant ranges from 6.1 to 7.4. It has the peculiar property
th its resistivity decreases upon exposure to light; the resistivity in darkness
m be anywhere from 5 to 200 times the resistivity under exposure to light.
Sf paper by W. J. Hammer, Trans. A. I. E. E., 1903, Vol. XXI, pp. 372 to

BESISTOR MATERIALS
i8.Nickel silver is an alloy of copper, nickel and zinc. It is usually
li.d commercially in terms of its nickel content; thus 18 per cent, wire
cc ains 18 per cent, of nickel. The properties vary considerably with the
C( position. Perrine gave the following composition of three grades of
mel silver: 57 Cu, 12.5 Ni, 30.5 Zn; 56 Cu, 20 Ni, 24 Zn; 50 Cu, 30 Ni,
2iZn. The resistivities were respectively in the ratio 1 1.25 2.51. : :

E^iteen per cent, alloy has about 18 times the resistivity of copper, and 30
p cent, alloy has about 28 times the resistivity of copper. See Par. 147.
49. Copper-manganese alloy containing either nickel or aluminum is
u 1 for rcsi.stors, and has a very low temperature coefficient. The alloy
c iposed of copper, ferro-manganese and nickel, or copper, manganese and
nickel, is known as manganin. The com-
position of manganin varies somewhat, one
formula being 65 Cu, 30 Fe-Mn, 5 Ni.
160. Copper-nickel alloy is used exten-
sively for resistor wires. The alloy of cop-
per and nickel found in nature is known as
Monel metal (Par. 399). See Par. 147.
161. Ferro-nickel alloy has a very high
) 800 1000 1200
electrical resistivity but is not as resistant to
0«Dtlgrade
corrosion, for resistor service, as some other
!G. 13. —Resistance-temper-
ature curve for nichrome.
alloys. The nickel-chromium alloys are
superior in the respect of having somewhat
larger resistivity. See Par. 147.
1S8. Nickel-chromium alloy is used for resistor wires where very high
istivity is desired. One alloy of this kind has a resistivity of more than
ohms per mil-ft. The nickel-chromium alloy known as " Nichrome" has
.characteristic resistance-temperature curve of the form shown in Fig. 13.

CARBON AND GRAPHITE

163. Forms of carbon. Carbon occurs in two forms, amorphous and
ystalline. The crystalline forms include diamond and graphite, the
Iter also being knownas plumbago. The amorphous forms include char-
al, coke, lamp black, bone black; coal is an impure variety of amorphous
rbon. The density of carbon in the diamond state is 3.47 to 3.56; gra-
nite, 2.10 to 2.32; charcoal, 0.28 to 0.67; coke, 1.0 to 1.7; gas carbon, 1.88;
mpblack, 1.7 to 1.8.
164. Resistivity. The resistivity of amorphous carbon (petroleum coke)
ordinary temperature (25 deg. cent.) may be taken as varying between
;

300 and 4,100 microhm-cm. An average value for retort carbon, such
_

i used for electrodes in electric furnaces, at about 3,000 deg. cent., may
e taken as 720 microhm-cm. Graphite at 3,000 deg. cent, has a resis-
vity of approximately 812 microhm-cm. Experiments by Mr. C. A.
[anson* made in the research laboratory of the General Electric Company
low that the resistivity of carbon depends upon the temperature at which
, is fired. As the temperature of firing increases, the resistivity decreases,
pproaching a constant value which is approximately the same as that of
raphite. If carbon be heated above the temperature at which it was fired,
;s resistivity is permanently decreased, and upon cooling it will not return
o its original value, but to a value corresponding to that which it would have
f fired at the temperature to which it has been heated. Also see table of
irush characteristics. Par. 165, and electrode carbon, Par. 169.
Experiments made by Morris Owen show that graphite possesses magnetic
usceptibility, and under certain conditions the electrical resistivity is in-
reased in very marked degree by magnetization.

• Electrochem. and Met. Ind., Vol. VII, 514 (1909).

p.

277
Sec. 4-155 PROPERTIES OF MATERIALS

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278
 PROPERTIES OF MATERIALS Sec. 4r-156

t 6. Resistance of arc lamp carbons. The resistance of | in.X 12

In nclosed arc carbons varies from 0.012 to 0.015 ohms per linear inch.
0' r sizes down to | in. diameter vary according to their cross-sectional
ar 3. The resistance of a J-in. diameter projector carbon varies from
0. J to 0.011 ohms per linear inch. The i-in. and /j-in. carbons vary
acrding to their cross-sectional areas.
1 high-grade forms of carbon, such as that used in the manufacture of
se ?h-hght carbons and also enclosed arc carbons, may be given the value of
aht 0.002 ohms per cu. in. Flame-arc carbon material such as is used in
tl homogeneous electrodes varies from 0.004 to 0.006 ohms per cu. in. All
tl above values are for ordinary room temperatures.
i7. Temperature coefficient of resistance. Carbon exhibits a
di easing electrical resistivity and a decreasing thermal resistivity with
riig temperature. Graphite exhibits but little change in electrical re-
si vity, tending downward with rising temperature, but its thermal resis-
with rising temperature. The coefficients vary over
ti;y increases slightly
a jnsiderable range; see Landolt and Bornstein, " Physikalish-Chemische
LeUen," 1912.
58. Resistances of carbon contacts vary with pressure, current and
tie. See results of investigation published by A. L. Clark in the P/ij/sica/
hiew, Jan., 1913.
59. Electrode properties of carbon and graphite were given by
I'ing in his paper, "The Proportioning of Electrodes for Furnaces"
( ans. A. I. E. E., Vol. XXIX,
1910, pp. 485-545), from experimental de-
tninations. The table below is abstracted from Table I in Bering's
j)er above mentioned; the paper itself gives elaborate details and many
eves. Other papers bv Hering on this general subject are noted below.*
yo see Rasch, Ewald, "Electric Arc Phenomena," published by D. Van
; strand Co., N. Y., 1913, Chapter III.

Material
Sec. 4-162 PROPERTIES OF MATERIALS

where a is the radius of the conductor in cm., /is the frequency in cyclf-
sec., M is the magnetic permeability of the conductor (here assume. i.
be constant) and p is the resistivity in absohms {10~» ohm) per cm-oube.
If L' is the effective inductance of a linear conductor to sinusoidal al
nating current of a given frequency
L'=-Li + K'Li i

where Li is the external portion of the inductance, Lt is the internal port

(due to the magnetic field within the conductor) and K' is determined fr
the table in Par. 166 in terms of x. Thus the total effective inductance
unit length of conductor is
^' = 2 1og.(f)-fX'© (

See Sec. 2 for further discussion of inductance of linear conductors; also

Sec. 11. For details underlying the above formulas see Bulletin of i

Bureau of Standards, Vol. VIII, No. 1, pp. 172 to 181; 1912. Fig. 14 she
values of K in terms of aV/ for cylindrical copper conductors of 1

per cent, conductivity. Also see Bureau of Standards Circular No.

'

An integration method of calculating the skin effect is given in Scient;

Paper No. 374, Bureau of Standards, 1920; this paper al.so shows the increi
in skin effect caused oy close spacing of parallel conductors.
 PROPERTIES OF MATERIALS Sec. 4-164

10 314). Ill No. 12 B.W.G. iron wire (B. B. grade), at 800 cycles per
jec<and with currents of telephonic magnitude, the increase in resistance
,ya'ound by measurement to be 47 per cent. See Par. 203.
,. Effect of very high frequencies on iron has been investigated by
I? W
Alexanderson; see "Magnetic Properties of Iron at Frequencies
Vol. XXX, 1911, pp. 2433-2454.
UP 200,000 Cycles." Trans. A. I. E. E.,
Htoncluded that the permeability is unaffected by the frequency. In
ine Steinmetz's formula for skin effect (see "Transient Electric
an
Ph omena and Oscillations," New York, 1909), he recommended
using
avige constants as follows: permeability, 2,250 and conductivity,
0.! 10', for soft iron.

165. Table of constants for skin-effect formulas (Par. 161)*

K K' K K' K K'

1.00000 1.00000 I
4.0 1 67787
. 68632 12.5 4 67993 0.22567
.

1.00000 '1.00000 4.1 1.71516 67135 13.0 4.85631 0.21703

1.00001 {1.00000 4.2 1.75233 65677 13.5 5.03272 0.20903
1.00004 0.99998 4.3 1 78933
. 64262 14.0 5.20915 0.20160
1.00013 0.99993 4.4 1.82614 62890 14.5 5.38560 0.19468

1.00032 0.99984 86275

1 . 61563 15.0 5.56208 0.18822
1.00067 0.99966 1.89914 60281 16.0 5.91509 0.17649
1.00124 0.99937 1.93533 59044 17.0 6.26817 0.16614
1.00212 0.99894 4.8 1.97131 57852 18.0 6.62129 0.15694
1.00340 0.99830 4.9 2.00710 56703 19.0 6.97446 0.14870

1.00519 0.99741 5.0 2.04272 0.55597 20.0 7.32767 0.14128

1 00758
. 0.99621 5.2 2.11353 0.53506 21.0 7.68091 0.13456
1.01071 0.99465 5.4 2.18389 0.61566 22.0 8.03418 0.12846
1.01470 0.99266 5.6 2.25393 0.49764 23.0 8.38748 0.12288
1.01969 0.99017 5 2.32380 0.48086 24.0 8.74079 0.11777

1 02582
. 0.98711 6.0 2 39359 0.46521
.
25.0 9.09412 0.11307
1 03323
. 0.98342 6.2 2.46338 0.450.56 26.0 9.44748 0.10872
1 04205
. 0.97904 6.4 2.53321 0.43682 28.0 10.15422 0.10096
1.05240 0.97390 6.6 2.60313 0.42389 30.0 10.86101 0.09424
1.06440 0.96795 6.8 2.67312 0.41171 32.0 11.56785 0.08835

.0 1.07816 0.96113 7.02.74319 0.40021 34.0 12.27471 0.08316

.1 1.09375 .95343 7.22.81334 0.38933 36.0 12.98160 0.07854
.2 1.11126 0.94482 7.42.88355 37902 . 38.0 13.68852 0.07441
.3 1.13069 0.93527 7.62.95380 0.36923 40 14.39545 0.07069
.4 1 15207 . 0.92482 7.83.02411 0.35992 42.0 15.10240 0.06733

:.5 1.17.538 0.91.347 8.0 3.09445 0.35107 44.0 15.80936 0.06427

'.6 1 20056 . 0.90126 8.2 3.16480 0.34263 46.0 16.51634 0.06148
;.7 1.22753 0.88825 8.4 3.23518 0.33460 48.0 17.22333 .05892
!.8 1.25620 0.87451 8.6 3.30557 0.32692 50.0 17.93032 0.05656
i.9 1.28644 0.86012 3.37597 0.31958 60.0 21.46541 0.04713

3.0 1.31809 0.84517 9.0 3.44638 0.31257 70.0 25.00063 0.04040

3.1 1.35102 0.82975 9.2 3.51680 30585 80.0 .
28.5359310.03.535
3.2 1.38504 0.81397 9.4 3 58723 0.29941
. 90.0 32. 07127!0. 03142
3.3 1.41999 0.79794 9.6 3.65766 29324 100.0 . 35.60666 0.02828
13.4 1.45570 0.78175 9 3.72812 0.28731
I

3.5 1.49202 0.76550 10.0 3.79857 0.28162

-3.6 1 52879 . 0.74929 10 3.97477 26832
.

3.7 1.56587 0.73320 11.0 4.15100 0.25622

3.8 1.60314 0.71729 11.5 4 32727 . 0,24516
3.9 1 64051 . 0.70165 12.0 4 50358 . 0.23501

, 'See Bureau of Standards Circular No. 74, pp. 309-311, for additional
cables.

281
 Sec. 4-166 PROPERTIES OF MATERIALS

166. Skin eSect in steel 3G0

cables at 50 cycles per sec. is
shown in Fig. 17, based on test
data from the Allgemeine Elek-
tricitats Gesellschaft {Elek. Zeit.,
Dec. 10, 1914).
BIBLIOQRAPHT
167. Reference literature
on conductors.
Perrine, F. a. C—
"Conduc-
tors for Electrical Distribution."
D. Van Nostrand Co. , New York,
1903.
Cohen, L. — "Calculation of
Alternating-current Problems."
McGraw-Hill Book Co., Inc.,
1913.
Del Mar, W. A. — "Electric
Power Conductors." D. Van
I Nostrand Co., New York, 2nd
edition, 1914.
—
Bureau of Standards, Circular
No. 31. "Copper Wire Tables,"
3rd edition, Oct. 1, 1914, Wash.,
D. C.
Trans. A. I. E E., Jour. I. E.
E.; Bulletins and publications of
the Bureau of Standards; Trans.
A. E. S.
 PROPERTIES OF MATERIALS Sec. 4-174

of soft iron, while

after which the permeability decreases below that
isses,
ironloss begins toincrease rapidly. See also Ruder,
h W
Ihe J^ffect ,

Properties Steels; General

Chemical Composition upon the Magnetic
of
ctric Review, March, 1915, pp. 197 to 203.
Carbon increases the resistivity, decreases the
74 Effect of carbon.
meability, lowers the saturation point and increases
the coercive force
1 the retentivity.
Concurrently the hysteresis loop is broadened and ita
a increased. These effects are greater in hardened steel than in soft or
lealed material. In slowly cooled iron-carbon alloys the carbon exists as
LrUte UD to the eutectoid point (about 0.85 carbon);
above this point the
diminishes the
bon exists as cementite (FesC). The cementite carbon
iductivity less than does the pearlite carbon. At,a quenching tempera-
dissolved carbon is about 1.4 per cent.;
e of 850 deg. cent, the limit of
excess of carbon above 1.4 is soluble at this temperature.
of manganese are not
75 Effect of manganese. Very small proportions
urious in any substantial degree, but it is customary
to limit the propor-
much as practicable. The true effect of small pro-
n of manganese as
association in
tions of manganese is difficult to determine because of its
cases with carbon.
8t See Jour. I. E. E., April, 1911, Vol. XL\ I, No.
pp. 263 to 266.
),
When the manganese content reaches 12 per cent, tne
el becomes practically non-magnetic.
176. Effects of silicon and aluminum. The researches of Barrett,
5wn and Hadfield (1900 and 1902) established the fact that the only mag-
ic alloys superior to the purest commercial iron are
the alloys of iron witft
,con, and with aluminum. The best silicon alloy contained 2.5 per cent,
'silicon, and the best aluminum alloy contained 2 25
per cent, ol aluminum.
.

Hysteresis
(B for loss, ergs Coercive
Maximum maximum per cu. cm. force for Q.
permeabil- permea- per cycle (max) =
ity for (B (max) 17.700
bility
-9,000

redish charcoal iron 2,100 4,000 2,334 1.10

5 per cent, silicon 5,000 4,000 1,549 0.80
25 per cent, aluminum . . 5,400 5,000 1,443 0.80

:5uggenheim has shown (Elek. Kraft U. Bahnen, Sept. 24, 1910), for iron
Gaining 0.2 per cent, of carbon, that silicon in quantities up to 1.8 per
.t. decreases the permeability, but from 1.8 to 5 per
cent, it improves the
'meability and decreases the hysteresis loss; for (B(max) = 10.000 in sheets
f mm. thick the hysteresis loss was 2,910 ergs per cu. cm. per cycle, for best

: con steel, compared with 6,000 ergs for ordinary sheet iron.
For electrical and mechanical effects of silicon and aluminum, see appro-
ate portions of this section.
177. Effect of nickel. The addition of nickel, up to 2per cent., causes
.le change in magnetic quality (Burgess and Aston). A higher nickel
,itent rapidly decreases the permeability. At 25 to 30 per cent, mckel,
,! magnetic properties are greatly impaired, but improve again upon a
ther increase in nickel.
of tungsten, chromium and molybdenum. These
178. Effects
'
ments have the general property of increasing the magnetic hardness and
irticularly the coercive force, making a very desirable steel for permanent
.gnets. See "Magnet Steel," Par. 225 to 230.
179. Effects of arsenic and tin. These elements are similar in their
•ects to silicon and aluminum, increasing the resistivity and reducing the
steresis loss. Tin increases the permeability at higher inductions and
•ureases the hysteresis loss even more than silicon.
180. Sulphur, phosphorus and oxygen are in general injurious in their
fcts, even in small percentages.

283
Sec. 4-181 PROPERTIES OP MATERIALS

181. Effect of heat treatment. Suitable heat treatment during mai.

facture reduces the iron loss, increases the permeability and gives bet-
physical properties. The best physical properties and the permeability ,1

to some extent opposed, and the most suitable heat treatment as rega 1

magnetic properties is not generally the one which gives the highest phyai
properties. The general method of annealing is in boxes, under cover, w^i
slow cooling. ,

188. Effect of temperature. Both iron and steel lose their magnei
properties at about 750 to 800 deg. cent., and are non-magnetic above tl;
temperature. The exact temperature at which this transformation occur
_ 1

somewhat variable, and depends upon the chemical composition of the met
183. Effect of temperature on permeability. Hopkinson'a ezpe
ments (Phil. Mag. and Troc. Roy. Soc.)_ showed that with weak magnetui'
forces the permeability increases with rises of temperature up to the criti 1

point, or about 785 deg. cent., above which iron becomes non-magnel
Under moderate magnetizing forces the permeability first increases slight
with rise of temperature, and then decreases rapidly as the critical point)
approached. Under strong magnetizing forces the permeability suffers
change at first, and then decreases gradually as the critical point is 1
proached. See Chap. VIII of E wing's "Magnetic Induction in Iron a
Other Metals."

_
 PROPERTIES OF MATERIALS Sec. 4-187

-ated for 27 days at 50 deg. cent.; 53 per cent,

when heated for 25 days at
cent 89 per cent, when heated for 25 days at 87
deg cent. 140 per
fd^ ;

25 days at 135 deg. cent. Also see Mordey W.

;

M
•nt when heated for
•roc Rov Soc, June. 1895; also
see aging tests in "Electric Machine De-
" bj Parshall and Hobart; Allen. T. S., 'The Comparative Aging of
>Kn
:iectric Sheet Steels;" Electrical World, 1908,
Vol. LII, p. 579.

187 Non-aging steel. Silicon-steel, aside from having low hysteresis

possesses the valuable property of being non-agmg.
ad high resistivity, also
impaired by prolonged heating
hat is to say, its magnetic properties are not
"moderate temperatures, but on the contrary may be slightly improved.
,-hile as much as 3 to 4 per cent, of silicon
is present m
silicon-steel. it is also

3eful, in much smaller quantities, in improving the aging qualities ollow-

irboi steel. Parshall and Hobart recommend
("Electric Machine Design.
-
36) the following composition for sheet steel
having good aging qualities:
irbon, 0.06; manganese, 0.50; silicon, 0.01 sulphur, 0.03
;
phosphorus, 0.08.
;

of mechanical stresB on magnetization. Ewing states

188. Effecta
that the prra-
:hap IX, " Magnetic Induction in Iron and Other Metals )
the susceptibility
ice of any moderate amount of longitudinal pull increases
when the magnetism is weak, but reduces it
when the magnetism is strong. With hard-
ened metal the effects of stress are in general
much greater than with annealed metal.
189, Page effect is the faint metallic sound
resembhng a light blow which is heard when a
piece of iron is suddenly magnetized or demag-
netized.
190. Cast iron is magnetically inferior to
wrought iron or low steel, but is used to a
limited extent on account of the facility with
which it can be molded into complex forms.
The permeability is decreased by the presence
of carbon, the effect being in the ratio of com-
bined to graphitic carbon. Cast iron of good
magnetic quality contains from 3 to 45 per
cent, carbon, of which from 0.2 to 0.8 per cent,
is in the combined form. A normal induction
curve for cast iron is given in Fig. 18. Curve
1 in Fig. 19 applies to cast iron containing
0.195 combined carbon. 3. 29 graphitic carbon,
2.01 silicon, 0320 manganese, 0.988 phos-
phorus and 0.08 sulphur. Curve 5 is for cast
iron containing 0.72 combined carbon, 207
silicon, 0.38 manganese, 0.85 phosphorus and
0.035 sulphur.
Silicon and aluminum in small proportions
(lake the casting more homogeneous and tend to reduce the combined
arbon. Silicon tends also to counteract sulphur.
191.Malleable cast iron is magnetically superior to cast iron, being
:)wer in combined carbon and improved by the heat treatment
which it
oceives Curve 7 in Fig. 19 is for malleable cast iron (see Parshall and
'lobart, "Electric Machine Design") containing 0.83 combined carbon,
201 graphitic carbon, 0.93 silicon. 0.116 manganese, 0.039 phosphorus and
.080 sulphur.
'

192. Wrought iron is among the best of magnetic materials from the
tandpoint of permeabiUty, but has higher core losses than silicon steel, bee
'ar. 200 comparing Swedish iron with other materials.

193. Rolled steel of the low-carbon variety is used very extensively in

he form of electrical sheets and rods. A normal induction curve is shown in
ug. 18. Commercial sheets are described in Par. 217 to 224.
194. Cast steel is extensively used for those portions of magnetic circuits
vhich carry uniform or continuous flux and need superior mechanical
trength. Parshall and Hobart state ("Electric Machine Design, p. f^)
hat cast steel of good magnetic qualities should be limited in its composition
i follows; combined carbon, 0.25; silicon, 0.20; manganese, 0.50; phos-

285
Sec. 4-195 PROPERTIES OF MATERIALS
phorus, 0.08; sulphur, 0.05. A normal induction curve is shown
Fig. 18.
196. Alloy steel. The principal alloy steel in extensive use is silicon sf
Its properties are covered under "Commercial Sheets," Par. 217 to 224,
Figs. 24 and 26. It is low incoreloss, non-aging, and highinpermeabilitj
cept at the higher densities. Tungsten steel and tungsten-chrome steel a
used extensively for permanent magnets; see " Magnet Steel," Par. 226
230. Mitis iron is steel to which has been added a small proportion
aluminum, ranging from 0.06 to 0.27 per cent. Magnetically it is a litt
better than ordinary steel up to densities of about 100 kilolines per sq. ii:
and inferior at higher densities. See Parshall and Hobart, "Elect:
Machine Design;" published by Engineering, London, 190C; p. 26. Tt
material is now seldom used.
196. Best composition of dynamo sheets; De Nolly and Veyre
High carbon and cold working are both injurious to electrical sheets. Ti
recommended composition and treatment is as follows: (1) The steel shou;
have less than 0.1 per cent, carbon, from 3 to 4 per cent, silicon, less thanOi
per cent, manganese, less than 003 per cent, sulphur and phosphorus; (:
the sheets after rolling should be annealed at 750 to 800 deg. cent, with slo
cooling; (3) the rolling should be finished at low temperature; (4) after fin
annealing, no cold working should be allowed (IX 5, No. 9, Sixth Congress >i

Int. Assoc, for Testing Materials, New York City, 1912).

197. Electrolytic iron melted in vacuo. "Magnetic and Oth<
Properties of Electrolytic Iron Melted in Vacuo" is the subject of a valuab
monograph by T. D. Yensen, and is published as Bulletin No. 72, Enginee
ing Experiment Station, Univ. of 111., 1914; this monograph is the 80ur<
of the following data.
The electrolytic iron was doubly refined from Swedish charcoal iro
anodes, and contained from 99.97 to 99.98 per cent, of chemically pui
iron, 0.006 carbon and 0.01 silicon. The iron as deposited was crushe<
cleaned and placed in a magnesia crucible; then it was melted in a vacuui
furnace and allowed to cool. Finally it was hot forged to rods about 0.5 il
diameter and 20 in. long. The average results from rods annealed at 90
deg. cent, were as follows:
Carbon content, per cent 0. 0125
Maximum permeability 12,950 M
Flux density at maximum permeability 6,550
Hysteresis loss, ergs per cu. cm. per cycle: V
At (B (maximum) = 10,000 1,060 1
At (B (maximum) = 15,000 1,990
Coercive force, (B (maximum) = 15,000 ().34 fl
Retentivity, (B (maximum) = 15,000 9,940
Resistivity (microhm-cm) at 20 deg. cent 9 96
.

Critical temp., deg. cent 894

The magnetic quality of electrolytic iron melted in vacuo is decidedl;
superior to any grade of iron thus far produced; the maximum permeability
obtained was 19,000 at a density of 9,500 gausses, and the average hysteresi
loss obtained is less than one-half that found in the best grades of com
mercial transformer iron. Swedish charcoal iron melted in vacuo ap
proaches electrolytic iron in magnetic quality, due chiefly to reduction o
carbon content. Low-carbon iron melted in vacuo will lose 50 to 90 per cent
of its original carbon. Electrolytic iron is at present purely a laborator;
or experimental product, and therefore too expensive for commercial appli
cations. See the bibliography appended to Mr. Yensen's monograph
Also see Proc. A. I. E. E., Feb., 1915, pp. 237-261.
198. Approximate saturation values of different magnetic material
are given by Steinmetz as follows, in gausses.

Iron
Cobalt
Nickel
 PROPERTIES OF MATERIALS Sec. 4-200

Quantity J in the formula

it of volume. •, , j = •

t3very alloy which they examined was found to have a definite saturation
'ensity of magnetism, which they termed the specific magnetism.
'is intensity was reached in most cases in a field of 5,000
units. The
icific magnetism of commercially pure iron of density 7.80 was
found to
1,680 within 1 per cent.
'
Tfie presence of carbon in annealed iron-carbon
el reduces the specific magnetism by a percentage equal to six times the
-centage of carbon, if other elements are present only in small propor-
"ns. No alloy was noted having a higher specific magnetism than pure iron.
lenching an iron-carbon alloy from a high temperature reduces its specific
Ugnetism by a large but uncertain amount. The addition of silicon or
iminum to iron reduces the specific magnetism roughly in proportion to
-? amount added; but if carbon is present, silicon seems to neutralize it
some extent.
200. Comparisons of magnetic materials
i
(T. P. Yensen, Bulletin No. 72, Eng. Exp. Sta., Univ. of 111.. 1914)

Material
1
Sec. 4-203 PROPERTIES OF MATERIALS

The latter applies to hard-drawn iron wire; in another case the i

permeability was 87. The foregoing relationships are accounted for 1)\
fact that the saturation curve is sensibly a parabola in its earliest sti.
starting, however, with a finite inclination to the axis of 3C. For -

tremely feeble forces it is virtually an inclined straight line. SeeEwin, I.

A., "Magnetic Induction in Iron and Other Metals," London, 1900, 3rd ',

d.. Chap. VI.

203. Permeability of iron at high frequencies has been investigfd
by E. F. W. Alexanderson and H. Pender (see "Magnetic Properties of In
at Frequencies up to 200,000 Cycles," Trans. A. I. E. E., 1911, Vol. X::,
pp. 2433-2454). Mr. Alexanderson concluded that iron has practically c
same permeability at 200,000 cycles as at 60 cycles, but the magnetic j

tration is greatly reduced at high frequencies, on account of the excessiv.

effect, which must be taken into full account. See Par. 164.
204. Heusler's alloys are composed of copper, manganese and alumin ,

and possess marked magnetic properties, fne permeability increases vi

the addition of manganese until the proportions of manganese and alumin
are the same relatively as their atomic weights (Par. 432). The maxim
magnetization obtained is about one-third of that of the best iron. * Corr
serves apparently no other purpose than to make the alloy soft enougli
be cast and handled, McTaggart* performed experiments on these alli
varying the composition in many ways. The particular composition wl i
exhibited the best magnetic properties contained 14.3 per cent, alumini
28.6 manganese and 57.1 per cent, copper.
Dr. Heusler, who discovered these alloys in 1901, stated that the v. t
magnetic alloy contained 25 per cent, of manganese, 12.5 per cent, of ;
-

minum, and 62.5 per cent, of copper, or in the respective proportions of tU

atomic weights. Also see tests made by Guthe and Austin, Bulletin of j
Bureau of Standards, 1906, Vol. II, No. 2, and tests by Stephenson, Build
No. 47, Eng. Exp. Sta., Univ. of 111., 1910.
205. Electron theory of maprnetism. Mr. E. H. Williams has writi
an extended monograph on this subject, which is published as Bulkl.
No. 62, Univ. of 111., Eng. Exp. Sta., 1912, and contains a bibliograi^
of the important works up to that date. Also see Chap. XI of Ewirl
" Magnetic Induction in Iron and Other Metals."
CORE LOSSES |
206. Total core loss is composed of two elements, hysteresis and edif'i
currents. These two lossesfollow different laws, briefly set forth in Sec!
The lo.s3 may bo stated in terms of total energy per unit volume per qyijij
or it may be stated in terms of power loss per unit weight of materia^
some stated frequency. The effect of wave-form is discussed in Par. u|
and 211.
207. Values of hysteresis coefficient for different materials ii
^
(M. G. Lloyd) 'H

Material
Autho
Material Authority
rity

Hard tungsten 0.058 Steinmetz Soft machine steel. 009 FOSN

steel. Annealed cast steel ,008 Fostrr
Hard nickel 0.039 Steinmetz No. 36 iron wire. . 005 Llovd
Hard cast steel. 0.025 Stcinmetz
. . Ordinary sheet iron 004 Lloyd
Magnetic iron ore. 0.020 Steinmetz Pure iron 003 Guiiili'
Forged steel 0.020 Steinmetz Heusler alloy II. . 0024 Guinli.
Two-mil steel wire 0.016 Lloyd Soft iron wire 002 Fostrr
Cast iron 0.013 Stemmetz Annealed iron sheet 002 Llov<i
Soft nickel 0.013 Steinmetz Ingot iron 0016 Llovd
Cast steel 0.012 Steinmetz Best annealed sheet 0010 Llov,!
Cobalt 0.012 Steinmetz Silicon steel sheet. 0010 LloyJ
Heusler alloy I . 0.012
. . Gumlich Silicon steel 0009 Guiiilif
Electrolytic iron. 0.009 Schild Best silicon steel. . . 0006 Lloyd

See Lloyd, M. G., "Magnetic Hysteresis," Journal of the Franklin Inatilu

July. 1910, pp. 1-25.
_^^
• McTaggart, H. A. Univ. Toronto Studies, Papers from Phys. Lab., I'M
No. 23.
288 >
_tj
 PROPERTIES OF MATERIALS SeC. 4-208

cycles per sec. (Bisthemaxi-

;^u omper sel: /it'hrfrequency in
;;.; coefficient,
'

''nHnrVronand is here 10,000 gausses, and v is the hysteresis

diparta Widely from this value at very low
nexponenrof ffi, which is 1.6,

-ZiS^^^ for sheets aregiven in Fi^^^ ^^^oyj ^^^ f^s,^

a .0. Also see Sec. 7, Par. 214. t^ ht o Lloyd

ti ;„
Dr. ^I^G -4 in
Effect of wave form upon hysteresis
•0 loss. .

hi'.aDeTentitled "Dependence of Magnetic Hysteresis upon Wave Form

No. Feb. 1909. pp. 381-411),
SSof the Bureau of Standards, Vol. V, 3.

hysteresis is greater
"i^r a dtfinUetalimum'valu'of the flux density, the stand-
»' a flat wave of flux, but the effect is small, and from the industrial
waves. If, however, the wave of
pc't negligible even ^ith very distorted
is dimpled, the hysteresis may
be much increased.
fli'

The hysteresis determined by the ballistic method

may be smaller than
tl which Sns
with the use of alternating current, but the differences
imall.
"' losses by means of runs at
rhe separation of hysteresis and eddy-current
tv frequencies, using the Steinmetz
formula, is not accurate, but is a close
Bj -oximation when the sheets are thin." , x- x j k .
1. Effect of form-factor upon
the iron loss was investigated by
upon the I'^" bosses in Trans-
,

d'm. G. Lloyd (see "Effect of Wave Form

frtiers." Bulletin of the Bureau of
Standards, Vol. IV, No. 4, 1907, also
B rint No. 88), who reached the following conclusions. losses in a trans-
With a given effective electromotive force the iron
f( ler depend upon the
form-factor of the e.m.f., and vary inversely with it.
the iron losses
E proper design of the generator supplying transformers,
nt- be reduced to a minimum." ». * « j. i«,..
12. Effect of unsymmetrical
periodic cycles on hysteresis loss.
J M. Rosenbaum in a paper entitled
"Hysteresis Loss in Iron laken
1 ough Unsymmetrical Cycles of Constant Amp
itude. before the I. hj. t..
conclusions.
( Jour. I. E. E.. Mar., 1912), presented the following
-It is seen that the hysteresis loss increases
very appreciably as direct-
magnetization is superposed on the a ternating flux. This
phenom-
c ent
static balancers.
e'a manifests itself in practice in inductor alternatois and
does not reverse, but oscillates
I ome kinds of inductor alternators the flux
t wen positive maximum and positive
minimum values, thus the iron loss
in the
T cu. cm. is much greater in inductor alternators than
c .nary type for the same change of flux in
the armature coil. In static
direct-current magnetization
bincers this effect also takes place where the
i'ot neutralized. It is therefore important, if high efficiency
be aimed at,
tieutralize the direct-current flux."
[ SHEET GAGES
! 18. Two systems of gaging sheets are in use, the U. S. Standard Gage
t\ the Decimal Gage. These two gages arc fully covered in the two
e ceeding paragraphs. Also see Par. 30. . , * i
act establishing a standard gage for sheet and plate iron
14. An
il steel. Be it enacted by the Senate and House of Representatives of the
lited States of America in Congress assembled. That for the
purpose ol
fiuring uniformity, the following is established as the only
standard gage
f sheet and plate iron and steel in the United States of America, namely:
e Par. 216.)
( And on and after July 1, 1893. the same and no other shall
1 used in determining duties and taxes levied by the United btates ot
.lerica on sheet and plate iron and steel. But this act shall not be con-
rued to increase duties upon any articles which may be importeO.
Sec. 2. That the Secretary of the Treasury is authorized and required
1 prepare suitable standards in accordance herewith. . j
That in the practical use and application of the standard gage
,

'
ec. 3.
.I-eby established a variation of 2.5 per cent, either way may be aUowed.
Approved, March 3, 1893. I

289
Sec. 4-215 PROPERTIES OF MATERIALS

a» K *>
a-Sg iC'OM'ro'* coc<3TO»N t»cst-iNt~ iNo-H^rH (oeoi-H a>l
CO'Ot)<c<5M -hOOSOOOO t^b.^--'^' -^^^-w"^-_^ ^—.^^s "
N^.^wwO' v_v^-_-CiCJ v^^tooio •jO'1<1<MCO (Mt^MJ
•Si'' S)
•- g o t~'-i^Oin N.r-t'^r-ioO iO<N0550C<3 O t~ ^ i-c QO lO M IN <
OlOOOt-t- tOOlOlO-"!" fTllCOroM CO (N IM C<l 1-H r-l rH rt r

a-" S
o 5
-tJ ?<!P??r''a" f^^MOao cjos'OiNoo loc^oo-*-^ t^co-^Hl
OCCINOSt^ •<JilNi-lC

•>1<C0MC<5C0 C>iM(M»H.-l rHi-lrHr

^§3

>0(N
o«5 0_>o •raomci t^iOlN t» •OIN
(N—l
a> CO Q, o Ot»«5<NO t'.wllNOO
000 (^ to 10
^1 ^

S°S3 00000 00000 00000

Noooo'* Mooni^o m u^ <j< c<t rH
pc
oc
C<3CC<N(N<N C^^ (N •-< 1-H r-l t-( rl rt rM rH r-l

« e8 o O

^ ^ ^ ^ ^ ^ ^"S
SSg-2 ic^^'O "Sz-^iow
NiOt^CC
iN'OW,-^<N
weqco'OO
'Ot» wo t-ro^";
MOj"h»
lis (NiOt-^-^
coc>ioo»o i-Ht^cco^-N co^Cic^to
t>-00.~'-ilN
00^'CoOi-i tjoo^go
Scic^Si
t^O'-ico'Ci
C5SSS SSSSS
t~o>rHb.co 05>f5"-<h-ro
o?^?:'J^«
ai'0—<t^co
SE'SoooJ^t-
ot~'OT)<iN
i^Jt^doi odt-t-cDO icoio-o*^ rocoMiNiN ,-ir-i»-(i-ii-H

S m S " ,-^ ,^10

^ ^ ^ ^
10 ^^lo 10 ^^»o
.-V ^-s
•n.^N
^-^>o
'ON .-^
•a u_— -T-^^10
,

in,-vioc>) t~"OiN^~.r^ >nM t>.io m<-i,—^lo

o c) f a !f;u5N t>«3oico cot-'-i'Ooo 5^ to SSSJl
J3.t.
OOwS-lO COC^^iO »J<OOCOt^'-i CDO'OOiCO
lOtlNOO
CCOdO
l^l^OiCi*
0t~ COi-iOOOt^
55 So
„S;^C«5
.2"*'*«
T)<r-<00tDl(5
COCOININC^ (NININ-H'H i-ii-HT^i-lO 0000 C
o "odo ddddd ddddd ddddd doooo

Pil
a o o
»< iNCOM'f
CO >-i e<5 to >}< (p05«Oi-<tp P5CO00COC0 tCH-ii-KM
a." S « ^10 OS h- "-I
I I I I I

JOi-llNCO -iiuStOt^OO OlO'-'NM r)<U)tOt-or)

PROPERTIES OF MATERIALS Sec. 4-215
Sec. 4-216 PROPERTIES OF MATERIALS

216. Standard decimal (r&ge for sheet iron and steel adopted b
Assoc, of Amer. Steel Manufacturers and the Amer. Railway Master M(
ics Assoc, is based on the following standard thicknesses, expressed

0.002
 PROPERTIES OF MATERIALS Sec. 4-220

220. Maximum total losses of electrical sheets

J loeses at 10,000 gausses; as determined under American Society for
Testing Materials Specification "A34-14"
(American Sheet & Tin Plate Co.)
Apollo Special Electrical (non-aging, density 7.50)
30 29 28 27 26 25 24
G. G. G. G. G. G. G.

jitts per pound, CO cycles. . 0.86 0.86 0.89 0.94 0.98 1.04 1.10
atts per kilogram, 60 cycles 1.90 1.90:1.9612.07 2.16 2.292.42
itts per pound, 50 cycles. , . 0.71 0.71i0.73 0.77 0.80 0.85 0.90
itts per kilogram, 50 cycles. 1.57 1.57 1.61 1.70 1.76 1.87 1.98
Extra Apollo Special Electrical (non-aging, density 7.50)
atts per pound, 60 cycles. . 0.80
atts per kilogram, 60 cycles 1.75
atts per pound, 50 cycles. . . 0.66
atts per kilogram, 50 cycles 1.45
Dynamo Special Electrical (non-aging, density 7.50)
atts per pound, 60 cycles 0.950. 97 1.01 1.04 1.08 1. 13 1.17
,atts per kilogram, 60 cycles 2.22 2.29 2.3812, 49 2.57
2. 1012. 14
.atts per pound, 50 cycles 0.78j0.80 0.83 0.860.8910. 930.96
latts per kilogram, 50 cycles 1.72,1.76 1.83 1.90 1.962. 05 2.12
U. S. Electrical (practically non-aging, density 7.70)
atts per pound, 60 cycles . . 1.38 1.45 1.52 1.6211.68 822.05
atts per kilogram, 60 cycles 3.04 3.19 3.35 3.563.70 004.51
atts per pound, 50 cycles . . 1.13 1.18 1.24 1.3011.36 50 1.65
'
atts per kilogram, 50 cycles 2.49 2.60 2.73 2.863.00 30i3.63
American Armature (.slight aging, density 7.70)
iatts per pound, 60 cycles 1 .65 1.75 1 .95 2.05 2. 19'2. 5012. 80
atts per kilogram, 60 cycles 3.63l3.85l4.29 3.51 4.82 5. 50 6.16
•atts per pound, 50 cycles 1 .32| 1.40' 1.56jl .641 1 .76 2.00 2.24
jatts per kilogram, 50 cycles 2.90|3.08j3.43 3.61i3.87]4.40i4.93

B
20000

ISOOO

16000

*. 14000
o
^12000

I 10000

8000
I
•S 6000
a

4000

mar2i
Sec. 4-221 PROPERTIES OF MATERIALS

221. Effect of mechanical working on sheets. The only working le

material receives is puncliing and compression in the finished core, la
effect of punching is to deteriorate the magnetic
properties, which can be removed by subsequent an-
nealing, but if the cutting edges are sharp the effect
is very small.
222. Data on FoUansbee steel sheets are given
in Figs. 26 to 28. Normal induction curves are shown
in Fig. 26. Curves of total core loss are given in
Figs. 27 and 28, all data being supplied by FoUansbee
Brothers Company. Both grades, carbon steel and
silicon steel, aremade by the basic open-hearth process.
Further data may be obtained from articles by J. G.
Homan in the Electrical World, Sept. 7, 1912, pp. 501-
502, and the Iron Aye, Jan. 2, 1913.
223. Stalloy is the trade name for a commercial
transformer steel. Hamlen and Rossiter {Electrician
(London), Nov. 3, 1911) found the maximum permea-
bility to be as follows: unannealed, 3,100 at (B = 4,500;
annealed, 4,200 at (B = 7,000. Hysteresis loss, 2,500
ergs per cu. cm. per cycle at (B = 10,000. Fig. 21.-
224. Curves of total core losses in electrical age hy8tere.si.s
sheets are given in Fig. 29, taken from the article on "American Ar
"Transformers," by Dr. A. S. McAllister in the 3rd ture" sheets.
edition of the Standard Handbook. (A. S. & T. P. C
MAGNET STEEL
236. Desired characteristics in permanent magnets are maxiir^l'
retentivity or retained flux, high coercive force and permanency or r!-]'
aging characteristics. Alloy magnet steels having a coercive force ofO
to 70 units have in recent years replaced the plain carbon steels, wla'
coercive force cannot be made to exceed 45 to 50 units.
B
20000 r
 PROPERTIES OF MATERIALS Sec. 4-227

7. Carbon magnet steel is a high-carbon steel, and must be hardened

by uenching after it has been forged and machined to shape. Fig. 30
}h d the normal saturation curve and the hysteresis loop of a glass-hard
iforte steel wire (Ewing, J. A. " Magnetic Induction in Iron and Other
pi;
Mils;" London, 1900; 3rd rev. ed., pp. 83, 84). The maximum per-
no'iility in Fig. 30 is only 118. For information relative to the effect of
+(B
10000
Sec. 4-228 PROPERTIES OF MATERIALS

228. Tungsten magnet steel usually contains from 5 to 6 per ci .

tungsten; and from 0.2 to 0.4 per cent, of chromium, which rende \U
magnetic properties appreciably better than when this element is • '

omitted, for the reason, it is thought, that the latter element inon
solubility of the tungsten in the molten steel. Quenching is doin

Fig. 25. —
Average hysteresis loop,
Fig. 26.
Magsetltlng Force,

— Normal induction
3C
"Apollo Special Electrical" sheets ct a
(A. S. & T. P. Co.). of FoUansbee steel sheets

ning water, from temperatures ranging between 1550 to 1600 deg. iB

depending upon the cross section of the sample. The carbon cont( i

American steels averages about 0.7 per cent., which is a little lowers
the average used in the case of chromium steels. Using max. ol( H
gausses, common magnetic values are, residual flux = 10,500, and coiil
force = 65.

>,4 aoa8 1.0 1.2 1.i 1.0 1.8 &0 2.2 2.4 2.0 2,8;L0S,S
Watts per Ib.^ at SO Cycle s

Fig. 27. —-Total core loss in FoUansbee improved electric steel slifo

229. Chromium magnet steel usually contains from 2 to 3 per oei i

chromium, and 0.8 to 0.9 per cent, of carbon. The addition of small am(f
of tungsten to chromium steel results in no appreciable benefits ttl
magnetic properties, and therefore, is never made. Quenching of chror i

magnet steel Js frequently done in oil, and at somewhat lower tempera <

296
 PROPERTIES OF MATERIALS Sec. 4^229

hft'or tungsten steel, ranging between 1475 to 1525 deg. fahr. If quenched
1 lower temperatures are used; viz., 1450 to 1500 deg. fahr.;
ter, still
^Bf quenching, however, tends to result in more or less hardening breakage,
^onil-hardened specimen."?, common magnetic values are, residual flux =
5<; ind coercive force = 63, with // max. of 300 gausses.
 Sec. 4-230 PROPERTIES OF MATERIALS

230. Chemical analysis of tungsten and chrome magnet sili

recommended limits
(Data from Halcoinb Steel Co.)

Steel Range
W Cr Mn
Tungsten Min. 0.70 5.0 0.20 0.30
Max. 0.90 6.0 0.40 0.50 0.030 0.03(

Chromium. Min. 0.70 0.0 2.00 0.30

Max. 0.90 0.0 3.00 0.50 0.030 0.03lr
231. Non-magnetic steels. Hadfield found the presence of -g
proportions (12 per cent.) of mangaijese in steel deprived the me (
nearly all of its susceptibility. Hopkinson found that a specimen of
containing 25 per cent, of nickel was practically non-magnetic at ore ir
temperatures, but after cooling to a very low temperature it became strji
magnetic and remained so upon returning to normal temperature, h
self-hardening steels (see "Structural Materials," Sec. 4) are also p;ti
cally non-magnetic. Any steel in the austenitic state is non-magnetic
BIBLIOGRAPHY
232. The authoritative literature on the magnetic properties of m
steel and other metals is for the most part scattered through many >i
dealing primarily with other topics, and through the transactions ci
leading engineermg and scientific societies and the technical press. Ti
—
following is a selected list of the more important works and sources.
EwiNG, J. A. "Magnetic Induction in Iron and Other Metals. " Lo a
1900, 3rd rev. ed.
Steinmetz, C. p.— " Alternating-current Phenomena." McGraw-Hill '4
Co., Inc., New York, 1908.
Karapetopf, v.— "The Magnetic Circuit." McGraw-Hill Book Co. *
New York, 1911. —
Pender, H. " Principles of Electrical Engineering." McGraw-li
Co., Inc., New York, 1911.
—
Gray, A. "Electrical Machine Design." McGraw-Hill Book ( <,
New York, 1913.
Trans. A. I. E. E. Jour. I.E.E.; Trans. Faraday Soteiety; Bulletin i ti
Bureau of Standards.

INSULATING MATERIALS
CLASSIFICATION
233 Methods of classification. Dielectrics may be classified i
number of ways:(a) physical grouping, under solids, plastics, liquidiad
gases; (b) according to working temperature limits; (el according to the p«
of application.
234. Classification of dielectrics according to heat-resistinfr r
erties. Messrs. Steinmetz and Lamme in their A. I. E. E. paper oi.
perature and Electrical Insulation" (1913, Vol. XXXII, p. 79)
the usual insulating materials as follows, in three general classes.
Class A. This includes most of the fibrous materials, as paper,
etc., most of the natural oil resins and gums, etc. As a rule, such i

become dry and brittle, or lose their fibrous strength under long-o
moderately high temperature, or under very high temperature for
time.
Class B. This includes what may be designated as heat-rosisting niau-i
which consistof mica, asbestos, or equivalent refractory materials, freanjdl
used in combination with other supporting or binding materials, the OtM
ration of which, by heat, will not interfere with the insulating prop^ii
of the final product. However, where such supporting or binding niafi.l'
are in such quantity, or of such nature, that their deterioration by heal ill
greatly impair the final product, the material should be considered as be «•
ing to class A.

298
 PROPERTIES OF MATERIALS Sec. 4-235

ass C. This is represented by fireproof, or heat-proof materials, such as

m 80 assembled that very high temperatures do not produce rapid
,

df rioration. Such materials are used in rheostats and in the heating

-' ""t? of heating appliances, etc.

imperature limits specified by the A. I. E. E. Standardization Rules

r, Par. 188) are as follows:

1 Cotton, silk, paper and other fibrous materials, not so treated as to

1)
iDi'ase the temperature limit, 95 deg. cent.
1-2) Same as -.4-1, but treated or impregnated, and including enameled
w 105 deg. cent.
,

?) Mica, asbestos or any other material capable of resisting high tem-

p. ture, in which any class A material or binder, if used, is for structural
p joses only, and may be destroyed without impairing the insulating or
tthanical qualities, 125 deg. cent.
f) Fireproof and refractory materials, no specified limit.

335. Physical Classification of Dielectrics

Gums and resins
Asbestos
Wood
Natural. Soapstone
Slate
Marble
Lava
Solids Mica
Papers and sheets
Fabrics and yarns
Hard rubber
Fabricated. Synthetic resins
Molded compositions
Glass
Vitrified materials
Caoutchouc
Gutta percha

I
'lectncs
Plastics Pitches
Asphalts
Waxes
Compounds
Mineral oil
Used as such \ Animal oil
Vegetable oil
Liquids Varnish
Shellac
Solidified on application Paint
I
Enamel
[ Japan
Atmospheric air

I I

Classification of dielectrics according to type of application.

i36.
Hydrogen
Nitrogen
Carbon dioxide

jder this classification can be named: (1) Wire insulation; (2) cable insu-
Lon; (3) insulating supports, combining dielectric properties with mechan-
llstrength; (4) coil and slot insulation for electrical apparatus and machin-
i; (5) insulating sheets, slabs and barriers; (6) molded insulation, shaped
iler the application of heat and mechanical pressure; (7) impregnating and
f ng compounds; (8) superficial paints and varnishes; (9) fluid insulators;
I
) gaseous insulators.
Use of trade names in connection with insulating materials has
137.
'
become very common. On account of the great number of
ortunately
l^h names no attempt has been made to state or define them all. Wherever
Ksible, insulating materials have been grouped and described in accordance
*h a rational classification, and adhering if possible to the natural or de-
uptive name of each thing instead of its trade name.

299
Sec. 4-238 PROPERTIES OF MATERIALS

DISCUSSION OF PROPERTIES
838. Desirable characteristics of dielectrics may be enumer^
follows, under four heads: (1) electrical, (2) mechanical, (3) thernj;
chemical.
(1) Electrical (3) Thermal ,^
(a) Great resistivity. (a)Large specific heat. |j|l
(b) Small surface leakage. (b)Small thermal resistivity. "^
(c) Great disruptive strength. (c) Small coefficient of expaii-
(d) Desirable magnitude of dielectric (d) High softening temp,
constant depends upon types of (e) High melting point, for -
application. (f) High boiling point and Ic^
(e) Small dielectric absorption. ing point, for liquids.
(f) Small dielectric hysteresis. (g) Low viscosity.
(g) Minimum power factor.
(h) Minimum temperature coeffi-
cients.
(2) Mechanical (4) Chemical
(a) Great tensile strength. (a) Stability.
(b) Great shearing strength. (b) Insoluble in acids, alkalu .

(c) Great compressive strength. oils

j
. .

(d) Desirable magnitude of modulus (c) High flash point.

f
of elasticity depends upon type of (d) High fire point. 'j^
application.
(e) Desirable degree of hardness
ditto (d).
(f) Not brittle.
(g) Dense non-porous structure,
(h) Non-hygroscopic.
(i) Readily workable.
239. Insulation resistance is separable into two components, \itat
resistivity and surface resistivity. The leakage path through the sulince
or interior of the dielectric is electrically in parallel with the surface 1 cage
path composed of a film of moisture or oil (with the frequent addition luit i

or foreign matter) on the surfaces of the dielectric. For exhaustive cu»-

sion of the characteristics of insulation resistance and the insulating ppw-
ties of dielectrics see the following:
'

Evershed, S. "The Characteristics of Insulation Resistance; -ow.

I. E. E., 1913.
Curtis, H. L. "Insulating Properties of Solid Dielectrics; ^
Paper No. 234, Bureau of Standards, 1915.
Fleming and Dyke. "On the Power-factor and Conductivity of »:-
tries;" Jour. E. E., 1912, Vol. XLIX, No. 215. pp. 323 to 431.
I.

340. Volume insulation resistance of dielectrics is dependent pon

the resistivity, usually expressed as volume resistivity in ohm-cm., •

ohm-cm. for greater convenience. Practically all dielectrics have a i

temperature coeflScient, or decreasing resistance with rising tenii

When the volume resistivity becomes very high, on the order of 10" c!
the dielectric absorption current is likely to be of sufficient relative ni
to influence the observed value of volume resistivity unless sufficient
allowed for complete electrification. In the case of two materials h
resistivity of 10" ohm-cm., hard rubber and fuzed quartz, the appan
tivity under continuous electrification increases for a long time.
For most practical cases, however, that portion of the leakage
which flows through the body of the dielectric is negligible in compan
the portion which flows through the surface film. But when thi
resistivity is less than 10'* ohm-cm. and when the insulator is plar.
atmosphere having a humidity of less than 25 per cent., the great ir
the current may flow through the body of the insulator.
In porous materials or those containing appreciable moisture,
slate and marble, the volume resistivity decreases somewhat withinr
applied voltage. In all suoh cases the volume resistivity increases
aa the moisture is dried out. .

The effective resistance with alternating currents is usually Ices thfwiti"

continuous currents, and decreases progressively as a rule with incr«
frequency, owing to dielectric energy losses (Par. 281).

300
 PROPERTIES OF MATERIALS Sec. 4-241

J/ Surface insulation resistance. The surface conductivity is the

«ii cal of thesurface resistivity, and the surface resistivity is the resist-
ice etween two opposite edges of a surface film which is 1 cm. square.
mc or most materials under ordinary conditions of humidity the surface
sis ity is much lower than the volume resistivity,
the resistance per
jnt eter length between two linear conductors 1 cm.
apart, pressed upon
ie 'face of a slab of the material, is
approximately equal to the surface

T relationship between surface resistivity and humidity, for a number of

iffi it materials, is given in Fig. 32. These curves are generally typical
1
of solid dielectrics. The sur-
face resistivity is often a
million times as great at low
humidity as at high humid-
ity. Measurements made on
various molded composi-
tions at the Bureau of
Standards (Scientific Paper
No. 234) gave values ranging
from 1010 to IQi' ohm-cm.
(between opposite edges of a (
film 1 cm. square), at 22
deg. cent.
242. Dielectric constant
is defined in Sec. 2. The
customary medium of refer-
ence is almost universally dry
air at normal temperature
and pressure. For most ma-
terials the temperature coeffi-
cient is positive, but for
90 100 india-rubber it appears to be
negative at ordinary tem-
peratures. _
The coefficient
for celluloid at 15 deg. cent,
proximately 0.005 per deg. cent., whereas for mica it is about 0.0006.
Dielectric absorption is the term applied to the apparent soaking
t.

F electric charge within the body of a dielectric when theelectric stress is

r nged for an appreciable time. In other words, it requires appreciable
I* for the dielectric to become fully saturated with electric charge or dis-
I mi^nt, when a steady stress is applied. In some materials this phenom-
» is marked, while in others it is slight. Due allowance should be made
1 t, however, in certain classes of measurements, notably insulation
ii ance.
Dielectric strengrth, usually expressed in volts or kilovolts (kv.) per
4.
I >r mm.,' is a property which it is impossible to determine with high
per
r and which is affected by numerous variables such as the size and
sion,
»3 of the test electrodes, the time rate at which the test voltage is raised to
I iisruptive point, the order of frequency of the test voltage and the
i':ness of the test specimen. Furthermore, disruptive discharge requires
:merely a sufficiently high voltage, but a certain minimum amount of
;y. There is no accepted standard apparatus or method for testing
ctrics, and hence the results obtained by different investigators are com-
Ible only as to general order of magnitude, if at all. Moreover the prob-
=error in measurements of disruptive strength is unusually large and any
jet of observations is likely of itself to be in error by as much as plus or
'IS 10 to 20 per cent. Consequently the values of disruptive strength
!d in this section are to be considered as piuely approximate and not
rately comparative.
i6. The factors affecting dielectric strength may be stated as fol-
; i nternal o r external heating, chemical change, absorption of moisture,

1 volt per mil =39.4 volts per mm.

1 volt per mil = 0.394 kv. per cm.
1 volt per mm. =0.0254 volt per mil.
1 kv. per cm. =
2 54 volts per mil.
.

301
Sec. 4-246 PROPERTIES OF MATERIALS
nature of surrounding medium, size and shape of test electrodes, thif
test specimen, time rate of applying the disruptive voltage, wheti:
tinuous or alternating test pressure is employed, and order of ma
of the test frequency.
246. Efitect of size of electrodes. Farmer concluded from his tests it

the average dielectric strength of insulating materials in thin sheet fo Ji

materially higher with small electrodes than with large ones; upon mj'
the electrodes very small, such as needle points, however, the diel«
strength apparently decreases again. See Farmer, F. M., "The Dieli
Strength of Thin Insulating Materials;" Trans. A. I. E. E., 1913, Vol. XJs l"

pp. 2097 to 2131. Also see Franklin, W. S., "Dielectric Stresses fror m
Mechanical Point of View;" Jour. Franklin Inst., 1913.
247. Effect of thickness of test specimen. It is comparative!:,
find an insulating material whose dielectric strength varies uniformly
thickness. In the case of fibre, for example, the disruptive strr;
creases very slowly with increasing thickness. On the other hand,
ruptive strength of multiple layers of glass with intervening oil films ;

proportional to the thickness. A law was proposed by Baur whicii

expressed E
= kl^, where S is the disruptive voltage, ? is the thicknos
dielectric and A is a constant; in other words, the disruptive volta^;
as the two-thirds power of the thickness. This law is a rough guide for n
materials. Another law proposed by Walter, for air, is E = a bl, v+ •(

a and b are constants and I is the thickness; this law holds for needle )i

from 50 to 450 mm. under ordinary pressures and temperatures.

248. Lamination. Hendricks* states that a finely laminated .stru i

improves the dielectric strength. This is partly explained as follows: I

spots in successive layers very rarely coincide in position, rupture at y

local internal point may be confined to one lamination, and thin mat I
are in general superior in point of electric and mechanical unit strength.
249. Effect of frequency. There is usually considerable diflc ,

between disruptive strengths as determined by alternating e.m.fs. an ;

continuous e.m.fs. In the case of continuous e.m.fs. there is much Ics i-

ternal heating than there is with alternating e.m.fs. Disruptive strer n

of solid dielectrics measured with continuous e.m.fs. are about one and f
half to two times the strengths meas- ;.

ured with alternating e.m.fs. under 14,000

like conditions. When the order of
frequency is increased from commer- gl2,000
cial power frequencies to those repre-
sentative of high-frequency high-power AlCOOO
surges, say 200,000 cycles, there is
reason to believe that the disruptive
strength is reduced. Creighton has
shown that this is the fact in the case
of porcelain (see Proc. A. I. E. E.,
May, 1915, p. 819, Fig. 29), where
disruptive values at very high fre-
quency were on the order of 60 to 80
per cent, of the 60-cycle values.
250. Effect of the time element
in applying the disruptive pressure is
pronounced. For very brief periods
dielectrics will withstand much greater
potentials than for longer periods.
This is apparently a consequence, in _

part at least, of the fact that disruptive discharge requires a certain mini
amount of energy in each instance. Thus the disruptive energy requir
the case of oil is about 30 times that required for air. It is charactc i

of oil and of materials impregnated with oil that the dielectric streiig i

greater for instantaneous or very brief applications of stress than it is u 3

prolonged stress. The brief time interval required to energize the dielc I
 PROPERTIES OF MATERIALS SeC. 4^251

breakdown occurs is sometimes referred to as the dielectric spark lag.

ire
fod illustration of the comparative effects of
slow versus fast rate of apph-
(see Froc.
wf.n of the disruptive voltage is given by Creighton for porcelain
A E E May, 1915, p. 818,
,
Fig. 28). Also see Hayden and Stemmetz,
Strength with Transient Voltages;"' Trans. A. I. E. E.. 1910.
"SruDtive
curves (plotted from
V; XXIX, pp. 1125 to 1158. Fig. 33 shows typical
It ner's 1912 paper. Jour. I. E. E.) of disruptive voltage with respect to the
til" required
for puncture.
in dielectrics, and is
i '11 Dielectric hysteresis is a form of energy loss
Impendent of any loss due to pure conduction. The latter loss
is expressed

t?!^ where a is the total conductance in mhos of a given body of dielectric

impressed difference of potential in effective volts, the power loss
hrB IS the
iri n thereby being
expressed in watts. The Static component of dielec-
tr hysteresis probably is proportional to
the 1.6th power of the maximum
di'ctric flux density. The viscous component of dielectric hysteresis
The latter component is probably the predominating
fo ws the square law.
oi since experimental evidence* from
condenser tests with alternating
cients goes to show that the angle of phase difference due to hysteresis is a
<;c fant for any particular condenser. It follows from this that the POwer
Jo- in the dielectric is proportional to the square of the flux
density and the
Boire of the frequency, which corresponds to the viscous
component of hys-
teiis As a rule these electrostatic hysteresis losses in a condenser are
h smaller than the losses occasioned by magnetic hysteresis and
are rather
m more than a fraction of 1
d cult to measure. Frequently they amount to no
pioent of the volt-ampere input of the condenser, at frequencies
from 25 to
U cvcles See Rayner, E. H., "High-voltage Tests and Energy Losses in
Eectrics;" Jour. I. E. E., 1912, Vol. XLIX, No. 214, pp. 3 to 89; also
see
Dielectrics;
Fjiing and Dyke, "On the Power-factor and Conductivity of
:/?. I. E. E., 1912, Vol. XLIX, No. 215, pp. 323 to 431.
52. Dielectric power-factor. "When a dielectric is subjected to a pe-
ri'ic alternating e.m.f. less than the disruptive value there is a loss or expen-
d energy within the dielectric from two causes: (1) the leakage con-
re of
dtion current, (2) the dielectric hysteresis. Consequently, the volt-
a,')ere input to the dielectric, instead of having a zero
power-factor as in the
Ci! of the ideal dielectric of infinite resistance and
zero hysteresis, has a
per-factor of finite value but usually small magnitude. This total dielec-
ti'loss may, in some cases, have considerable importance.
Fleming and
r>e* made tests on eleven different materials at 920, 2,760 and 4,600 cycles,
a found that the power-factor was less than 1 per cent, in the case of dry
Anila paper, paraffin wax, mica, ebonite, pure india-rubber, vulcanized
iua-rubber and sulphur; about 2 per cent, for glass and gutta percha;
a 8 per cent, for dry slate.
Efiects of temperature.
'63. If a dielectric contains moisture, the
alication of heat will reduce the moisture content and simultaneously
iiease the resistivity and the disruptive voltage. In the case of a thor-
o hly dry substance, however, increase of temperature has the reverse
e ct. Prolonged heating of a dielectric, if in excess of the safe or conserva-
t hmit of working temperature, is injurious and tends to hasten the break-
;

din of the material by disintegration or chemical change, and ensuing dis-

r tive failure. Except in the case of fireproof and refractory materials, the
vking temperature is a most important factor in determining the life of
ialation. See Par. 234 and also see the temperature limits specified the m
S ndardization Rules of the A. I. E. E., Sec. 24, Par. 187 to 200.

SOLID NATURAL MATERIALS

164. Asbestos is a mineral fibre comprised of hydrous silicate of magnesia,
Vich melts at a temperature in the range from 1,200 to 1,300 deg. cent.
lis useful as an insulating material because of its heat-resisting qualities,
e1 is fabricated into boards, paper, tape, etc., frequently in combination
\h a binder to make it stronger mechanically and less absorbent of mois-
t e. It is not inherently a good insulator, and for this reason is frequently
rsed with other fibres or loading material to impart greater strength, higher
iulation and better finish. The commercial varieties of asbestos often
•
Steinmetz, 0. P. "Alternating-current Phenomena;" New York, Mc-
"aw-Hill Book Co., Inc., 1908; 4th ed., pp. 212 and 213. ^uui^ai^- -

303
Sec. 4-255 properties of materials

contain iron and other impurities, making it almost useless as an electri

insulator. Asbestos is an excellent thermal insulator. Its electrical rei;
tivity is on the order of 16X10* ohm-cm.; disruptive voltage, 60 to 1'
volts per mil; maximum working temperature, 500 to 600 deg. cent. Wl
used for arc defectors in controllers, switches, etc., it is usually impr'
nated with a solution of silicate of soda and then subjected to hea-
pressure.
Asbestos is frequently combined with magnesium carbonate, or with fini
ground sponge, or with wool felt, as a thermal insulation for steam pipes
is also mixed with cattle hair, for similar use, and known as asbestos hair fi
Asbestos is also extensively employed in the manufacture of molded compc
tions designed to withstand high temperatures.
2S6. Chalk is a fine-grained limestone of marine origin, composed of fim^
comminuted shells, particularly those of the foraminifera. The specific grr
ity may be as low as 1.8. A theoretically pure limestone is merely a massi
form of the mineral calcite, consisting entirely of calcium (lime) carbona
CeO-|-C02 = CaC03, or 56 per cent. CaO and 44 per cent. CO2.
256. Fire clay. Clay is the term applied to fine-grained unconsolidat
natural materials which possess plasticity when wet, but lose it on bei
heated and become hard. The specific gravity ranges between 1.5 and 2
The clays are composed essentially of silica and alumina, in a state of exccf
ingly fine subdivision, resulting from the decay of older rocks. Fire clay
the variety of clay which is most highly refractory, containing much sili
and little lime, iron or alkalies. As an insulator it is applied in semi-liqi
form and baked, after the conductors are imbedded. It is not affected '

acids, oils or alkalies.

267. Gums and resins. The natural gums and resins such as caoi
chouc, gutta-percha, pitch, etc., are seldom if ever employed for insulati
purposes while in their native condition, but are treated, or mixed with ott
materials, or adulterated, in a great variety of ways. They form the bases
constituents of many different insulating compounds, but undergo numero
chemical or physical changes in manufacture.
288. Ice. The disruptive strength of ice is 11 kv. (max.) per cm.; diele
trie constant, 86.4; resistivity, 7.2X10' ohm-cm. See Thomas, P., "T
Dielectric Properties of Non-conductors;" Jour. Franklin Inst., 1913, Vi
CLXXVI, pp. 283 to 301. According to Whittaker's Pocketbook, pu
water has a resistivity of 7X 10^^ ohm-cm.
209. Ivory has a resistivity at 22 deg. cent, of 2X10' ohm-cm.
260. Kaolin is a white china clay whose chief ingredient is the miner
kaolinite, and the latter has the chemical composition H2Al2Si2O8-|-lH20,
hydrous silicate of aluminum. Kaolin is highly refractory and is one of t.
principal materials employed in the manufacture of porcelain. It is som
times employed for insulating purposes.
261. Lava is a mineral talc, which has the chemical composition HsMf
Si«Oi2, or hydrated magnesium silicate, and is similar to soapstone, pumi
and talc. It is slightly soluble in hydrochloric acid, but is not attacked 1
other acids or alkalies. While in the natural state it can be machined wi
the same facility as brass. It neither shrinks nor expands under the i
fluence of moisture and has a very small coefficient of expansion.
After machining, it is baked at about 1,100 deg. cent, which renders
extremely hard. Its insulating resistance is high and according to tes
made by the American Lava Co., its dielectric strength varies from 3,000
10,000 volts per mm., according to the thickness. See Par. 270 and 271.
262. Lavite (also see lava) is a light buff or cream-colored insulating m»1
rial invented and patented in 1885 by D. M. Steward. The manufacture
supply the following information: Density, 2.5 to 2.7; electrical resistivit
500 to 2,500 megohm-cm.; disruptive strength, 200 to 250 volts per m
modulus of rupture, 6,000 to 12,000 lb. per sq. in.; compressive strcngt
20,000 to 30,000 lb. per sq. in.; compares with glass in hardness; not affect
by temperatures up to 1,000 deg. cent.; unaffected by acids except aqua regi
263. Marble is a limestone of the crystalline variety which will take
high polish and exhibit pleasing color effects. Its chief constituent.s a
lime and magnesia, or their carbonates; it also contains water of formatji
and sometimes metallic veins. It is used very extensively for low-tens*
304
 PROPERTIED OF MATERIALS Sec. 4-264

Its properties can be improved by treatment

in molten
itchboard panels.
or linseed oil, after all moisture has been expelled,
wax but such
raffin
The resistivity is on the order of 10
atnient results in discoloration.
disruptive voltage in the vicinity of 50 to 100
10^ megohm-cm. and the is

.\U per mil. See tests in Par. 269.

insulating material
264 Mica is generally recognized as the most superior
bein" the best, the
,own to the art, that which is imported from India
Either domestic or
inadian grades next and domestic varieties last.
„dia mica is satisfactory for nearly all
insulating purposes except for com-
fast as the copper bars. J? or
iutators, where it is too hard to wear down as
•e latter service Canadian amber
mica is considered more satisfactory,
muscoyite (white) mica
ing softer than the other grades. All grades of
heating appliances. Mica sheets and
e considered suitable for electric
ashers are used in electrical apparatus and
appliances in almost innumer-
Cut mica in sheets becomes very expensive in the larger sizes.
.le shapes.
le largest
^ commercial listed size being 8 in. by 10 in. On this account it
is customary to build up larger
sizes by connecting together thin
:
B50 layers of mica. Such manufac-
EOO tured mica plate takes a number
of forms.
265. Composition and prop-
erties of mica. Mica is a
refractory mineral constituted of
the double silicate of alumina or
magnesia, and potash or soda,
combined with varying propor-
tions of potash, soda and other
impurities. Iron in excess colors
itgray and black magnesia tends
;

to darken the color; aluminium

and potassium silicates tend to
make the mica transparent.
Mica crystallizes in laminated
form and may be split along its
axis to sheets as small as 0.006
mm.
has a high dielectric strength
It
and is suitable to withstand high
temperatures. However, in its
— Disruptive strength of mica in
air and in oil.
natural state it is not flexible nor
uniform, and permits large sur-
face leakage; so that most mica
K34. instructed and put on the market in the form of micanite, megomit,
negotalc. etc. . . >

The properties of mica are very fully covered in a publication by Zeitler. H,

w •
i u
""Mica: Its History. Production and Utilization;" D. Jaroslaw. London.
;1913: also in the 1912 edition of "Mica," by the Canadian Dept. of Mines.
These sources were utilized in the preparation of the following table.
Sec. 4-266 properties of materials

results of tests made by Rayner at the National Physical Laboratory (Jour.

I.E. E., 1912, Vol. XLIX, No. 212). Power-factorat 920 cycles, 0.001. The !

density of mica is from 2.7 to 3.1. Specific heat, 0.200 to 0.208. It is not !

affected by heat until a temperature of several hundred degrees centigrade'

is reached, when the laminae separate in the harder varieties and tend to
disintegrate into small scales or flakes; amber mica is less affected. Melting-
point, 1,200 to 1,300 deg. cent. It will withstand great mechanical pressura
perpendicular to the plane of cleavage.
266. Mica products. Many products are manufactured from mica, in-
cluding paper, cloth, plate and molded insulation. In some cases the strips
of mica are mounted on paper or cloth, in alternate layers, using an insulating
binder such as shellac. Molded products are usually made from ground
mica mixed with a binder, and sometimes mixed with other insulating mate-
rials such as asbestos, or a gum or compound.
267. Quartz is a form of silica (SiOz) occurring in colorless transparent
hexagonal crystals, but sometimes yellow, brown, purple, green and
other colors. It also occurs in crystalline masses of vitreous luster. Dens-
ity, 2.65. Dielectric constant 4.3 to 5.1. The resistivity is from 10'* to 10" '

ohm-cm. Silica is the principal constituent of glass. Quartz fibres of very

small lateral dimensions are sometimes used for suspensions in delicate
electrical instruments; such fibres have a tensile strength of about 10X10'
dynes per sq. cm. Also see fused silica (Par. 278).
268. Slate is a rock of clay composition, in which pressure has produced
a very perfect cleavage, so that it may be split into thin tough plates. The
principal constituents are silica and alumina, with small percentages of iron
oxides, lime, magnesia, potash and soda. It frequently contains metallic
veins, which make it worthless for electrical work. It is hygroscopic, in
addition to containing water of formation, and is therefore far from an
ideal insulator. The resistivity of a good grade of slate at normal tempera-
ture is of the order of 10^ to 10* megohm-cm., and decreases rapidly at high
temperatures; higher values of resistivity have been obtained with very
dry specimens. The dielectric constant is between 6 and 7. Power-factor
at 920 cycles, 0.086. The disruptive voltage for 1 in. of thickness is from
5,000 to 10,000 volts, or 5 to 10 volts per mil. See tests in Par. 269. Specific
heat, about 0.2; thermal conductivity, 0.0036 g-cal. per cm-cube per ,

deg. cent, per sec. The density is from 2.7 to 2.9. Slate is a satisfac- '•

'
tory insulator where a non-combustible, low-tension material having fair
insulating properties is required. It is sometimes varnished or enamelled to '

keep out moisture.

269. Puncture tests of Vermont slate and marble, * made with flat ij

circular brass electrodes 0.785 in. in diameter having slightly rounded edges,
indicated values ranging from 50 volts to 100 volts per mil for marble (test
pieces 14 in. square and about 1 in. thick) and roughly one-tenth of these ,

values for slate. Blue marble was considered superior to white marble.
Marked heating of the specimens was noted at or near the rupturing voltages,
being less marked in the case of blue marble, and especially marked in slate;
the test pieces were air dried in a warm room for several weeks before ^

testing, but undoubtedly retained a certain amount of moisture. Corona or

brush discharges were very noticeable during the tests, at pressures in the
vicinity of the rupturing values.
270. Soapstone is a kind of soft stone, which is soapy or slightly oily to
the touch. It is also known as steatite, or rnassive variety of talc, of
grayish-green or brown color. It forms extensive beds and is mined for
hearths, sink linings, etc. It is occasionally used for electrical insulation, in
the form of slabs or barriers and will withstand very high temperatures. It
is soft, not very strong, not affected by acids, oils or alkalies; can be ma-,
chined, drilled and sawed, and absorbs moisture. j

271. Talc is a hydrous magnesian silicate, H2Mgj(SiOj)4, containing when I

Eure 63 per cent, of silica, 32 per cent, of magnesia and 5 per cent, of com-
ined water. It has a specific gravity of 2.6 to 2.9. Soapstone and French
chalk are varieties of talc; other varieties are used in making soap, paper,
lubricants, etc. See Par. 261.

* Report of the Vermont State Geologist, 1912, pp. 196 to 219.

306
 i PROPERTIES OF MATERIALS Sec. 4-272

272. Wood is used as an insulating material to a considerable extent. The

of wood employed are usually the hard woods, such aa maple and
'irieties
ckory, impregnated with oil, paraffin wax, or clear air-drying
varnish. The
sistivity of paraffined wood, at 22 deg. cent, is of the following
magnitude:
•ahoganv, 4X10" ohm-cm.; maple, 3X10">; poplar, 5 10"; walnut,X
09X10'"" to IX 1010 (Scientific Paper No. 234, Bur. of Standards).
The
'electric constant and the disruptive voltage are both
dependent upon
hcther the electric stress is parallel or perpendicular to the grain. Paral-
to the grain the dielectric constants of red beech and oak are between
I

5 and 4.8; perpendicular to the grain, 3.6 to 7.7.

" In maple boiled in transformer oil under vacuum, dried under vacuum and
;>iled again at atmospheric pressure, the disruptive voltage along
the grain,
in. of separation, was 70 kv.; at 2 in. it was 90 kv.; across the
1
grain, at
in., it was 60 kv.; at
"i 1 in. it was 80 kv.; dielectric constant, at 20 to 25
g. cent., across grain, 4.1. Well-dried wood should stand 10 kv. per in.
ithout signs of burning or heating. It is extremely important .that the
.ood should be well dried before impregnation, because it is very difficult to
'>'ove the moisture subsequently. When wood contains moisture it is a
. vely poor insulator in the cells conducts elec-
and the water contained
pally. Wood treated with zinc chloride to protect it against decay has
: i

,;..paratively low resistivity; see Electrical World, 1911, Vol. LVII, p. 828.
•or curves of disruptive strength of maple see Hendricks, A. B., "H«h-
jnsion Testing of Insulating Materials;" Trans. A. I. E. E., 1911, Vol. XXX,
p. 167 to 213.
VITRIFIED MATERIALS
Glass is an insulating material in very extensive use, possessing high
273.
esistivityand dielectric strength at ordinary temperatures. The principal
onstituent is silica, ranging from 50 to 75 per cent, of the total contents;
,.otash, soda, lead oxide and lime are also present, in various proportions,
resistivity at ordinary temperatures is on the order of 10" to 10'* ohm-
.^he
and decreases with great rapidity as the temperature increases. Gray and
.m.
Jobbie found that potash glass has higher resistivity than soda glass, and
.nnealing increases the resistivity {Proc. Royal Soc, 1900, Vol. LX VII, p. 197).
\t very high temperatures glass becomes a fairly good conductor. Moisture
eadily condenses upon its surface and it has consequently a high surface
eakage. It is also soluble in water to a slight degree and under weather
,!xposure the surface tends to roughen. The dielectric constant ranges from
ibout 5.5 to 10. The dielectric strength ordinarily ranges from 150 to 300
Volts per mil, and is higher in very small thicknesses. At 920 cycles crown
class has an apparent resistivity of 17X10» ohm-cm.; dielectric constant,
').60; power-factor, 018. Mechanically glass is unreliable and brittle; the
ensile strength is uncertain and anywhere from 1,000 to 10,000 lb. per sq.
'n., with somewhat higher compressive strength. Coefficient of linear ex-
pansion, 0.000008 to 0.0000095 per deg. cent. Density 2.5 to 4.5. For
nformation on glass manufacture see Rosenhain, W., "Glass Manufacture,"
O. Van Nostrand Co., New York.
I 274. Porcelain. The three principal constituents of electrical porcelain
iire feldspar, clay and silica. There are three feldspars: orthoclase, or potash
'eldspar, which is the most important; albite or indianite, which is soda feld-
spar; anorthite, or lime feldspar. The two clays used are ball clay, and china
3lay or kaolin. A
standard mixture of these constituents for testing pur-
poses 20 parts feldspar, 50 parts kaolin and 30 parts quartz. The func-
is
tion of the feldspar is to act as a flux to unite the other constituents into a
vitreous mass when fired. There are two processes of manufacture, the
dry process and the wet process. For details on the manufacture and proper-
ties of electrical porcelain, see an exhaustive paper by E. E. F. Creighton,
"Electrical Porcelain;" Proc. A. I. E. E., May, 1915, pp. 753 to 841. Also see
Perrine, F. A. C, "Electrical Conductors;" D. Van Nostrand Co., New
York, 1903; Chap. XIII.
278. Dry-process porcelain is manufactured by rnolding the moist raw-
mixture under high mechanical pressure and then vitrifying by the usual
firing process. This grade of porcelain is usually very porous and consequently
has a disruptive strength on the order of atmospheric air, or less. At or near
disruptive pressures, however, it heats rapidly and is not suitable for high-
voltage insulation. The safe dielectric strength is on the order of 1,000 volte.

307
Sec. 4-276 PROPERTIES OF MATERIALS

276. Wet-process porcelain is made by mixing

the raw ingredients w
water. The mixture is placed in a and the surplus water
filter press
tracted, leaving a wet plastic cake. The cake
re-mixed in a pug mill
is
make it more homogeneous, then molded or jiggered into a blank of appro,
mate final shape, and allowed to dry. When fairly dry it is turned ii
lathe or tooled to final shape, dipped in the glazing bath and placed in (

kiln preparatory to firing. The glazing mixture is the same as the porcelr
except that it contains more flux, and thus melts at a temperature ban
sufficient to vitrify the porcelain. The finished glaze is virtually a species
glass. During manufacture porcelain shrinks from 10 to 20 per cent, a
much care is required to proportion the parts so that cracking will r
result. The thickness is limited both by the shrinkage and the difficulty
obtaining satisfactory vitrification. High-voltage porcelain is made in
cases by the wet process.
277. Properties of higrh-voltage porcelain. The density is from 2.3
2.5. It is not affected by oils, acids or alkalies; the glaze is said by soi
authorities to be very slightly soluble in ordinary water. Unglazed porcelf
should be non-hygroscopic and on immersion should not increase in densit
A good rough test is to place a drop of ink on the porcelain and note whetl
it spreads or penetrates; alcohol solutions are still better. The linear expa
sion coefficient is from 4.5 to 6.5 X 10"' per deg. cent. The specific heat
0.17 and the thermal conductivity is 0.045 per cent, of that of silver. T
electrical resistivity of unglazed porcelain is on the order of 10'* to lO'' ohi
cm. at ordinary temperatures, and decreases very rapidly with increasi
temperatures; at very high temperatures porcelain becomes a fair conducti
and is therefore unsuitable for electric furnaces.
The dielectric constant is from 4.4 to 6.8 with continuous e.m.f. and abo
10 per cent, less at 50 cycles per sec. At low frequencies the disruptive vc
.

tage is about 30 kv. for a thickness of 0.1 in. and about 110 to 120 kv. for.
thickness of 0.5 in. At frequencies of the order of 200,000 cycles the disru
tive strength, for a thickness of 0.5 in., is on the order of 80 to 90 kv. and
the test voltage is applied rather slowly the disruptive strength varies in mu
smaller proportion than the thickness (see paper by Creighton mention'
below). In some cases mechanical stress has been observed to reduce the d
ruptive strength, but in other cases had little effect. _
i

American porcelains have a tensile strength which is variously stated fro

650 to 2,200 lb. per sq. in., with an average of about 1,400 lb. per sq. i'
The compressive strength is about 10 times the tensile strength. Modul
of elasticity, 2,500,000 in-lb. European porcelains are generally reporti
as having a tensile strength of 4,500 to 6,500 lb. per sq. in. and a compre
sive strength of about 65,000 lb. per sq. in. The follo>ving references C
porcelain are given for the convenience of those who wish more comple?
information. '{

Kempton, W. H. " The Application of Porcelain to Strain Insulatorail

Trans. A. I. E. E., 1910, Vol. XXIX, pp. 967 to 974.
Lustgarten, J. "High-tension Porcelain Insulators;" Jour. I. E. E?,
July, 1912, pp. 235 to 288. li

Imlay, L. E. and Thomas, P. H. "High-frequency Tests of Line Insulators'!

Sothman, P. W. " Comparative Tests on High-tension Suspension Inat*
lators;" Trans. A. I.E. E., 1912, Vol. XXXI, pp. 2143 to 2226. .,

Austin, A. O. "Factors Producing Reliability in the Suspension Insuli;

tor;" Proc. N. E. L. A., Hydroelec. and Transmission Sessions, pp. 201 tj
223' 1913 I

Creighton, E. E. F. "Electrical Porcelain;" Proc. A. I. E. E., May, 191-

pp. 753 to 841.
Also see Trans. American Ceramic Society.
278. Silica. The properties of fused silica are as follows: Resistivity:
ordinary temperature*, on the order of 10'* to 10" ohm-cm., decreasing raj
idly at higher temperatures; dielectric constant, 3.5 to 3.6; dielectr
strength, above 600 volts per mil; melting-point, 1,700 to 1,800 deg. cent
coefficient of expansion, 0.0000006; density, about 2.07. Also see ChemiC'
Abstracts. Vol. IV, p. 866, and Vol. VII, p. 3443. !

279. Tile. Vitrified clay tile is very extensively used for undergroun";
conduits. Although it possesses very fair insulating properties, its use ft
this purpose is owing very largely toitsimmunity from corrosion and disintt
gration under sub-soil conditions and also its ability to withstand a gret

308
 PROPERTIES OF MATERIALS See. 4-280

lee of temperatures without injury. As a rule, it is slightly absorbent,

1 he
•Mvine as much as 3 or 4 per cent, of water, in some cases,
in ii iir.
with a 0.6-in. (1.5 cm.) wall, after 24-hr. immersion,
-ncture voltage,
iiees from about 16,000 to 30,000 volts. It is not affected by arcs unless in
melt locally and
ect contact with them, and in that event will be likely to
area in consequence of unequal heating
,ip or fracture in the surrounding
d expansion.
280 Vitreous enamel consisting of opaque white glass is extensively used
,•coating iron resistor grids and imbedding the resistor wires, thus
forming
n-inflammable and highly fireproof devices capable of withstanding unus-
lly high operating temperatures. Enamelled iron-ware is made exten-
•ely by the process of sprinkling powdered
glass upon red-hot me^al,
lereupon the glass fuses and forms a continuous thin coating.
Ihe
rmulas used for compounding the glass are quite closely guarded as manu-
eturing secrets. What is desired is a thin, strong elastic coating which will
pand and contract with temperature changes at as nearly as possible the
^me rate as iron.
FIBKOnS MATERIALS
"
S81. Cellulose the base of practically all fibrous insulating materials and
is
an organic compound composed of 48 per cent, carbon, 46 per cent, oxygen
id 6 per cent, hydrogen. It is a carbohydrate of the formula (CsHioOs)*,
Wilar in composition to starch. When pure it is a white amorphous mass;
asized, well-bleached hnen paper is nearly pure cellulose. It has a resistiv-
y on the order of 10« to lO'" ohm-cm. at ordinary temperatures and a dielec-
ic constant of about 3.9 to 7.5. All untreated cellulose materials break
bwn at about 120 deg. cent, and should not be subjected to a maximum of
lore than 95 deg. cent. A safe operating limit is about 80 deg. cent.

882. Untreated fibrous materials are as a whole hygroscopic and are

lerefore relatively inferior insulating materials. They are nevertheless
tnployed, some of them, to a great extent, but their use is very largely con-
ned to conditions under which moisture is restricted or expelled. Their
roperties are greatly improved by treatment or impregnation.
283. The impregnation of fibrous and asbestos products with var-
ishes, gums, bakelite, etc., produces several results: First, the treating
laterials fill up the pores of the basic material and eliminate moisture; sec-
ind, the dielectric strength is increased even where there is no moisture to be
onsidered; third, most treating materials assist in producing smooth sur-
-ices; fourth, the heat-resisting quality of the basic material is often in-
reased, and, fifth, the filling up of the pores may in certain cases reduce the
endency to shrink. Incidentally the treating materials increase the heat
onductivity of the insulation, resulting in better radiation.
284. Paper is manufactured from wood pulp, rags or plant fibre. The
ssential processes in manufacture are (1) the reduction of the raw material
'o the consistency of a thin pulp, by means of operations involving the use of
chemicals and steam; (2) the running of this pulp upon a continuous sieve of
ine mesh, which retains the fibres that become felted together; (3) the
-emoval, drying and finishing of the felt so formed. Finished paper retains
Taces of the bleaching or coloring matter employed, and in addition fre-
quently contains a certain amount of loading matter such as china clay, cal-
Mum sulphate and other inert mineral matter. A sizing of vegetable or
mineral solution is sometimes added to render the paper less porous- and
mprove the surface.
The mechanical properties of paper are derived in large degree from' the
5asic fibres employed in its manufacture; thus paper made from wood pulp is
orittle and easily torn, whereas linen or Manila fibre produces a much tougher
and stronger paper. Owing to its porosity paper is hygroscopic and nor-
mally contains from 7 to 12 per cent, of moisture. When thoroughly dry it
bas a very high resistivity, on the order of 10" ohm-cm., but it easily absorbs
water and when wet descends to the class of a poor conductor. The dielec-
tric constant of dry paper is from 1.7 to 2.6. Dry Manila paper has a
power-factor of about 0.007 at 920 cycles. The dielectric strength of various
kinds of untreated paper, ranging in thickness from 1.8 to 28 mils, should
average from 110 to 230 volts per mil; higher values are obtainable from
extremely dry paper. The tensile strength will range from a few thousand up

309
 Sec. 4-285 PROPERTIES OF MATERIALS

to many thousand lb. per sq. in., depending upon the quality of fibre. 3
'

elongation at fracture is slight, about 2 or 3 per cent. For temperature 1

its see cellulose, Par. 281. There are numerous varieties of insulating pa;;,
such as rope paper, Japanese paper, Manila paper, whale-bone paper, fui-
board, pressboard, etc., some of which are briefly mentioned in ot
paragraphs.
285. Treated paper is a clear dry paper impregnated with oxidized lins 1

oil, or a mixture such as oxidized oil and asphalt, or a gum-base varn .

Well-treated papers in thicknesses ranging from 6 to 12 mils break dowi

about 500 to 750 volts per mil. The Mica Insulator Co. gives disruptive ' •

tages for Empire oiled papers, in thicknesses of 1.5 to 18 mils, ranging fr,
1,740 to 800 volts per mil; these values include condenser, rope, bond i\
cement paper and fuller board. The same manufacturer gives for rope pa
treated with a compound of oxidized oil and asphalt, disruptive vofta
ranging from 1,600 to 600 volts per mil, corresponding to thicknesses of T
15 mils. According to Jona, the dielectric strength of impregnated pa
cable insulation is frOm 200 to 250 volts per mil, and the dielectric constan
about 2.5 to 4. The value of the constant k (see Par. 293) for impregna
paper is usually between the extremes of 1,000 and 3,000.
286. Bakelized paper, known under the trade name of bakelite-micar
\ is a dark, hard, homogeneous material considerably stronger than hard fib.
It can be worked with sharp tools, punched only in thin sheets, and cannot
molded. It will withstand continuously a temperature of 150 deg. cent, a'
for short periods 260 deg. cent. It is infusible. The density is about 1.
Moore gives the following properties of bakelite-micarta, measured at 1.
cycles (see Moore, R. W. E., "Properties and U.ses of Bakelite-micarti
Electric Journal, 1913, pp. 645 to 650): resistivity, 2.13X10>» ohm-ci
dielectric constant, 5.2; power-factor, 0.024; dielectric strength, 500
1,000 volts per mil; tensile strength, about 20,000 lb. per sq. in.; coefficie
of expansion, 0.00002 per deg. cent. It is said to be insoluble in alcohol, b(
line, turpentine, weak acids and alkalies, hot water and oils and non-b
groscopic.
287. Asbestos paper, comprised of an asbestos base, is a soft, fiezil'
material of little strength and is hygroscopic. It will withstand an operati;
temperature of 260 deg. cent, without •

injury. The dielectric strength is on

the order of 100 volts per mil. (n Boiled In Trang

Treated asbestos paper. A vari- (2) BoUed Id Usgee

Vanilelied
ety of treated asbestos paper known
(3) T>nilshcd
as Delta sheeting is impregnated with
a black insulating compound which
softens at about 120 deg. cent, and
melts at about 200 deg. cent. It is
claimed that from 2,500 to 5,000 volts
is required to puncture it, in thick-
nesses of 10 to 25 mils.
288. Pressboard and fuller board.
Pressboard is manufactured from cot-
ton rags and paper clippings, in a
number of grades. It is similar to
faper, but thicker and less flexible,
n the untreated condition it is hy-
groscopic, and its properties improve
with its dryness. Uppenborn gave the
resistivity as 11X10' ohm-cm. and
Turner and Hobart gave the dielectric
strength as 200 to 330 volts per mil.
Presspalm is another name for pressboard, applied to a grade manufacture
in Germany. The qualities of pressboard are greatly improved by imprej
nation.
389. Treated pressboard. Extensive tests of oiled and varnished
board are given by Hendricks in " High-tension Testing of Th.-^i
Materials." rron«. A. I. E.E., 1911, Vol. XXX, p. 167. The dielectn
etant of pressboard dried and boiled in transformer oil ranges from 1.3
13 deg. cent, to 7.5 at 100 deg. cent. The dielectric constant of varnishe

310
 PROPERTIES OF MATERIALS SeC. 4-290

about 2.9 at 20 to 23 deg. cent., measured

on 0.1-in board
vssboard is
Fig 3o: eurve (1)
'pSctric strength of treated pressboard is given in
transformer curve (2) for Prcssboard
ipSoard dried and boiledgiven in oil;
two coats of varmsh; curve (3), dried
ed boiled in linseed oil and gum varnish, depending on
of linseed oil and
I riven two to four coats the puncture
clSLs When these sheets are laid together in laminations,
the case of very thin
decreases, but in
Itaee per mil of complete thickness
decrease in as rapid ratio
nfnations^e puncture voltage does not appear to
with single thicknesses. . .

290 Vulcanized fibre* is a hard, dense material of which other the principal
ingredi-
T-edient is paper or cellulose made from
cotton rag stock; the
matter, the latter consisting of analine
fs are zinc chloride and coloring
mineral pigments. The finished material is heavily compressed into
lors or
bf tubes, etc.
sheets, The water and chemicals are not completely
hygroscopic and not a supe-
moved durng manufacture and the product is
™ It will absorb about
material except for moderate voltages.
insulating
per cent of its weight of water in 24
hours. The density ranges from
3 to 1 5 according to the grade;
average 1.4. The resistivity is compara-
dielectrics, or on the order of 10' to 10>o ohm-cm. Certain
/elv low for
Sies are s^d to have a resistivity as high as
TXlO' ohm-cn... Probably
dry state. The measurements of dielectric strength by different
a very
.serverl are widely discrepant. Parshall and Hobart gave 10.000 volts as
e dielectric strength of all thicknesses
from 4 to 1 in. Hendricks gave
,out 200 volts per mil at thicknesses of 50
to loO mils. 160 volts Per mil at
per mil at 0.7 in. and 90 volts per mil at 1.0 in Others
4 in 100 volts
ive found values ranging as high as 300
volts per mil; the results depend
dryness of the material. The tensile strength ranges frpmlO,-
rgely on the
)0 to 20.000 lb. per sq. in. and the
compressive strength is froni 3o 000 to
D 000 lb per sq in. Fibre is not soluble in water or oil. but is attacked by
rone acids, and swells when soaked in water; upon
drying it shrinks appre-
ably and warps badly. Numerous grades of fibre are manufactured and
hard fibre, indurated fibre,
nown by various trade names, as horn fibre,
varieties ha ve better
atheroid, fish paper, etc. The flexible and more fibrous
isulating qualities. Impregnation improves the qualities in marked degree.

291 Treated fibre. The insulating properties of hard or vulcanized fibre

re much improved by treating the pulp with bakehte. A material of this
haracter, known as bakeUte-dielecto, is manufactured by
The Continental
have the following characteristics. It is a hard,
ibre Co and is ?aid to
ough material, hght brown or black in color, and manufactured
in sheets,
ubes and certain special forms; cannot be molded, but can
be machined
iinpervious to hot
ither with or against the grain; is non-hygroscopic and
.-ater oils and ordinary solvents; will withstand continuously a temperature
f 150 deg. cent.; resistivity, 1.1 X lO'^
ohm-cm. at ordinary temperatures,
Qcreasing with temperature up to 100 deg. cent. dielectric
;
strength, 700 to
sq. in.; eompress-
,150 volts per mil; average tensile strength, 18,000 lb. per
ve strength, 21,000 lb. per sq. in.

892 Impregnated fibre duct is in extensive use for both inside and out-
ide construction. It is made in the form of a cyhndrical tube by
wTapping
nany layers of paper or pulp on a mandrel and impregnating it during the
)rocess with bitumen or a compound of hquid asphalt and coal tar, it is
,ometimes known as bitumenized fibre. Tests made on a certain grade
)f this material show that it absorbed from 2
to 3 per cent, of water after 9b
ir. immersion; one manufacturer guarantees not more than 0.75 per cent,
when the ends are sealed. The compound softens slightly at 5o deg. cent,
guar-
md commences to break down at about 95 deg. cent. Manufacturer s range
inteos on minimum puncture voltage, dry, through a 0.375-in. wall,
from 25 to 50 kv after
;
prolonged immersion the dielectric strength will
usually be lowered, depending naturally upon the amount of moisture
absorbed.
293. Varnished cloth is a thin white fabric of cotton or linen muslin
coated with a mixture of boiled linseed oil, resin and benzine. Upon drying
the oil oxidizes in contact with the air and leaves a smooth, hard surface.

* See " Manufacture of n&rd Vihre," Electrical World, Vol. LIII, p. 1437;
also see Vol. LV, p. 1342.

311
Sec. 4-294 properties of materials

Successive coats may be added to secure the desired thickness. This ma

is also known as Tarnished cambric and as varnished muslin.
varnished cambric the usual value of the constant k in the formula _
logio (D/d) is from 500 to 2,000; R is the insulation resistance of theinst
wire in megohm-miles, d is the diameter of the conductor and D is the ol
diameter of the insulation. Dielectric constant, 3.5 to 5.5. Dies'
strength, in commercial thicknesses of 5 to 16 mils, about 500 to 1,300]
per mil; the Mica Mfg. Co. gives 1,000 volts per mil. Also see tests bj
mer, P. M., "The Dielectric Strength of Thin Insulating Materials:"
A. I. E. E., 1913, Vol. XXXII, pp. 2097 to 2131.
Varnished cambric is more elastic than paper and is very suitab
cable insulation. A separator of treated paper, cloth or rubber is apf
to the copper core to prevent any action of the varnished cambric film on ti'
copper. Then strips of varnished cambric are taped over the separat '

with applications of a plastic non-hardening compound between layers

exclude moisture and make the cable flexible. The core is finished by cottc
braiding and weather-proofing, or asbestos braiding and flame-proofin
or a lead sheath over tape. In some types of cable the insulation is grade,
first using rubber and then varnished cambric. The General Electric C
recommends a working temperature limit of 80 deg. cent. (176 deg. fahr^
for varnished cambric cables.
294. Oiled cloth is a thin, white fabric of cotton or linen muslin coate
with two or more applications of pure oxidized linseed oil. The insulatio
properties are derived chiefly from the oil or compound with which the fabri
is impregnated. This material is known by a number of trade names, amon
them Empire cloth. Gray gives the normal dielectric strength, with
10-mil thickness, as 750 volts per mil; the Mica Insulator Co. gives 1,000 t
1,100 volts before baking and 1,100 to 1,200 volts after baking. Silk, liner
canvas and duck are treated by the same process, with dielectric strength
ranging from 1,100 to 1,450 volts per mil with silk, 1,250 to 1,375 volts per m;
with linen and 600 to 775 volts per mil with canvas (Mica Insulator Co.).
296. Impregnated cloth is similar to varnished or oiled cloth, with th
difference that the fabric is treated with an impregnating compound. On'
manufacturer employs a mixture of oxidized oil and asphalt; others use ai
asphaltum or a paraffin base, dissolved in a thinning material. The Mici
Insulator Co. gives puncture voltages for "Kabak" cloth (impregnated cam
brie) ranging from 1,065 to 1,650 volts per mil.
296. Composite insulation of fibrous materials and mica. Ii
applying mica to coils or heavy strap conductors it is necessary to u-se some
fibrous material like paper or cotton as a base for the mica. It is customarj
to build up mica on thin sheets of fish paper or Japanese paper, and to wrap
the resultant sheet around the straight parts of armature coils or heavy con-
ductors. It is also customary to build up mica on a thin cotton tape and to
use the resultant material for taping coils or heavy conductors. If the'
amount of paper or tape is small and if the material is applied in such a
location, as in an armature slot, that the mica will remain intact even after
the paper or the cotton tape has deteriorated, these materials may be expected
to withstand fairly high temperatures.
297. Paper and mica, or mica paper, is prepared from various grades of,
paper by coating them with thin mica scales which are made to adhere by
means of a cementing varnish such as shellac. The layers of mica and paper
are built up in a variety of ways, depending upon the degree of flexibility,
or stiffness, desired. Parshall and Hobart give puncture voltages for compo-
site laminae of alternate paper and mica, ranging from 700 to 1,300 volts per
mil, in thicknesses of 5 to 11 mils. Various combinations of paper and nnca
are manufactured, including Japanese, fish and rope papers and pressboard.
298. Cloth and mica, or mica cloth, is prepared from various fabrics by
coating them with a thin layer of mica, cemented together with a cementing
Varnish like shellac. A layer of paper is sometimes added to the cornbina-
tion. An extra flexible cloth is made by using rubber tissue as a binder,
instead of cementing varnish.
299. Cotton insulation for magnet wires, employed more extensively
than any other material except onaiuel, i.s applied in one, two or three thick-
nesses. Untreated cotton is hygroscopic and breaks down at a temperature
of 120 deg. cent. The thickness of covering varies with the size of wire (see
312
 PROPERTIES OF MATERIALS Sec. 4-300

bles in Sec. 5). Gray gives the puncture voltage of a 7-mil thickness
omposed of two layers) as about 150 volts; impregnated, about 600 volts.
300. Silk insulation for magnet wires is applied in one or two thick-
•sses', ranging from 1 to 2.5 mils per
layer. While it is somewhat hygro-
opic'in the untreated condition, it has superior insulating properties com-
with cotton, and is much improved by impregnation.
ired
Neither cotton
)r silk are the equal of baked enamel
(Par. 351) in dielectric strength.
'
801. Asbestos insulation for magnet wires. Asbestos insulation can
applied to wires and small straps with the use of binding materials, but
;

'all cases, except in that of asbestos tape which can readily be used in tap-
g armature or field coils, the mechanical qualities are quite poor. Asbestos
indings also require considerable space if used in sufficient thickness, they
'•e not in themselves moisture-proof, they have
low dielectric strength, and
D not give a smooth surface.
'
Deltabeston magnet wire is insulated with asbestos fibre cemented to the
ire with a special bond. It is claimed that the maximum continuous work-
\g temperature is 150 deg. cent.; for short periods, 260 deg. cent. The
'isulation thickness is about the same as idouble cotton and breaks down at
'30 to 600 volts.

303. Tapes. Insulating tapes are chiefly of four varieties: (a) those
oven from cotton or silk and untreated; (b) those woven from cotton and
•eated with insulating varnish, or cut from treated cloth; (c) those cut from
loth which has been loaded with rubber or adhesive compound. The lay of
le threads is arranged in three different ways, straight, biased and webbed;
Qe last one is the strongest and does not stretch readily, (d) Paper tapes,
reated and untreated, are cut from finished stock. See "Specifications and
'ests for Insulating Tapes," Electrical World, Vol. LVII, p. 488; also Vol.
.VI, p. 689.
303. Untreated tapes are hygroscopic and for that reason are not entirely
atisfactory unless finally impregnated or protected from moisture.^ Gray
tates that a half-lapped layer of untreated cotton tape 6 mils thick will
withstand about 250 volts when dry; about 1,000 volts when impregnated,
'recautions should be taken to detect the presence of bleaching and chem-
:;al matter, such as chlorine, which may attack copper. Webbing is some-
imes used for mechanical protection, aside from its insulating qualities.
304. Varnish-treated tapes are cut from sheets of treated cloth, such as
Empire cloth, varnished cambric and the like, and are used for taping wind-
Qgs which cannot readily be impregnated. They are cut straight or on the
lias, the latter being sometimes preferred for taping uneven surfaces. See
reated cloth. Par. 293 to 296.
305. Rubber-treated tapes are composed of fabric loaded with plastic
ubber gum or compound in a soft adhesive state. Such tapes are used ex-
ensively in making water-proof joints on underground rubber-insulated
ables, or in other locations where a moisture-repellent wrapping is desired.
They are frequently used in conjunction with a splicing gum of similar com-
and protected by water-proof insulating compounds and outside
)Osition,
vrappings of adhesive tape with insulating paint over all. In the case of
_

mderground cables a lead sleeve is wiped over the whole joint, making it
iompletely water-tight.
306. Adhesive or friction tape is composed of fabric loaded with a
iticky or adhesive compound. The base of the compound in the more
jxpensive grades is rubber gum, adulterated with fillers in various well-
cnown ways, while the less expensive grades contain little or no rubber and
ts place is taken by one of the numerous bituminous compounds. This kind
,)f tape possesses fair insulating properties and is very extensively used in

low-tension work.
. 307. Paper tapes of both the treated and the untreated varieties have a
Host extensive use in the manufacture of paper-insulated cables for power
md communication service. See paper. Par. 284.
308. Asbestos tape, or a tape having a base of asbestos fibre, is superior
n its heat-resisting properties to cellulose materials such as paper and cloth.
Such tapes are usually known by trade names, among them being deltatape.
rhe latter it is claimed can be raised to 260 deg. cent, before breakdown oc-
jurs; puncture voltage, about 250 volts per mil.

^^_ 313
Sec. 4-309 PROPERTIES OF MATERIALS

MOLDED COMPOSITIONS
309. Molded insulation embraces a great number of different
positions and compounds, which are difficult of classification. The -

ingredients of some of these materials are well known, while others are;

by secret formulas and processes. Among the raw materials employ

the manufacture of molded materials are mica, asbestos, silica, clay, alk
earths, wood pulp, cotton, hemp, flax, asphalt, camphor, hydraulic cei
rubber, shellac, copal, dammar gum, rosin, paraffin wax, linseed oil, tui
tine, benzine, alcohol, phenol and formaldehyde. The following gi :

classification of molded materials has been adapted from "Classific

and Characterization of Molded Insulations," by E. Hemming (Elec
World, 1914, Vol. LXIII, pp. 761 to 762, 798 to 799, 813 to 817).
limiting properties given for each class of material below should be i

sidered in connection with more specific particulars in the paragra

immediately following.

Class
 PROPERTIES OF MATERIALS Sec. 4-313

la Asbestos molded with a binder,

known under the trade names of
by the Hemming Mfg. Co..
i

iamon hen^t and tegit. is manufactured ^Gammon is black and can be

^rXm the followini data was obtained.
tegit is dark brown and can be po ished, though less highly
"ly polished;
both gray and black and will also take a
?n gummon; hemit is made in These materials
sh The density varies, in the
neighborhood of 2
but will gradually carbomze at
suitable only for molding; are infusible,
will not resist concentrated acid; are not
Lher than working temperatures;
wmmended for working pressures above 1.000 volts.
Strength
Ohm-cm. Max. Dielectric (lb. per sq. in.) Absorp-
at 22 working strength tion of
deg. cent. temp (volts per moisture
(Bur. of (deg.
Com- (per
mil) Tensile press-
Stds.) cent.) cent.)

lX10i» 1,100 50 2,000 1,600

jinit
immon. 3X1012 320 75 600 550
2X10'2 200 50 1,200 1,100
git

\.ls9 see Hemming, E. " Molded Electrical Insulation and Plastics;"

t.usen and Co., New York, 1914.
•114 Asbestos wood or lumber, known also by the trade names " Trans-
asbestos
iAsbestos Wood" and "Asbestos Building Lumber," consists of
le and hydraulic cement, and is used as a substitute for wood in building
for slate and
.istruction. It is also used to some extent as a substitute
irble in electrical construction. The following data (Par. 316 and 316)
3 furnished by C. L. Norton; also see his paper entitled, borne Refractory
Institutes for Wood," Jour. A. S. M. R. 1912; and "The Manufacture
;i Use of Asbestos Wood," on pp. 375 and 379 of "Technology and In-
I atrial Efficiency," McGraw-Hill Book Co., Inc.,
New York, 1911.
U6. Transite asbestos wood is light gray in color and is
manufactured
i sheets up to about 4 ft. by 8 ft. by 2 in. It has a density of about 2.0
can be sawed and bored like wood but is harder and slower to
cut. At
') deg. cent., partial dehydration and partial loss
of strength occurs, but
idoes not soften. At 1.100 deg. cent, the material holds shape and con-
:erable portion of its strength, but it will not stand temperatures
above
The temperature coefficient of expansion at ordinary
00 deg cent.
nperatures is about 0.000008 per deg. cent. The thermal conductivity
i
0.0005 cal. per cm-cube per sec. per deg. cent. Transverse breaking
'ts give a modulus of rupture of about 5,000 lb. per sq. in and the crushing
length is from 20,000 to 25,000 lb. per sq. in. When dry, at or near .20
.?. cent., it has a resistivity of about 150,000
megohm-cm It is dissolved
!wly by acids. When used in dry or hot places it is suitable for electrical
iulation and is tougher than slate or marble. Since it absorbs moisture it
iaot suitable for damp locations.
<J16. Ebony asbestos wood is asbestos bonded with magnesia, cement
.d saturated with an insulating compound. It is black, smooth and glossy
d has a density of about 1.9. It can be worked the same as slate but more
•>idly and easily. The working temperature limit is about 200 deg. cent.;
loes not soften; the melting-point is above 1,400 deg. cent. The coeltici^nt
_

cent. The thermal conductivity is 0.000b5

expansion is 0.000010 per deg.
per cm-cube per sec. per deg. cent.
.
It has a modulus of rupture
.about 5,000 lb. per sq. in. and a crushing strength of lo 000 lb. per sq. in.
\ 20 deg cent, after 96 hr. immersion the resistivity is above 3 XIO" meg-
m-cm. and changes 5.3 per cent, per deg. cent. The disruptive strength
greater than that of slate or marble, and it also withstands better
the
ects of surface arcing. It is also tougher than slate or marble.
,317. Bakelite and bakelite compositions. Bakelite is a condensa-
-n product of phenol, manufactured in three grades. Bakelite A is
3 initial raw material and exists in liquid,
pasty or solid condition; upon
ating it is converted into "B" which is an intermediate solid
product,

315
Sec. 4-318 PROPERTIES OF MATERIALS

softening under application of heat and suitable for molding; bakelite "(
is the final product, produced by heating "A" or "B," and is a hard, no
resinous, infusible solid, in appearance resembling amber or hard rubb(
In color it can be made transparent or opaque; colorless to yellow, brow
red and black. The coloring matter, when any is used, consists of orgai
dyes or mineral pigments. The raw material is sold in dissolved, liquid
solid condition, and is used for varnish, lacquer, enamel, impregnation, a
hesive cement, plastic molding compositions and molded articles. It c:
be molded into any shape by casting or by forming in the hot press, and w
receive metal inserts. In condition of final hardness it can be worke
machined and polished like amber or hard rubber, and can be used at co
tinuous temperatures considerably above 100 deg. cent. It is not a gi
conductor of heat. For short periods it will stand 250 to 300 deg. ci
Swoboda gives 230 deg. cent, as the maximum working temperatur<
bakelite-asbestos. At higher temperatures it is infusible, but chars. It
not attacked by the solvents or many of the acids, but will not withstai
hot sulphuric acid, nitric acid, bromine or strong alkaline solutions; tl
effect of chemicals is dependent in some degree upon the grade of materia
It is non-hygroscopic, and is said to resist steam and boiling water. The dal
given below were furnished by Dr. L. H. Baekeland, the inventor of bakelit
 PROPERTIES OF MATERIALS SeC. 4-320

which will not harden under heat; thia product is heated and
then
B stance
hard, infusible and practically
ribined with a hardening agent, producing a
which the manufacturer (Condensite Co. of America)
niuble substance
f ms is high in dielectric
and mechanical strength and heat resistance
'- following data on the properties of molded condensite were furnished
I the manufacturer:
Density, 1.25 to 2.0; not hygroscopic, unaffected by
attacked by strong nitric
ver insoluble in the ordinary solvents and oils,
potash, slightly attacked by sulphuric acid. The resistivity
, i and caustic
ohm-cm. (Bur. of Stds.); dielectric strength.
'2 dee cent is about 4X10'"
Jmt 300 to 400 volts per mil at a thickness of 0.15 in. and per 500 to 600 volts
strength, 4,300 lb. sq. in. com-
5 mil at a thickness of 0.04 in.; tensile ;

l-^sive strength, 26,000 lb. per sq. in.;

not perceptibly affected by 48 hr. of
5.03ure to a temperature of 200 deg. cent.; maximum working temperature.
cent. (Swoboda, Elec. Jour., May, 1913).
deg Also see Electrical
II
Uew and West Elec, Vol. LX, p. 199.
Dielectrite is a black molded composition composed of
vegetable
120
application of
re and mineral filler. It is molded and vulcanized by the
,it. Resistivity at 22 deg. cent., 5X10>2 ohm-cm.
liSl Electxose is a dark brown or black composition of hard, tough
which it is claimed is non-hygroscopic and not affected by
water
ality
oil It can be molded in any form, will hold
metal inserts, and can be
is about 95
en a smooth glossy finish. The working temperature limit ohm-cm The
reent. Resistivity at 22 deg. cent., 1 X10'« to 209XIO"
of at least
inufacturer (Electrose Mfg. Co.) claims a dielectric strength
5 volts per mil, in a thickness of i in.
Electrose is used mthe naanufacture
many different forms of insulators and bushings and is alsoVol. made in pliable
and LVI. p. 887.
;ulating flooring. See Electrical World, Vol. LI V, p. 797
323. Gohmak is a molded substitute for hard rubber made
by the Vulcan-
d Products Co. The density ranges from 1.4 to 1.8 according to compo-
ion The claim is made that it is non-hygroscopic and insoluble m oils
10>o ohm-cm. at ordinary
d weak solutions. Resistivity, on the order of 2 X on
oiperatures, decreasing with rising temperature. Dielectno strength,
e order of 400 volts per mil. at a thickness
of 0.25 in Tensile strength,
Softens slightly at 100 deg. cent.
300 to 12,000 lb. per sq. in.
323. Insulate is a black molded composition composed of
mineral eom-
und and resembles hard rubber. It can be moulded in any shape and can be
The manufacturers (General Insulate Co.) claim
jrked and machined.
'at it is non-hygroscopic, insoluble in all weak
solutions and has a maximum
Drking temperature of 150 deg. fahr. The resistivity of No. 2 grade at
: deg.cent, is SXW ohm-cm. The dielectric strength is on the order of
volts per mil, at a thickness of 0.4 in.
,.

together by
324. Molded mica is made of finely split mica scales held
sheets or
strong insulating varnish, binder, or cement, such as shellac, the
rms thus built up being subjected to heat and pressure. These composi-
jns are more or less heat resisting, dependent upon the nature
and propor-
3ns of the binder employed. They are known by a variety of trade names
,ch as micanite. mica plate, micabond, micabeston,
turbomic. tormica,
'egomit. megotalc, etc. The less binding material they contain the nearer
ley approach the properties of natural mica. Such reconstructed or molded
ica is made in three commercial forms, as follows: (1) Molded plate,
which
Scomes flexible when heated and in that condition can readily be formed
to various shapes such as rings, troughs, spools, and. mthinner sheets,
.lied into tubes. Upon cooling it regains its rigidity. It can be used for
ly purpose where very high temperatures ares not encountered, except
for
)mmutator bars. (2) For insulating commutator segments. It cannot
= molded and offers great resistance to heat. Canadian amber mica is
(3) Flexible sheets which may be bent to
-ef erred for this purpose.
shape
ithout application of heat, for insulating armature slots, magnet and
com-
lutator cores, etc. It is also used in conjunction with tapes for insulating
ires and cables. ^ , x ._
. ^ \ iu *
Rayner concluded from his tests (National Physical Laboratory) that
.'^nerallyspeaking, thin qualities of micanite up to about 1 mm. will with-
-and a stress of 20,000 volts per mm. (500 volts per mil) in air for 10
min.
Ibove this thickness, up to 2.5 mm., there is more difficulty in making
Material which will withstand this stress, and usually the material withstands
16 voltage longer under oil.

317
Sec. 4-325 PROPERTIES OF MATERIALS
The Mioa Insulator Co. gives the following dielectric strengths for micani
of different grades:

Use Grade Thickness Volts per

(mils) mil

For molding India 10. to 125. 955

For commutators. India 10. to 125. 955
For molding Amber 20. to 62.5 830
Plate for flat work India 62.5 to 500. 800
Flexible India 5. tol25. 588

The resistivity is on the order of IQi' ohm-cm.

326. Kozite is a black moulded composition, the properties of whi •

are given as follows by the Northern Industrial Chemical Co. Density, l.^
can be molded into any shape and will receive metal inserts; will take a hig
polish; infusible and insoluble; will not support combustion; absorbs 0.5 t
1 per cent, of water after 24 hr. immersion; dielectric strength, 80 volt
per mil.
326. Sternoid (Dickinson Mfg. Co.) is a black, heat-resisting, moldei;
material which the manufacturers claim has high dielectric and tensil
strength and is heat-proof up to 260 deg. cent. The same manufacturer
also produce other molded materials known as stern-asbeston, heat-proo
up to 200 deg. cent.; stern-condensit«, heat-proof up to 175 deg. cent
and capable of being worked, machined and polished; rubber-substitutes
heat-proof up to 70 deg. cent.
327.Vulcabeston (Johns-Manville Co.) is an insulating material mad(
of asbestos and rubber, the latter being used as a binder. This materia
is grayish brown in appearance, can be molded into nearly any shape, anc
has a surface which will not take a smooth finish. The softening point ii
about 175 deg. cent., with a safe working temperature of about 150 deg
cent. The resistivity at 22 deg. cent, is about 2X10'° ohm-cm. Th«
dielectric strength is about 90 volts per mil, the test pieces being 0.25 in
thick. Change in temperature has no effect on the dielectric strength.
Since this material is of a fibrous nature, it is not suitable for use in damp
places. Acids have a slight effect upon it. The transverse strength is
3,600 lb. per sq. in. See Electrical World, 1912, Vol. LX, pp. 893 and 894.
328. Vulcabeston No. 201 (Johns-Manville Co.) is a material composed
of asbestos and a special gum
used as a binder. In appearance it ha«
a brown mottled surface which will take a very high finish. Intricate and
complicated pieces can be readily molded from it, using metal inserts if
desired. The softening temperature is between 260 and 300 deg. cent.,
and the safe working temperature is about 230 deg. cent. The dielectric
strength is about 115 volts per mil with test pieces 0.25 in. thick. Trans-
verse strength, 9,000 lb. per sq. in. Not affected by most acids, and not
affected by oil or water.
329. Vulcalose is a molded material having the properties of hard rubber,
except that it is said to be considerably tougher. It can be molded in any
form and is used, among other purposes, for insulators.
RUBBER AND ITS DERIVATIVES
330. Rubber or caoutchouc is the general name applied
to a great
number of different natural gums, the different varieties being of decidedly
unlike characteristics, but having among themselves certain common prop-
erties and similar constituents. The synthesis of rubber shows that it
belongs with the terpenes, having the formula (CioHie)™, but thus far all at-
tempts to show the size of the molecule have been unsuccessful. In addi-
tion some of the crude rubbers contain proteids, resins, hydrocarbons, etc.;
in some cases it requires extensive treatment to obtain the pure gum. Crude
rubber is obtained by coagulating and drying the milky latex obtained from
certain species of trees and plants, the principal sources being in South
America, Central America, Africa and Aisia, the Amazon district of South
America being especially noted for its high-grade rubber. Crude rubber is
affected in marked degree by temperature, being soft and sticky when warm
but stiff when cold.
318
i PROPERTIES OF MATERIALS SeC. 4-331

331 Reduction of crude rubber. The lumps or biscuits of crude

ibber are boiled in water, ground, washed, dried,
mixed with sulphur,
dulterants and filler and then calendered. For details of the process see
errine F A C. "Conductors for Electrical
Distribution, New
York,
-903- and Esch, W. "Handbook for India-rubber Engineers," Haraburg,
912' Owing to the high cost of pure rubber it is almost universally adulter-
ted and many rubber products do not contain
over 20 to 30 per cent, of
ure gum, and sometimes much less. Among the numerous adulterants in
pitch, oil, etc., and hllers such
se are rubber substitutes, ozokerite, paraffin,
s zinc oxide, white lead, red
lead, barium sulphate, magnesium carbonate,
arium carbonate, chalk, lamp-black, talc, alumin flakes, etc.
Vulcanization. When rubber and sulphur are heated to a temperature
bove the melting-point of the latter, 120 deg. cent., the two combine and
)rm a new product termed vulcanized rubber, which is stronger, more
and less susceptible to temperature changes than pure rubber. 1 he
iastic
egree of vulcanization depends upon the proportion of sulphur, the tempera-
ire and the duration of heating.

332. Bubber substitutes in the true sense have not yet been
produced
n a commercial scale. There are certain so-called substitutes, produced
cm vegetable oils by processes of vulcanization or oxidation, which can
'dvantageously be mixed with rubber for the production of certain articles,
principally
lubber substitutes used not infrequently in wire insulation consist
f oxidized oils, paraffin, resins and rubber
shoddy. The latter is a com-
ound obtained by treating old rubber with steam, sulphuric acid and chlor-
ic of zinc, thus removing most of the vegetable
fibres and the sulphur,
ut leaving the mechanical admixtures of earth and oxides
employed in the
Original manufacturing process. Such substitutes are usually known under
-ade names.
333. Klectrical properties. The resistivity is on the order of 10>* to
0" ohm-cm., varying greatly according to the composition and increasing
•ith the content of pure rubber. The temperature coefficient is negative
nd unusually large, ranging from 2 to 4 per cent, per deg. cent. Del Mar
bates that at any given temperature the rate of change of resistance per deg.
f temperature change is approximately proportional
to the resistance at
•aat temperature, values of the factor ranging from 0.02 to 0.03 for 30 per
'ent. Para compound.
=
Values of k in the formula i2 A; Iogio(Z)/a) for in-
alation resistance of cylindrical wires in megohm-miles, are variable be-
ween wide limits, ranging from about 1,000 to 20,000; d is the diameter of
be wire and D is the outer diameter of the insulation, in the same units.
Tie value of k is very much higher with alternating currents.
» The dielectric constant of pure vulcanized rubber is from 2 to 3; rubber
ompounds, 3 to 4. Jona gives values as high as 6 for certain compounds
fontaining relatively large percentages of Para.
The rubber compound ranges from 300 to
dielectric strength of high-grade
:00 volts per mil; it decreases quite appreciably for long periods of electnfica-
,on. Lufkin states {Electrical World, 1913, Vol. LXI, p. 1310) that for each
ubber compound there is a critical temperature at which the puncture vol-
age is a maximum. This ranged between 40 deg. and 80 deg. cent. fo>" five
ifferent grades, in a certain scries of tests. One particular grade, or high
uality, gave a maximum at 70 deg. cent., being 30 per cent, above the value
t 20 deg. The range was carried to 100 deg. cent, at the upper limit, and
deg. at the lower.
Fleming and Dyke measured the power-factor of rubber at 920 cycles
nd found values of 0.005 for pure India-rubber and 0.002 for vulcanized
ndia-rubber. For further data on electrical properties, consult the follow-

Jona, E. "Insulating Materials in High-tension Cables;" Trans. Int.

;;iec.Congress, St. Louis, 1904, Vol. II, pp. 550 to 571.
Fisher, H. W. "Rubber-covered Wires;" Trans. A. I. E. E., 1907, Vol.
;:XVI, pp. 997 to 1025. . t t. r^
Osborne, H. S. "Potential Stresses in Dielectrics;" Trans. A. I. E. ti.,
910, Vol. XXIX, pp. 1553 to 1681. .

Hering, C. "Thickness of Electric and Thermal Insulation," Electrical

Vnrld, 1911, Vol. LVIII, pp. 1303 to 1305.
Lendi, J. H. "The Thickness of Insulation on Wires and Cables," Elec-
ical World, 1912, Vol. LIX, pp. 590 to 592.

319
Sec. 4-334 PROPERTIES OF MATERIALS
334. Mechanical properties.* The density of pure rubber is 0.93
0.97; rubber compounds, 1.7 to 2.0. A properly vulcanized compound
high-grade rubber suitable for the best hose and packing, has a ten
strength of about 2,000 lb. per sq. in. and may be stretched to about sev
times its original length. The physical properties, however, are subj
to wide variations depending upon the relative proportions of gum and fil
and the extent of vulcanization. The real value of rubber depends ui
the length of time which it will retain its desirable properties. It of
deteriorates less rapidly when in use than when lying idle; deterioratior
accelerated by heat and especially by sunlight, probably as the result
oxidation. Other things being equal, the better grades are stronger, ni
elastic and more durable than the poorer grades.
The following tests made by the Bureau of Standards indicate the prop
ties of six different grades of rubber (See Circular No. 38).
 PROPERTIES OF MATERIALS SeC. 4-341

rcha and Balata," Cologne, 1903; Seeligmann, Torrilhon and Falcounet,

and Gutta Percha," 1910; Del Mar, W. A., "Electric Power
•?idia-rubber
(nductors," 2d edition, New York, 1914; Kempe, H. R., "A Handbook of
Ictrical Testing," 7th edition, London, 1908.
41. Hard rubber or ebonite is a rubber compound containing a large
I'centage of sulphur and highly vulcanized. It is a hard dense material
isessing many desirable properties as an insulator at temperatures not
gitly exceeding normal. The resistivity is on the order of 10'' to 10'*
cci-cm. at ordinary temperatures; the surface resistivity is impaired by
^osure to sunhght (See Scientific Paper No. 234, Bureau of Standards.)
Ii dielectric constant is from 1.9 to 3.5. In small thicknesses, of 20 mils,
X dielectric strengthrangesfrom 1,700 to 3,750 volts per mil, tested between
ii. spheres; 1,000 to 2,000 volts per mil, tested between flat electrodes. At
(' cycles it has an effective resistivity of about 1.5X10" ohm-cm.; di-
€!tric constant, 3.17; power-factor 0.005 (Fleming and Dyke). Mechanic-
f it is brittle, but can be worked, machined and polished; tensile strength,
'

t.ut 1,100 lb. per sq. in. and compressive strength about double; density,
\ to 1.25. It is attacked by oils and ozone, but is non-hygroscopic. See
]-mer, F. M., "The Dielectric Strength of Thin Insulating Materials,"
'jins. A. I. E. E., 1913, Vol. XXXII, pp. 2097 to 2131; also Paterson,
lyner and Kinnes, "Notes on the Testing of Ebonite for Electrical
Jrposes," Jour. I. E. E., 1913, Part 217, Vol. L.
:42. Eerite is a vulcanized compound of oxidized linseed oil and rubber
(nbined with various vegetable oils, invented by A. G. Day. According
iPerrine* it has a specific insulation resistance somewhat less than pure
j)ber, but is said to be mechanically more durable than any insulation
inufactured from pure rubber. It is employed in the insulation of wires
1 cables as a substitute for the usual rubber compound.
1 The value
c;he constant k in the formula R = k logio (D/d) is given by the Kerite Ins.
"re and Cable Co. as 4,000 at 60 deg. fahr.; R is the insulation resistance of
i wire in megohm-miles, d is the diameter of the conductor and D is the
;side diameter of the insulation.
<

143. Sulphur has a resistivity of 10" ohm-cm. at 22 deg. cent.; dielectric

»jstant, 2.2 to 3.9; power-factor at 920 cycles, 0.0003.

Kulcanite. See hard rubber. Par. 341.

VARNISHES AND COMPOUNDS
' !••, solidifying: materials, such as varnishes, which are applied as
luids and emerge as solids, are of interest chiefly in their final state. They
I: divisible broadly into two classes: (1) those employed to impregnate or
iat basic materials, such as the fibres and the pulps; (2) those employed
1filling compounds, to permeate or seal extensive voids which otherwise
uld offer lodgment for moisture and deleterious foreign matter. The
pperties of the former class are obviously of importance, principally, in
! ociation with the treated or impregnated base; while materials of the latter
iiss constitute a species to themselves.

_
U6. Insulating varnishes are divisible, according to their applications,
JO four groups :t (A) For impregnating windings; (B) for treating papers
ii fabrics; (C) for cementing purposes; (D) finishing varnishes. They are
10 divisible, according to their properties, into (a) oxidizing and (b) non-
tdizing, and again into (1) air-drying and (2) baking. Oxidizing varnishes
• slass A are frequently composed of linseed oil with a resinous base of copal

« other fossil gum, and when thoroughly oxidized are almost impervious to
• and moisture. The drying action in linseed-oil varnishes takes place
:'t by the evaporation of the volatile solvent and then by the oxidation of
^! oil and the gum; the latter action is hastened by the addition of mineral
'er, the quantity of which depends upon whether air-drying or baking
"imish is desired. In another form of oxidizing varnish the gum base is
1 )laeed by asphaltum, but this is said to lower the dielectric strength and the

J istanee to attack by oil. Non-oxidizing varnishes of class A contain a

*
Perrine, F. A. C. "Conductors for Electrical Distribution," New York
f Van Nostrand
Co., 1903, p. 106.
rt See Fleming and Johnson. " Insulation and Design of Electrical Wind-
Ijb;" Longmans, Green and Co., London, 1913; pp. 63 to 76.

321
Sec. 4-347 properties of materials

base of gum or asphaltum with a spirit solvent, shellac varnish being

example. Varnishes of class B are composed in some instances of linseed
with a gum base, and a mineral drier such as manganese borate or lithar
in other cases linseed oil alone is used. It is essential that varnishes'
class A and class B should be as nearly as possible impervious to moistu
and, for oil-immersed apparatus, not attacked by transformer oil. In t
varnishes of class C, shellac is probably the most extensively employi
Class D varnishes are used mainly for the sake of appearance and to provi
a hard smooth exterior surface in the interest of cleanliness.
347. Impregnating, filling and sealing compounds are prepared frc
a multitude of different formulas. In most instances their composition
guarded as a manufacturing secret and they are marketed under various tra
names, such as Ajax, Armalac, Benolite, Insulatine, Insulac, Ohmlac, Ozi
Resistolac, S. V. W., Victolac, Voltalac, etc. Impregnating varnishes ha
been superseded to some extent by compounds having an asphaltum or p:
aflin base dissolved in thinning material, which are chemically more ine
more resistant to moisture, better heat conductors and capable of filhng t
interstices of windings. Their use is chiefly limited by their temperati
characteristics. The compounds on the market offer a fairly wide range
choice in temperature characteristics, the softening or flow points varyi
from about 50 to 130 deg. cent. The Minerallac Elec. Co. gives the followi
properties for Minerallac No. 2, a semi-solid compound: softening point,
deg cent.; melting-point, 63 deg.; flash-point, 202 deg.; burning-point, 2
deg.; resistivity, 1.3X10" ohm-cm.; dielectric constant, 2.1; dielecti
strength, 1,000 volts per mil.
In the case of filling and sealing compounds, the thermal properties a
relatively of more importance than the dielectric strength; chemical inertnt
and imperviousness to moisture are very important. These compoun
should be tested for softening point, evaporation, melting or pouring poii
flash-point, burning-point, characteristics at extremes of working temper,
ture, cubical expansion, chemical activity, effect of moisture and electric]
properties. !

348. Vacuum drying and impregnation is very extensively employi

in the application of fluid or liquid treatipg materials. The winding
substance to be impregnated is first dried in a steam-heated, vacuum chambe
then the hot insulating fluid is admitted, the vacuum islet down, andpressu
is applied, to the extent sometimes of 60 lb. per sq. in. In this way the raoi
ture is driven out and the maximum degree of impregnation is secured.
349. Asphalt is a natural mineral pitch of bitumenous character er
ployed in the manufacture of insulating varnishes and impregnating cor
pounds. Chemically it is a mixture of hydrocarbons, generally black
color, hard at ordinary temperatures, becomes viscous at about 70 deg. cer
and melts at about 100 deg. cent. The density is from 1.04 to 1.40. It'
more or less soluble in oil of turpentine, ether, alcohol and chloroform. Tl
dielectric constant is about 2.7 and the dielectric strength according
•

Symons is 30 volts per mil at a thickness of j\j in.

350. Bitumen. The term originally referred only to asphalt or miners
pitch, but its meaning is now extended to embrace any of a number of inflar
mable mineral substances consisting mainly of hydrocarbons, and includir
also the mineral tars. Coal-tar pitch is a fair insulator, but is brittl
according to Symons it has a dielectric strength of about 50 volts per mil.
351. Enamel (baked) insulation for small magnet wires has to
great extent displaced cotton and silk, or is used in conjunction with ther
The composition of the enamelling compounds used by different mam
facturers is guarded with much secrecy; the base of the compound, in son
instances, is said to be stearin pitch. Chemically stearin is glyceryl tri
tearate; it melts at 67 deg. cent. It is also known as tristearin and is
prominent constituent of many animal and vegetable fats and oils.
The wires are drawn slowly through a warm bath of the melted compoun
and then through a baking oven, the process being repeated to secure £
many coatings as required. One of the defects sometimes found in the coa
ing is the occurrence of very small holes, like pin holes, exposing the condu«
tor; such defects can be detected by drawing the wire through a mercur
bath. The coating is usually very thin, on the order of a few tenths of a mi
The dielectric strength varies over a range of about 300 to 1,200 volts (max
322
 PROPERTIES OF MATERIALS SeC. 4-352
li

mil an average value being 500 to 600 volts per mil, or about
four times
t value for silk. The electrical resistivity at ordinary temperatures is
ry high, on the order of 10'* ohm-cm. Baked enamel should stand a tem-
I ature
of 100 deg. cent, continuously without injury, but breaks down elec-
{•ally at about 300 deg. cent. It is a fairly good thermal conductor and
Jich superior to cotton and silk. An enameled wire should withstand
Tiding around a mandrel four times its own diameter without injury,
'rpentine, shellac, alcohol, vegetable or animal oils, and coal-tar solvents
•
attack it, but it is not injured by clean mineral oil and is moisture-proof,
1

jshould be carefully handled to avoid injuring the coating.

152. Linseed oil is a vegetable material derived from flaxseed, having a
I'lsity of 0.932 to 0.936 at 15 deg. cent. It has excellent insulating proper-
U and is extensively used in paints and varnishes. For specifications and
properties see "A. S. T. M. Standards;" and Technologic Paper
'aeral
Bureau of Standards, 1912. Boiled linseed oil has the property of
9
. dizlng under ordinary exposure to air and the process will
contmue until Jt
;oraes viscous or even hard; the action can be hastened by
drying agents
i the application of heat.
563Ozokerite (ozocerite) is a wax-like mineral, colorless or white when
,reand consisting of a mixture of hydrocarbons. It is used in making cere-
'

candles, etc. Crude ozokerite has a resistivity on the order of 4.5 X 10'*
m-cm Liquid ozokerite has a dielectric constant of about 2.1. Ceresin
a yellow or white wax made by bleaching and purifying
ozokerite and
employed as a constituent of insulating compounds; its density is 0.75;
listivity, over 5 X 10'« ohm-cm. at 22 deg. cent.
of a com-
364. Paraffin is a colorless or white waxy substance, consisting
>x mixture of hydrocarbons, obtained by the distillation
of wood, coal or
Chemically it is inert, being unaffected by most strong reagents. Ac-
rding to composition, it melts at from 45 to 80 deg. cent, and has a density
i0 87 to 0.94; resistivity, 10" to 10>» ohm-cm.; dielectric constant, 1.9 to
i; dielectric strength, about 300 volts per mil
power-factor at 920 cycles,
;

)003.
366. Resin is defined as any of various solid or semi-solid organic sub-
mces, chiefly of vegetable origin, usually yellowish to brown in color, trans-
i.rent or translucent, and soluble in ether, alcohol, etc., but
not in water.
aey soften and melt on heating. Chemically they differ widely, but all are
;h in carbon and hydrogen and contain also some oxygen. Among the com-
ercial resins are amber, copal, dammar, guaiacum, lac, mastic, rosin and
ndarac. Lac is the raw material used in making shellac, which has a
sistivity on the order of 10" to 10" ohm-cm. and a dielectric constant of
)Out 2.7 to 3.8.
356. Waxdefined as any of a class of natural substances composed of
is
.rbon, of esters other than those
hydrogen and oxygen and consisting chiefly
glycerin or of free fatty acids. In this class are included beeswax, sperma-
ti, Chinese wax, carnauba wax, etc. Beeswax is a dull yellow solid, of
jnsity 0.96 to 0.97 at 15 deg. cent, and melting at 62 to 64 deg. cent.J
sistivity, 10" to 10" ohm-cm.; dielectric strength, about 250 volts per mil.
I 367. Weatherproof compounds for saturating the cotton braids on
eathcrproof wire usually contain an asphaltum base, with an admixture of
ax so that the surface of the braid may be given a dull polish.

INSULATING OILS
'
358. Oil is emp.oyed as an insulating medium in many ways. It is em-
loyed by itself to insulate transformers and switches by immersion; it is
'sed for saturating fibrous and other materials, as in cable work; drying oils
inseed) are used for coating papers and cloths in sheet insulation; various
inds of oil are employed in mixing insulating paints and varnishes. Oils
f practically every variety are possessed of very high resistivity and dielec-

•ic strength. Chemically oil is composed of hydrocarbons having the gen-

ial formulas CnH2n+2 and CnH2n. The desired characteristics of an insulat-
,ig oil are high resistivity and dielectric strength, low viscosity, high flash
oint, chemical neutrality toward metals and insulating materials, freedoni
,;om moisture, sediment and impurities, and chemical stability under local
igh temperatures.

323
Sec. 4-359 PROPERTIES OF MATERIALS

SB9. Transformer oil. The Ideal cooling and insulating fluid for a tra
former should have the characteristics named in Sec. 6, Par. 60. Thi-
largely used is a mineral oil obtained from crude petroleum by fractii)
distillation, having the following characteristics.

Medium Light

Flash point, deg. cent 180 to 190 130 to 140

Burning point, deg. cent 205 to 215 140 to 150
Cold test ,
-10 to -15 -15 to -20
Density at 13.5 deg. cent 0.865 to 0.870 0.845 to 0.8&
Viscosity at 40 deg. cent. (Saybolt test) 100 to 110 sec. 40 to 50 sec..i
Acid, alkali, sulphur, moisture None None ;

When free from moisture the dielectric strength, between 0.5-in. discs (:

in. apart, with sine-Wave e.m.f., should be from 45,000 to 50,000 volts;
between 0.5-in. brass spheres 0.15 in. apart the average dry oil should i
break down at less than 30,000 volts. The medium grade of oil is usua
employed in self-cooled apparatus and the light grade in water-cooled apj
ratus, but the dielectric strengths are the same. The dielectric streng
between and 100 deg. cent, increases about 0.4 to 0.5 per cent, per d«
The resistivity of dry oil is on the order of lO'^ ohm-cm. and decreases wi
rise of temperature. The effect of moisture is very harmful (Par. 36
and it is of the greatest importance to keep oil absolutely dry or as nearly
as possible. One of the principal advantages of oil as an insulator isits pre
erty of self-restoration after dielectric discharge or puncture; this property
not independent, however, of the energy of discharge, and excessive ener,
may overheat the oil and cause explosion or fire. The specific heat
transformer oil is about 0.39 to 0.51 and the thermal conductivity rang'
from 0.00033 to 0.00043 gram-calorie per cm-cube per deg. cent, per sec. T)
following references should be consulted for further information.
Skinner, C. E. "Transformer Oil," Electric Journal, May, 1904.
Kintner, S. M. " The Testing of Transformer Oil," Electric Journal, Oc
1906.
Tobey, H. W. "Dielectric Strength of Oil," Trans. A. I. E. E., 191
Vol. XXIX, pp. 1189 to 1232.
Farmer, F. M. "The Dielectric Strength of Thin Insulating Materiab
Trans. A. I. E. E., 1913, Vol. XXXII, pp. 2097 to 2131.

360. Electrical properties of oil

(Circular No. 36, U. S. Bureau of Standards, p. 24)

Density Phase difference

at 20 Resistivity Dielectric
Oil
deg. (ohm-cm.) 100 1,200 constant
cent. cycles cycles

Pratts astral (kero- 0.7852 470X10" 0°2'11" 0°0'25'

sene).
Paraffin 0.8710 1,100X10" 0°0'35" O'O' 5' 2.41
Transformer oil (A). 0.8795 0.49X10'2 1° 5'0" 0°5'10' 2.51
Transformer oil (B).. 8682
. 3.1 XIO" 0°30'0" 0°5'30' 2.47

361. Dielectric strengrth of oil with a 1-mm. gap (39.4 mils), expressed ii

volts permm., is given in the table below for numerous varieties of oil.
 PROPERTIES OF MATERIALS Sec, 4-362

voltage with the three different types of

he specifications for breakdown
ik
"'
eao most widely used are as follows: breakdown 22.000- vo ,,ts
To-in. disks spaced 0.1 in. apart,
n ^Jti fli^ko soaced 2 in. apart, breakdown 38,500 vo ts
own.- spheres spaced 0.15 in. a^art,
breakdown 40.000 volts
oils are given in the ac-
M Dielectric constants of various kinds of with the
e fpan°ng table values probably change very appreciably
The
t perature.

3.17 Petroleum 2.02 to 2.19

hid...
4 6 to 4 . Rape seed 1
2.2 to 3.0
istor. . . .
.

3.07 to 3.14 Sesame _ ^ • ^ „ „„

)lza to 3.09
men. . .
2.25 Sperm
Turpentine
P02
2.15 to 2.28
satsf oot 3.07
3.08to3.16 Vaseline 2.17
ive

properties of od
63 Meets of moisture and dust on insulating very serious effect on the
'
nres^ce of moisture in transformer oil has a
.
' P. ®
;!!;„+>, fl, <5hown bv Fie 36. In order to obtain a dielectric
0.5-in. discs), the water pres-
^^nXof
E:mgth 40 OwVolts
01 4U.UUU (0 2-in.'^gap^^
vous K^.^ f^^
^^^ distributed moisture in the oil must
not exceed 0.001 per cent. Fine dust is also
very injurious to the dielectric strength.
For these reasons, various manufacturers
have developed oil dryers and purifiers, which
operate on the principle of a filter press.

364. Formation of deposits In oil-

cooled transformers. The foregoing sub-
ject formed the title of a paper by
Dr A.
C Michie before the I. E. E. in April, 1913.
oxidize in
The author stated that all oils
9 ifl time, but the formation of deposits can be
_

'^itet-piirtJ In IQ.OOO ij
• Vaain* prevented or minimized by avoiding the
following conditions: (1) Overheating; (2)
of water on undue access of air to
the oil (3) conditions
5. 36.— Effect
;
:

likely to give rise to the formation of

ozone;
Jielectric strength of oil.
(4) contact of the oil with
clean surfaces of
)per. lead and iron.
No standard specification for transformer mJis
165. Specifications. the War
but a tentative specification has been >ssued by
available,
:

General. Director of Purchase and Storage,

partment. Quartermaster
gular Supplies Division. Raw Materials and
Paints Branch. Also see
.nufacturers specifications
GASES
366. The insulating propertiesof gases depend upon, and vary with,
affected also by the humidity^
p essure and the temperature, and are
.e only gaseous dielectric in
extensive use is atmospheric au-, whose prop-
ies have been the subject of extended research.
disruptive
367. Air. The dielectric properties of air, and particularly its
ength, have been the subject of more investigation
than any other dielecj
Extended investigations and researches have been made by
c in use.
Van. Mershon. Fisher. Peek, Whitehead, Faccioh,
Harding Bennett, FoN
have been published during the past
icue and Farnsworth, whose results
years in the Trans. A. I. E. E., and by RusseU
(see^our. I. i>. ). E
Air in the free state has electrical conductivity.. The "-f^^t? °btf„°«£,(?^«
hitehead, Proc. A. I. E. E., May, 1915, p. 846) indicate
that in the open the
•rrent passing between two parallel plates 10 cm.
apart and each cm. IW
uare, assuming perfect insulation, would be of the
order ?f "lagmtude 3X
and does
This is the maximum current which may be obtained
" amp.
tincrease with increase of voltage; it dimimshes
greatly if the air is con-
The conductivity may be greatly increased by
ed in a closed vessel.
Rontgen rays, ultra-violet light, etc.,but the magmtude
of
posing the air to
rrent still remains very small. „ , m „„j „;, ;„ olmr.of
usually taken as unity, and air is almost
,

The dielectric constant of air is

iversaUy the medium of reference in all measurements of this constant.

325
Sec. 4-368 PROPERTIES OF MATERIALS

The disruptive strength of air in a uniform, electrostatic field, under n t

favorable conditions, at ordinary temperature and pressure, is of the orde f

38 kv. per cm. or 97 volts per mil (maximum instead of r.m.s. value); Wl.
head found a value of 32 kv. (max.) and Peek found a value of 30 kv. (ma'.
Under unfavorable conditions, the strength is below 30 kv. max (21 \
r.m.s.), as shown by investigations of corona on cylindrical wires (see Sec. \
The disruptive strength is directly proportional to the air density, over a (-
siderable range. If the air density at 76 cm. barometer and 25 deg. cenij
taken as unity, the relative density at any other pressure and temperatui i

3.92&
''
273+<
where 6 is the barometer in cm. and t is the temperature in deg. cent. Apj
ently the degree of humidity has very often little, if any, effect on the -v
ruptive strength.
Advantage is taken of the low disruptive strength of air at low pressu
(small fraction of one atmosphere) in so-called vacuum-type lightning an
tors, recently developed for low- voltage, low-power circuits, such as ti-
phone, telegraph and signal lines.
Sparking distances in air, using needle gaps and sphere gaps, are giviii
the A. I. E. E. Standardization Rules, Sec. 24, Par. 274 to 276.
368. Belative disruptive strenjrths of hydrogen, oxygen, carboi
dioxide and nitrogen \

(Wolf)

Pressure
in
atmospheres
 PROPERTIES OF MATERIALS Sec. 4-370

THERMAL CONDUCTIVITIES.—Continued
Watt-cm. Watt-em.
Material per deg. Material per deg.
cent. cent.

ite 0.020 Woolen (pure) wadding,

ater,25 deg. cent 0.0057 slightly packed 0.00036
oolen (pure) wadding, Woolen (pure) wadding,
DOse 0.00049 tightly packed 0.00023
1 watt = 0.2389 g-cal. per sec. 1 g-cal. = 4.186 watt-sec.
1 watt = 0.0009468 B.t.u. per sec. 1 B.t.u. = 251.8 g-cal.
1 g-cal. = 0.003971 B.t.u. 1 B.t.u. = 1,054 watt-sec.
BIBLIOGRAPHY
70. Authoritative reference literature on. insulating materials
i ather difficult of access to anyone who is not conveniently situated with
lirence to a comprehensive technical library. The art has been advancing
E rapidly that very few up-to-date books are available, and the latest
iormation is scattered through the proceedings of engineering and scien-
1 3 societies and the technical press.

'erbine, F. a. C. —
"Conductors for Electrical Distribution." D. Van
j-.strand Co., New York, 1903.
—
Turner, H. W. and Hobart, H. M. "Insulation of Electric Machines."
'

—
littaker and Co., London, 1905.
Russell, A. "The Theory of Electric Cables and Networks." London,
)8.
Ratner, E. H. — " High-voltage Tests and
Energy Losses in Dielectrics."
. ir. L E. E., XLIX, No. 214, pp. 3 to 89; an extended bibliography
1912, Vol.
—
papers and articles is given on pp. 53 to 71.
Gray, A. "Electrical Machine Design." McGraw-Hill Book Co., Inc.,
w York, 1913.
—
Fleming, A. P. M. and Johnson, R. " Insulation and Design of Elec-
cal Windings."
—
Longmans, Green and Co., London, 1913.
Del Mar, W. A. "Electric Power Conductors." D. Van Nostrand Co.,
—
•w York, 1909; rev. ed., 1914.
Peek, F. W. Jr. " Dielectric Phenomena in High-voltage Engineering."
cGraw-Hill Book Co., Inc., New York, 1915.
Trans. A. I. E. E., Jour. I. E. E., Jour. Franklin Inst., Electric Journal,
neral Electric Review and Science Abstracts (B).

STRUCTURAL MATERIALS
CAST IRON
371.Cast iron derives its characteristic qualities from the impurities
esent. These impurities are the same as those in steel, except for graphite,
lich is one form of carbon. The carbon is always present in two forms:
combined carbon, in the form of cementite; (2) uncombined carbon, or
)

:aphite. The total carbon seldom exceeds. 4.5 per cent, or falls below 3.25
•r cent. The larger the proportion of carbon in the combined state, the
rder and more brittle will be the metal. Cast iron is not ductile, in either
•t or cold state.
Sihcon is a desirable impurity, because it tends to precipitate carbon
the graphitic fornri; about 3 per cent, of silicon gives the best results. Sul-
lur has the opposite effect of silicon, and is undesirable. Managnese in-
cases the total carbon and also the proportion of combined carbon, but
nds to neutralize the similar effect of sulphur. Phosphorus, if present in
fficient proportions to be chemically active, tends to hold the carbon in
mbined form, and also tends to weaken the metal.
372. White cast iron. If slowly cooled, white cast iron will contain
mbined carbon in the form of cementite, which imparts the qualities of
iirdness and brittleneess to the metal. Where the carbon is from 3 to 4
•T cent., cementite will form from 45 to 50 per Unless
cent, of the material.
e cooling is slow some of the carbon will be in the austenitic form. White
St iron has few uses, except as a hard coating or skin for gray iron castings.

327
Sec. 4-373 PROPERTIES OF MATERIALS

373. Gray cast iron usually contains 2 per -cent, or more of grapl.
and less than 1.5 per cent, of combined carbon. The graphite is mechanics'
intermingled throughout the body of the metal; although the percent
by weight may be no more than 4 per cent., the percentage by volume n
be as much as 14 per cent. The smaller the proportion of combined carb
the larger will be the proportion of graphite and the softer and more wo.
able the metal; at the same time this produces a metal of minimum Strang'
because of its porosity. The interstices are filled with graphite, which a
in a degree as a lubricant in machining operations.
Chilled castings are made by pouring cast iron into a metallic m
which cools it rapidly near the surfaces of the casting, thus forming a g|
of harder material than the body of the metal. The rapid cooling deorea;
the proportion of graphite and increases the combined carbon, resulting
the formation of white cast iron.
374. Density of cast iron. Stoughton gives the following densiti
pure iron, 7.86; white cast iron, 7.60; mottled cast iron, 7.35; light gray ci
iron, 7.20; dark gray cast iron, 0.80.
375. Strength of cast iron. (Stoughton)
 PROPERTIES OF MATERIALS Sec. 4-381

Coefficient of Unear expansion,

D^ watt-cm. per deg. cent., for pure iron.
0^00114 per deg. cent., between
- 18 and 100 deg. cent.
half-incli rods and
Jl Electrolytic iron melted in vacuo, forged into
a saied at 900 deg. cent., has
the following average tensile properties.

Tensile Yield Reduction

strength point Elongation of area
(lb. per (lb.per (per cent.).
(per cent.)
sq. in.) sq. in.)

54,800 48,400 33.3 83.0

/forged.

38,100 18,000 51.8 87.4

nealed at 900 deg. cent,
id cooled in 12 hr.

per cent. See Bulletin

he average carbon content of this iron was 0.0125
!« 72, Eng. Exp. Sta., Univ. of 111., 1914.

82 Tensile properties of wrought iron. The following properties

" Manufacture and Properties of Iron and
ve taken from Campbell's Wrought Iron
P>1
" 4th edition, p. 91. Also see Holley, "The Strength of
Reduction in Rolling, Trans. A.
a Effected by its Composition and its
1.

^ E., Vol. VI, p. 101.

Minimum Maximum

irbon, per cent 0.015 0.512

osphorus, per cent. 0.065 0.317
:con, per cent 0.028 0.321
mganese, per cent.. trace 0.097
0.192 2.262
,g, per cent

:imate strength, lb. per sq. in. 47,478 69,779

jngation in 8 in., per cent 6.5 32.7
duction of area, per cent 7.7 59.8

he general influence of reduction in rolling is to increase the tensile

s -ngth and the elastic limit, and diminish the elongation and the reduction
c irea.
STEEL
83. Carbonsteel. Increasing the carbon content of steel increases its
8 ngth, hardness, brittleness, and susceptibility to cracking under sudden
cling or heating; it also diminishes the elongation and reduction of area at
f -ture In acid steel, according to Campbell, each 0.01 per cent of carbon
i -eases the strength by 1,000 lb. per sq. in.,
when the carbon is deter mined
l combustion; or 1,140 lb. per sq. in. when the carbon
is determined by
cjr. In basic steel each 0.01 per cent, of carbon increases the strength by
7' lb. per sq. in., when the carbon is determined by combustion,
or 820
1 when determined by color. , %.
•hosphorus increases the tensile strength 1,000 lb. per sq. in. for each
CI per cent., but tends to make the metal "cold short " or brittle. Sul-
lur does not alter the tensile strength appreciably, but tends to make
t metal "hot short." Manganese increases the tensile strength from
f to 400 lb. per sq. in. for each 0.01 per cent., depending upon
the carbon
I sent, and whether the steel is acid or basic; it also increases the ductility
\en hot. Silicon in small quantities has little effect. Copper has also
Me on the cold properties as far as known. Nickel gives_ a metal
effect
vh a high elastic limit and great toughness under shock. Aluminum in
Pill quantities is added to molten steel to absorb oxygen and improve the
f dity; when present in the finished metal it increases the strength and^
i.jairs the ductility. , , , ,_
The thermal conductivity of steel containing 1 per cent, of carbon, at 18
c. cent., is 0.45 watt-cm. per deg. cent. The coefficient of hnear expansion
I. ges between 0.0000104 and 0.0000132 per deg. cent.

329
 Sec. 4-384 properties of materials
384. Effect of hot working. The effect of hot-rolling or hammej
carbon steel is in general to increase the tensile strength
and the elt"
limit, and to diminish the elongation and the reduction of area at fractu'
386. Annealing carbon-steel tends to remove the strains created by i
i
rolhng and distortion. In general the effects of annealing are: reductio (
tensile strength, elastic limit, and elastic ratio; increase in elongation 1
reduction of area at fracture. In short, the process of annealing tendo
restore the original properties, and to refine the grain or structure.
386. Heat treatment. The finer the grain or structure of steel i
general, the better will be the physical properties. When steel is hesl
to rolling or forging temperature, the crystalline structure is coarsei
but hot working tends to improve the structure. The best results are '
tained by reheating the finished steel to a temperature of about 800 to
)
deg. cent, and allowing it to cool slowly (annealing); the best temperaturi
any instance depends upon the constituents of the steel. The proper 1;
treatment of steel i.s virtually an art in itself. See Howe, H. M., "The Me •

lography of Steel and Cast Iron," published by McGraw-Hill Book Co., 1{.
387. Hardening and tempering. When high-carbon steel is heated i[
medium red and quenched in water or oil it acquires the maximum hardn
becomes brittle, and loses its ductility. The increase in tensile strength m'
to hardening will vary from about 10 per cent, in steel containing 0.10 car),
to 40 per cent, in steel containing 0.75 carbon. Fully hardened steci
usually too brittle for practical use, and requires softening by drawing :

temper; this is accomplished by slowly reheating the steel until its c(

changes from white to the proper shade, ranging anywhere from straw (b
temper) to purple (low temper). See A. S. T. M. specifications.
388. Chrome steel contains usually from 1 to 2 per cent, of chromium a
0.80 to 2 per cent, of carbon. It is characterized by great hardness and hr
elastic ratio. See "Magnet Steel," Sec. 4. Also see A. S. T. M. specificatic
389. Manganese steel. Hadfield* found that the addition of from
to 6 per cent, of manganese to steel made the product very brittle, but af
the proportion exceeded 7 per cent, there was a return of strength and at
to 15 per cent, of manganese a very strong hard alloy was obtained; above
per cent, a rapid decrease occurs in strength and toughness. In its m
serviceable form, manganese steel contains about 13 to 14 per cent, of m:
ganese, and is practically non-magnetic; on account of its extreme hardness
is almost impossible to work it with machine tools and it must be cast in i

approximate form in which it is to be used. Heating to 1,800 deg. to2,(

deg. cent, and quenching in cold water, or "water toughening," increases 1
hardness and resistance to fracture; this is true of both cast and forged n
terial. An alloy of 87 per cent, iron, 12 per cent, manganese and 1 per ce
carbon has a magnetic permeability between 1.3 and 1.5.t The hardnesS;
due partly to the hardness of manganese, and also in large degree to the f(
that the steel is in the austenitic condition, which renders it non-magnet.
On account of its hardness it must be cast in the desired form, since it cam
be machined and can be forged only with difficulty.
390. Nickel Bteel ordinarily contains 1.5 to 4.5 per cent, of nickel s:
0.20 to 0.50 per cent, of carbon. About 3.5 per cent, of nickel added to Cf
bon-steel will increase the elastic limit nearly 50 per cent, and reduce t
ductility about 15 or 20 per cent. The tensile strength is increased also, b
not in as large proportion as the elastic limit. The notable increase in clas
limit and ela.stic ratio is accompanied by an increased resistance to fatig
under repeated stress. In low-carbon steels, the addition of each 1 per cei
of nickel, up to 5 per cent., increases the elastic limit 5,000 lb. per sq. in. ai
the tensile strength 4,000 lb. per sq. in.; these effects increase with high
percentages of carbon. The resistance to compression is also greater. T
value of Young's modulus is the same as for carbon-steel. Nickel steel has
higher resistance to wear or abrasion than carbon-steel, and greater resistan
to corrosion. Special alloys very high in nickel arc known as Invar ai
Platinite; Invar contains 36 per cent, of nickel and its coefficient of expansi<
Mladfield, R. A. Trnnx. Amer. Inst, of Mining Eng., 1893, Vol. XXII
p. 148;Jaur. Iron and Steel Inst., 1888, No. 2, p. 41; Proc, Inst, of Civ. Kii;
1887-1888, Vol. XCIII, Part 3, p. 1.
Hall, J. H. " Manganese Steel," Proc. See. of Chem. Industry, 1914.
t Ewing, J. A. "Magnetic Induction in Iron and Other Metals."

330
 PROPERTIES OF MATERIALS Sec. 4-391

^p^actically zero. Platinito (42 per cent. Ni) has the same coefficient of
Jc)an8ion as glass. See Colby, A. L. "Nickel Steel," Proc. A. S. T. M.,
Ill, 1903.
1.

191.Silicon steel. * The addition of silicon to steel appears to increase

1! strength about 80 lb. per sq. in. for every 0.01 per cent., up to a content
ti per cent.; beyond this point it severely impairs the ductility. A
steel
ntaining 3.40 silicon, 0.21 carbon and 0.29 manganese had a tensile strength
'106,000 lb. per sq. in.; elastic ratio, 0.74; elongation, 11 per cent.; reduc-
\n of area, 14 per cent.; annealed strength, 87,000 lb. per sq. in. The
icon content in structural steels, when used, is ordinarily limited to 0.40
ir cent., in order to avoid brittleness. Silicon is used in electrical sheets,
[jause it substantially increases the electrical resistivity and thus reduces
i; core loss; such sheets are much harder than
ordinary dynamo sheets of
it steel; see "Magnetic Materials" in this section. The thermal conduc-
jity of 4 per cent, silicon-steel, between 20 and 250 deg. cent., is 0.32 watt-
"i. per deg. cent.

393. Tungsten steel is characterized by great hardness and toughness

d its remarkable tempering properties. The tungsten content ranges
•m 0.5 per cent, in ordinary bar steel to 2 to 5 per cent, in finisiiing and
nermediate steels, 4.5 to 12 per cent, in self-hardening or air-hardening
lels, and 14 tb 26 per cent, in high-speed steels. See Baskerville, C.
The Chemistry of Tungsten, Etc.," Trans. N. Y. Elec. Soc, Oct. 29, 1912;
io see "Magnet Steel," Sec. 4.

393. Vanadium steel. The use of vanadium as a constituent in alloy

;el produces more remarkable results than any other element except carbon.
1-tempered vanadium steel containing 0.25 to 0.30 carbon, 0.50 nianganese,
) chromium and 0.17 vanadium has been found to have a tensile strength
high as 233,000 lb. per sq. in., elastic ratio 96 per cent., elongation 11 per
nt., and contraction of area 39 per cent. The vanadium content is usually
.8 than 0.3 per cent. its effect in general is to improve the tensile properties,
;

rdness and toughness.

394. Protective coatings for iron and steel consist of the following: (a)
?ments of various kinds; (b) galvanizing or zinc coating, applied by hot-
pping, electroplating or dry-heating with zinc dust; (c) coating withalumi-
im alloy, by dry-heating with the powdered alloy; (d) tinning, by hot-
pping and rolling; (e) terne coating, of lead-tin alloy, applied in the same
inner as tinning; (f) nickel-plating, applied electrolytically; (g) coating
black oxide of iron, produced by application of oil to the metal when black
•t; (h) enamel coating of glass. For out-door exposures, methods (a) and
) are the ones chiefly used, but neither is free from faults or objections.

>r particulars see Wood, M. P. "Rustless Coatings; Corrosion and Elec-

Dlysis of Iron and Steel," New York, 1905; "Report of the Committee on
eservative Coatings for Structural Materials," 1903 to 1913, A. S. T. M.,
lila.. Pa.; Bulletins No. 30, 35 and 239, U. S. Dept. of Agriculture, Wash.,
. C. Stoughton, B. "The Metallurgy of Iron and Steel," McGraw-Hill
)ok Co., Inc., New York, 1911. Cushman and Gardner. "Corrosion and
eservation of Iron and Steel," McGraw-Hill Book Co., Inc., New York,
10.
STEEL WIRE AND GABLE
395. Table of steel wire
(Roebling)

Breaking Weight in pounds

dumber, Area in
Diameter load at rate
loebling square
ininches of 100,000 lb.
gage inches
per sq. in. Per 1,000 ft. Per mile

000000 0.460 0.1662 16,620 558.4 2,948

00000 0.430 0.1452 14,520 487.9 2,576
^ 0000 0.393 0.1213 12,130 407.6 2,152
I 000 0.362 0.1029 10,290 345.8 1,826
'
00 0.331 .08605 8,605 289.1 1,527
0,307 0.07402 7,402 248.7 1,313
' • Hadfield, R. A. Jour. Iron and Steel Inst., 1889; Jour. Inst, of Elec. Eng.
;"02; Royal Dublin Society, 1900 and 1904; Traris. Faraday Society, 1914.
Sec. 4-395 PROPERTIES OF MATERIALS
 PROPERTIES OF MATERIALS Sec. 4-398
I
;9S. Tensile tests of steel spring wire, of best quality tempered
isic-wire, from about 0.04 to 0.05 in. in diameter, gave from 342,000 to
rs.OOO lb. per sq. in.; elongation between 1 and 2 per cent.; contraction of
fa, 38 to 46 per cent. (Report of Tests of Metals, 1904; Watertown Arsenal).

NON-FERROUS METALS AND ALLOTS

rS99. Properties of miscellaneous non-ferrous metals and alloys
(Compiled from various authorities)
Sec. 4-400 PROPERTIES OF MATERIALS

CONCRETE, BRICK AND STONE

400. The composition of normal Portland cement* has been ',

subject of a great deal of investigation and it can be said that the quanti i

of silica, alumina, oxide of iron, lime, magnesia, and sulphuric anhydride i

vary within fairly wide limits without materially affecting the quality of
material. A normal American Portland cement which meets the staml
specifications for soundness, setting time and tensile strength has an apiT'
mate composition within the following percentage limits:
Silica
Alumina
 PROPERTIES OF MATERIALS SeC. 4-407

in 1 part Portland cement, and 3 of sand, have from 20 to

1 ok Diers laid up
the brick. Also see Report of Tests
Iner cent, of the crushing strength of
(lletals," Gov. Printing Office,
Washington, D. C, 1909.
atmospheric temperature, should
ao7 Fire-brick when tested on end, at
.l^fbit a crushing strength of more than
1,0001b. persq in. Moreimportant
t^^y to^ith^tand a compression load
d'cent. without failure; if the specimen shows
of 50 lb- Per sq m.
marked deformation or
at 1,350

of 9 in., failure is considered

ntracts more than 1 in. in the standard length
average melting points as
thave taken place. Fire-brick should have cliroraite.
sihca, 1,700;
owlin deg. cent.: fire clay, 1,650; bauxite, 1,695;
•
50; magnesia, 2,165. Also see "A. S. T. M. Tentative Standards.
108. Clay tile. The strength of drain tile is covered by standard
roifications of the A. S. T. M. Also see Bulletins No. 31 and No. 36,
,Aa Eng. Exp. Sta., Ames, la. m ui
Crushing strength of stone. (Smithsonian Phys. Tables,
. „,. mm
1910;
109
li,ed on data furnished by U. S. Geol. Survey.)

Material Size Lb. per sq. in.

4-in. cubes 7,600 to 20,700

larble
7,300 to 23,600
rownstone • • •

4-in. cubes 2,400 to 29,300

mdstone
4-in. cubes 9,700 to 34,000
ranite
'.'.'.'.'.'.
4-in. cubes 6,000 to 25,000
imestone'.

TIMBER
consists of a skeleton of cellulose permeated by a
mixture
-110 Wood lignum, and particles of
1
other organic substances collectively known as
ashes). Wood dried at 300 deg. fahr. is comprised of more
'neral matter (or
cent inorganic or non-
an 99 per cent, organic matter, and less than 1 per
nbustible matter In 100 lb. of wood dried at 300 deg. fahr will be found
put 49 lb. of carbon, 6 lb. of hydrogen and 44 lb. of oxygen; the composition
fairly uniform for the different species.
411 Spring wood and wood in coniferous trees are distinguished
summer
the different colors in each ring. The inner light-colored portion of a
dark-colored portion is the
g is termed the spring wood, and the outer
Smer wood In oak and other broad-leaved woods, however, the darker
rtions are the spring wood and the Ughter parts are summer wood.

412. Annual or yearly concentric rings which

appear at the cross-sec-
.n of a log are so many thin layers of wood,
forming a consecutive series of
veloping cones, each ring or cone representing one year s growth. As a
le the rings are widest near the pith or centre
of the tree.

413. Sapwood and heartwood. A

zone of wood next to the bark, 1
to 3 in. or more wide, of light color and containing 30 to 50 or more annual
igs, is the sapwood; the darker central portion is
the heartwood. Only
e outer portions of the sapwood assist in the growing processes and ulti-
The cells of the latter are lifeless
'itely the sapwood changes to heartwood.
d serve merely a structural function. The proportion of sapwood
in
niferous trees constitutes 40 per cent, or more of the bulk,
and a much
"ger proportion in young trees.
414. Moisture in wood. Water occurs in wood in three forms: (1)
forms the greater part (over 90 per cent.) of the protoplasmic contents
of
e living cells; (2) itsaturates the walls of all cells; (3) it wholly or partly
Is the cavities of the lifeless cells. In drying green wood in a kiln, trom
I
to 65 per cent, of the weight of the sapwood and 16 to 40
per cent, ot
e weight of the heartwood are lost as excluded
moisture. 1 he weight
obviously dependent in large degree on the extent of seasoning or drying.
418. Shrinkage takes place as green wood is dried, but does not
com-
ence until the fibre saturation point is reached; then it commences to shrink
)th laterally and longitudinally, but the latter in most species is
negligible.
he shrinkage of transverse area in drying from green to oven-dry condition
.5 per cent, of moi.sture) varies with different species from as
inuch as .^O
r cent, with hickory to as low as 7 per cent, with red cedar. The radial

335
Sec. 4-416 PROPERTIES OF MATERIALS

shrinkage in poles is usually small; the circumferential shrinkage in chestni

poles 1 year after cutting has been found not to exceed 1 per cent.
416. Specific gravity and fibre saturation point. The following tab
was abstracted from Circular No. 108, " The Strength of Wood as Influence'
by Moisture," by H. D. Tiemann, U. S. Forest Service, p. 11.

Per cent.
Average moisture
density
(small test specimens) at fibre-
(kiln-dry)
saturation

Long-leaf pine 0.62 25

Red spruce 0.38 31
Chestnut 0.48 25
Loblolly pine, green heart wood. 0.59 23
Loblolly pine, air-dry heartwood. 0.67 24
Loblolly pine, green sap wood 0.47 24
Loblolly pine, air-dry sap wood.. . 0.55 26
White ash 0.79 20
Red gum, air-dry 0.52 25
Douglas fir 0.58 23
Norway pine, heartwood 0.42 30
Norway pine, sapwood 0.44 28
Tamarack 0.54 30

417. Specific heat of oven-dry wood, based on 100 determinations wit

20 different species, was found to be represented by the formula
Sp. heat = 0.266 +0.001 16( (21

fora range from deg. to 106 dog. cent. The average was
0.327, with
maximum of 0.337 (for longleaf pine) and a minimum of 0.317 (for chestnut)
The material tested showed a variation of from 3 to 20 rings per cm. and :

range of 0.40 to 0.59 in density. See Bulletin No. 110, U. S. Forest Service
1912.
418. Standard names and standard defects ot structural timbei
were defined and adopted by the Amer. Soc. for Testing Materials, on Sept
1, 1907; see "A. S. T. M. Standards."
419. Effect of moisture on strengrth. Moisture is found in green woo(
in two states —
that which is in the walls of the cells and that which fills thi
pores. The latter has no influence on the strength. The point at which thi
cell walls become saturated with water, although the pores may continue t(
absorb it, is termed the fibre saturation point. When the absorption o
moisture continues past the fibre saturation point, there is no further swell
ing of the wood and no further effect upon the strength.
Green timber is in general weaker than seasoned or dry timber, except at
to shearing resistance parallel to the grain. While reduction of the moistun
content tends of itself to increase the strength, the seasoning process als(
has a counter- tendency or weakening effect which results from the forffiatior
of checks. The increase in strength due to drying is especially marked ir
small pieces free from defects, but large timbers almost invariably forir
checks during seasoning and it is not in general safe to count upon an>
increase in strength. In the ca.se of structural timbers it is safest always tc.
determine the strength from tests on pieces of the size and in the condition
in which they will be used. For further particulars see Bulletin No. 70,
Bulletin No. 108 and Circular No. 108, U. S. Forest Service, Wash., D. C.
420. Working unit stresses for structural timber, as adopted by the
American Railway Engineering Association, are given in the table below.
The working unit stresses given in the table arc intended for railroad
bridges and trestles. For highway bridges and trestles, the unit stresses _

may be increased 25 per cent. For buildings and similar structures, in which
the timber is protected from the weather and practically free from impact,
the unit stresses may be increased 50 per cent. To compute the deflection
of a beam under long continued loading instead of that when the load w
first applied, only 50 per cent.' of the corresponding modulus of elasticity
given in the table is to be employed.

330
 PROPERTIES OF MATERIALS Sec. 4-420

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337
Sec. 4-421 PROPERTIES OF MATERIALS
421. Tests of mapls and hickory
(Lb. per sq. in.)
 PROPERTIES OF MATERIALS Sec. 4-427

fl y the preservative is introduced under pressure. This method secures

litiaximum penetration and absorption.
e open-tank treatment, hot process at atmospheric pressure, is used
xi sively for treating the butts of poles. The penetration in open-grained
ois wDod is from 0.75 to 1.00 in., and in dense wood from 0.25 to O.SOin.
'thrush treatment secures a penetration ranging from 0.06 to 0.25 in.,
r im two to three annual rings. The absorption in all cases is increased
y*>asoning. Also see Bulletin No. 78, U. S. Forest Service, 1909.
,7. Talbot concluded from his tests of
Strength of treated timber.
jfsr No. 41, Eng. Exp. Sta., Univ. of 111., 1909; also see Forest
(Bulletin
el ce Circular No. 39) that creosoting, under ordinary practice, decreases

bfitrength and the stiffness. Also see Forest Service Bulletin No. 556,
isrd by the Dept. of Agriculture.

ROPE AND BELTINa

'8. Manila rope. The weight of Manila rope, based on the tests of the
I. ". Hunt Co., is expressed by the formula
Wt. per ft. = 0.34d' (lb.) (22)
'He (1 is the diameter in inches. The tensile strength is given by the formula
r = 7,160d' (lb.) (23)
'I:e T
the total strength of the rope and rf is the diameter in inches.
is
L ch concluded from his tests that a rope having a diameter of 1 in. would

f/ an average breaking strength as follows: Italian hemp, 9,910 lb.;

[ garian hemp, 9,293 lb.; Manila rope, 7,100 lb.
le Plymouth Cordage Co. gives the following rules for Manila rope: the
•'ht per ft. is equal to the square of the diameter in inches, multiplied by
the breaking strength is equal to the square of the diameter, multiplied
';

;.',500; the maximum permissible tension (rope drives) is equal to the

; re of the diameter, multiplied by 200.
tie C. W. Hunt Co. gives factors of safety, for computing the allowable
cing loads, approximately as follows: tackle, 7; hoisting, 18; transmis-
35. The efficiency of knots in rope ranges from 50 to 90 per cent.
)r further data on tests of rope, see "Tests of Metals," reporting Water-
1 Arsenal tests. Gov. Printing Office, Wash., D. C. Also see U. S.
ernment Specifications.
!9. Danger of metal filaments or strands in rope. Metal filaments
iometimes introduced in ropes to give added strength; when such ropes
used by linemen they become exceedingly dangerous, owing to the proba-
y of communicating electrical shock. Similar danger exists from tape
!fnade of a fabric base and containing metal threads.
iO. Leather belting weighs about 60 lb. per cu. ft. and has a tensile
ngth of from 2,000 too ,000 lb. per sq. in., or an average of about 650 lb. per
>f width of single belt. See tests of leather belting in Watertown Arsenal
•orts ("Tests of Metals") for 1893, Gov. Printing Office, Wash., D. C.

BIBLIOGRAPHY
31. Standard reference works on structural materials are given in
condensed list below. The works on this subject are so numerous that
HURSTON, R. H. —
not feasible to give a complete list.
" The Materials of Engineering." John Wiley and Sons,
V York, 3 vols.
—
3HNSON, J. B. " The Materials of Construction." John Wiley and Sons,
V York, 1912.
ANZA, G. ——
"Applied Mechanics." John Wiley and Sons, New York, 1905.
.vuvEUR, A. "Metallography of Iron and Steel." McGraw-Hill Book
Inc., New York, 1912.
,

'ampbell, H. H. —
"Manufacture and Properties of Iron and Steel."
Graw-Hill Book Co., Inc., New York, 1907.
towE, H. M. —
" Iron, Steel and Other Alloys." McGraw-Hill Book Co.,
New York, 1906.
,,
—
TOUGHTON, B. "The Metallurgy of Iron and Steel." McGraw-Hill
<k Co., Inc., New York, 1911.
'lEM/.NN, H. P. —
"Iron and Steel." McGraw-Hill Book Co., Inc., New
k, 1910.

339
Sec. 4-432 PROPERTIES OF MATERIALS
HoFMAN, H. O.
— " Metallurgy of Copper." McGraw-Hill Book Co., I
New — "The Metallurgy of the
York, 1914.
GowLAND, W. Non-ferrous Metals." CI
Griffin and Co., Ltd., London, 1914.
BuBL AND Hill. — "Reinforced Concrete." McGraw-Hill Book Co., I

New York.
— "Treatise on Concrete, Plain and
Taylor and Thompson. Reinforr-t
John Wiley and Sons, New York, 1909.
—
Bakeb, I. O. "A Treatise on Masonry Construction." John Wiley:
New
Sons,
Eckel, E. C.— York, 1909.
"Building Stones and Clays."
John Wiley and Sons, .\

Snow, C. H. — "Principal Species

York, 1912.
Wood: Their Characteristic
of Prop,
John Wiley and Sons, New York, 1908.
Weiss, H. F. — "The Preservation
ties."
Structural Timber." McGraw-I
of
Book Co., New York, 1915.
Inc.,
FowLB, Frederick E. — "Smithsonian Physical Tables," 7th Rev. L
Washington, D. C, 1920.
Publications of the U. S. Geol. Survey, Bureau of Mines, Forest Servi
Bureau of Standards; Report of Tests of Metals (Watertown Arsenj
Gov. Printing Office, Wash., D. C; Trans. A. S. C. E., A. S. M. E.,A. R,
A., A. E. S., A. S. T. M.; Bulletins of the Eng. Exp. Sta., Univ. of 111.

PROPERTIES OF THE ELEMENTS

432. Atomic weights, densities, specific heats and melting poii
of the elements in solid or fluid state. Compiled from Internatio'
atomic weights (1917), "Smithsonian Phys. Tables" (1920) and Circa
No. 35 of the Bureau of Standards (1912).

Element
 PROPERTIES OF MATERIALS Sec. 4r432

Table 432. — Continued

Melting
Sym- Atomic Density
Specific
point
bol weight heat
(deg. cent.)

La 139.0 6.15 0.045 810

Pb 207.20 11.34 0.030 327.4
Li 6.94 0.534 0.85 186
Lu 175.0
Mg 24.32 1.741 0.249 651
Mn 54.93 7.42 0.111 1230
Hg 200.6 13.55 0.033 -38.9
Mo 96.0 9.01 0.064 2535
Nd 144.3 6.96 840
Ne 20.2 -253
Ni 58.68 8.80 0.109 1452
Nt 222.4
N 14.01 0.83 -211
Os 190.9 22.5 0.031 2700
O 16.00 1.14 -218
Pd 106.7 12.16 0.059 1549
P 31.04 2.34 0.19 44
Pt 195.2 21.37 0.032 1755
K 39.10 0.87 0.170 62.
Pr 140.9 6.475 940
Ra 226.0 700
Rh 102.9 12.44 0.058 1950
Rb 85.45 1.532 0.080 38
Ru 101.7 12.06 0.061 >1950
Sa 150.4 7.75 1350
Sc 44.1
Se 79.2 4.55 t).068 218.5
Si 28.3 2.42 0.175 1420
Ag 107.88 10.6 0.055 960.5
Na 23.0 0.971 0.253 97.5
Sr 87.63 2.54
S 32.06 2.05 0.173 112.
Ta 181.5 16.6 0.033 2900
Te 127.5 6.25 0.048 452
Tb 159.2
Tl 204.0 11.85 0.033 302
Th 232.4 12.16 0.027 >1700
Tm 168.5
Sn .118.7 7.30 0.054 231.
Ti 48.1 4.5 0.110 1795
W 184.0 18.85 0.034 3400
U 238.2 18.7 0.028 <1850
V 51.0 5.69 0.115 1720
Xe 130.2 3.52 -140
Yb 173.5
Y 88.7 3.8 1490
Zn 65.37 7.19 0.093 419.4
Zr 90.6 6.44 0.066 1700

133. Density of water, from to 100 deg. cent. (Circular No. 19, Bureau
Standards)

emp.
 Sec. 4-434 PROPERTIES OF MATERIALS

434. Specific heat of water, from to 100 deg. cent. (Sniitlaoil

Phys. Tables, 1920).

Temp.

I
 SECTION 5

l\GNETS, INDUCTION COILS, CONDENSERS

AND RESISTORS
BY CHARLES R. UNDERHILL
Laiilting Electrical Engineer; Fellow, American Institute of Electrical Engi-
neers; Member, American Society of Mechanical Engineers

AND
LEONARD KEBLER
'^ident, Ward Leonard Electric Company; Member,
of Electrical Engineers

CONTENTS
American Inttitutt
i
(Numbers refer to Paragraphs)
Magnets
1 Portative Electromagnets 70
rmanent Magnets 4 Alternating-Current
ctromagnets 12 Tractive Electromagnets 77
laea of Electromagneta 17 Polyphase Electromagnets 87
leral Theory of Electromagnets 24 Heating of Electromagnets 90
itinuous-current Tractive Magnet Wires 97
Ilectromagncts for Long Range 46 Winding Calculations 100
Itinuous-cnrreut Tractive Construction of Coils 105
Electromagnets for Short Range 57 Testing of Magnets 112
Qtiitions for Maximum Work 62 Bibliography 118
ndard Electromagnets 63

Induction Coils
Qeral 119 Secondary windings 138
mary Type 120 Interrupters 148
ondary Type 128 Bibliography 154

Condensers
pes 155 Electrolytic Condensers 175
te Condensers 156 Bibliography 184

Resistors
pes of Rheostats 185 Resistors for Motor Starters 207
Id Rheostats 187 Battery-Charging Rheostats 215
(torSpeed-Regulating Rheostats 194 Miscellaneous Rheostats 219
eatre Dimmers 202 Resistor Units 229
Bibliography 236
343
 SECTION 5

MAGNETS
BY CHARLES B. UNDERHILL
1 If;. GENERAL
1. A magrnet is a body which possesses the property of attracting,!
netic substances. All magnets may be divided into two classes, i.e.,
nent magnets and electromagnets.
2. A permanent magnet is one which retains a nearly constant value!
m.m.f. for an indefinite period. The permanent magnets used in pract'
are made of hardened steel and are magnetized by placing them in a strc
magnetic field.

> 3. An electromagrnet or temporary magnet is one in which the magna'

field is produced by an electric current. In its simplest form, it consists
a helix of conducting material which, when energized by an electric curre
possesses many of the magnetic-field characteristics of a permanent magn
Since soft iron is capable of being magnetized to a high degree and retai
very little permanent magnetism, with the result that the magnetic field m
be varied in great degree by regulating the strength of the current, electi
magnets are usually provided with soft-iron cores.
PERMANENT MAGNETS
4. Permanent magnets are used where a constant field is desired,
in electrical instruments, magneto-generators, etc. In order to rets
its strength, a permanent magnet should have as short an air-gap .

possible and the ratio of its length to its cross-sectional area should be grei
Unless proper precautions are taken, the steel is likely to crack and warp
hardening.
5. Permanent magnets lose a portion of their origrinal magnetis
when used a long time, so that they become what is teriiu'il age
for
Those used in instruments, magnetos, etc., are artificially aged in t
process of manufacture. This is accomplished in various ways. 0:
method of aging magnets for watt-hour meters is to pass them sever
times through a bath of boiling water or oil and then to demagnetize the
to about 75 per cent, of the original value by rotating a copper disc betwet
th"! poles. Another method is to place a large number of magnets parall
to each other, with a copper strip between the poles, andjthen to demagneti
them by passing a strong current through the strip. (Also see Par. 10.)
6. Permanent magnets are made from the best grade of crucih
tungsten steel which contains about 5 per cent, of tungsten, a smt
percentage each of chromium and manganese, and from 0.63 to 0.66 P'
cent, carbon. Domestic steel of this variety is found to be equal to or betfc
than any imported magnet steel.
7. Details of manufactiu'e. The practice of the Sangamo F'
Co. is as follows: After preliminary testa, the steel bars are shearc:
and then heated in a special fuel-oil furnace so arranged that the primin
of combustion do not come directly in contact with the steel. The pien
are forged at a bright red heat, in a large press, using but one heat if po.s.sibi
A vertical type press is preferred to the "bull-dozer" tvpe. The picfi
are then allowed to cool in the air, if no drilling is required; or, if drilling
necessary, they are packed in mica dust to prevent air-hardening, whio
takes place to a certain extent even with steel containing no more tba

344
 MAGNETS Sec. 5-8

r cent, of tungsten. The pieces are then ground to dimensions, tumbled

1 nove all scale, and heated in a fuel-oil furnace, arranged with a recording
y neter for checking the temperature. The next operation is the harden-
ijr tempering.

The haxdeningr process is carried on in a darkened room so from

1
that the
y tor can judge the heat, aside from the
information obtained the
The pieces are brought to a temperature of 840 deg. to 860
V neter.
vent., the proper temperature varying according to the carbon content,
I ire quenched in pure running water at a
temperature varying from
) Bg. fahr. in winter, to 70 deg. fahr. in summer. During hardening
itieces are held in special tongs or clamps to prevent springing; they
are
tumbled to remove all scale, and then given any final finish grinding
5: .

1,'may be required.
Magnetizing process. The pieces are magnetized by placing them
I ecial jaws which form the pole pieces of a powerful electromagnet,
and
1 lent current is then
switched on, for a brief period, to force the maxi-
11. magnetic flux through them.
Artificial aging.
.
The magnets are artificially aged by placing them
I 1 and heating to a temperature of 250 deg. fahr. for about one-half
0, after which they are placed on a vibrating or humming device for
iition aging; the latter treatment reduces the strength of the magnet,
u lot so much as the heat aging. (Also see Par. 6.)
Precautions in handling. After being japanned, the magnets are
.

>! d for field strength and laid away in a tray. In handling, precautions
lid be taken to prevent undue throwing about after magnetizing and
gi?; but, unless the magnet has a long air-gap, it is found
a is necessary to prevent further loss in strength.
that no particular
In case a magnet
i
t,i, long air-gap, as in magneto field magnets, a keeper is placed across
hjoles.
ELECTBOMAGNETS
Vi. A continuous-current electromagnet is one which is designed
3 operation from continuous-current circuits. In this class, the effects
1 iductance are noticeable only when the magnet is switched in or out
f rcuit and while it is doing work.
An alternating-current electromagnet is one which is designed
'•.

D )peration from alternating-current circuits. In this case the magnitude

I the direction of the current are varying periodically; hence the effects
f'ductance are so great as to require the design of the coil and other parts
c s radically different from those for continuous-current circuits, although

t laws governing the pulls are similar.

\. There are so many uses for electromagnets that it would be

Uses.
enumerate them all, but in most_ cases their uses are
'nsiderable task to
ailiar. are being used in increasing quantities in the electrical
They
(rol of machines wherein mechanical devices were formerly employed,
reneral, they may be divided into two classes.
K A portative electromagnet is one designed for holding or lifting only;
1 is, it is merely intended to grip and hold in place material brought in
( ^act with it.
5. A tractive electromagnet is one designed to pull a load through a
:ance and thus do work.
ii
TYPES OF ELECTROMAGNETS
T. A solenoid is a winding of insulated conductor consisting of a series
Superimposed helices of right and left pitch. It is the basis of all of the
• mon forms of electromagnets.
?. A solenoid-and-plunger is a solenoid mounted on a suitable non-
r;netic bobbin or spool and provided with a movable bar of soft iron or
(1 called a plunger. When the coil is energized, the plunger becomes
t;netizcd by the influence of the magnetic flux from the current in the coil,
1:
mutual attraction then takes place between the coil and the plunger,
the force of attraction is great enough to overcome the load, the plunger
I advance into the coil until their magnetic centers coincide, and there-
r no more work can be done unless the relative positions of the coil and
I
plunger are again changed by external means.

345
 Sec. 5-19 MAGNETS
19. An iron-clad solenoid is a solenoid-and-plunger provided ti

an iron orsteel frame or jacket. The effect is to confine the magnetio J

within the limits of the frame. When provided with a stop, as in I'i,,
this type is commonly known as a plunger electromag:';
SO. A bar electromagnet is a solenoid-and-plunger -

the plunger inserted in the solenoid and rigidly fixed in . i

tion.
31. A horseshoe electromagnet is a bar electroman
F I a 1.
. — bent into U form in order to bring the pole ends neai.
Plunger elec- gether. The practical type consists of two bar electron,
tromagnet. nets magnetically joined together at one end by meanf
a yoke or backiron. Both coils are usually wound in i

same direction and their inside wires connected together. The armati
consists of a piece of soft iron or steel of sufficient length to bridge the i

from pole to pole, and of cross-section great enough to conduct the

, :

economically.
S2. An iron-clad electromagnet is a bar electromagnet inserted ii
soft-iron or steel cup, so that the rim of the cup and the core of the e-
tromagnet form the attracting surfaces (or poles) for the armature, wl(
usually consists of a disc of soft iron or steel.
23. Modified types. There are many modifications of the above fuD'
mental types. For instance, plunger electromagnets are sometimes mad ,

the horseshoe form, and a modification of the horseshoe electromagnet

> be recognized in the iron-clad electromagnet. In some telephone relays

angle-iron is employed instead of the shell or cup.
GENERAL THEORY OF ELECTROMAONETS
34. Maxwell's fundamental equation for the pull applies strictly
a portative electromagnet consisting of a bar electromagnet separated at
middle and having a hypothetically zero air-gap, so that no flux can 1

back from the abutting ends of the half-cores to their opposite ends.
equation for the pull in dynes per sq. cm. isP = {BV8jr. But (B = 4ir3-t
wherein 3 is the intensity of magnetization in the iron only. It is c
venient to reduce 4ir3 to <f>i/s, and 3C to <l>a/s, wherein (j>i is the iron fl
equivalent to the flux in a permanent magnet; <j>a is the flux in the air-c
only, and 8 is the cross-sectional area of the core in square centiniet'
Then
(B = (gausses)
8

whence P = b" o (dynes per sq. cm.)

8x8'
36. Theoretical components of pull. Conventionally stated, .VS
is the purely magnetic pull between the two half-cores; 2<j>i<j)a/iins^ is
pull due to the "solenoid effect" between the half-coils and the half-coi
and <)>a''/9,irs'' is the pull between the half-coils, which cannot be utili:;
in practical electromagnets with solidly wound coils. The actual puil,
dynes per square centimeter, for such a portative electromagnet, i.e., wl
there is no appreciable air-gap between the attracting surfaces of the hii
cores, and the coil is solidly wound, is

P" 5 -— (dynes per sq. cm.)

86.Total pull between two polar surfaces. An electromagu'

do work only when there is an air-gap. The longitudinal contrai i

the flux in the air-gap of a tractive electromagnet causes the pull. Ti

in dynes per square centimeter between the polar surfaces of the coi'
horseshoe electromagnet and its armature, or for any other type i>l >:
tromagnet with the coils and cores rigidly fixed, relatively, is P = 4>a'- '^'
wherein <(>g is the total average flux producing the pull. This equation i

presses the pull in an air-gap, or the pull between two magnetic m.i'^ '

contact, ana holds for permanent magnets.

37. The pull due to an iron-clad solenoid or a plunger electron
consists of two components, since there are two magnetic circuits in stiu

346
 MAGNETS Sec 5-28

one another. One of these circuits is through the air-gap, and

this p»ill,
rij

a vnes per square centimeter, is equal to <t>a'/8Tra^. The »ther circuit

e leakage circuit from the
inner end of the plunger (Fig. 1), through
I

hcoil and frame, back to the place where the

plunger enters the coil,
lie the pull, in dynes per square centimeter, is
I p = ^° (dynes per sq. cm.) (4)

is generally greatly
'hen the air-gap is relatively long, the value of <#..•

tt'tcess of that of <t>t, since the reluctance of

the leakage circuit is usually
r than that of the air-gap.

,. The useful work performed by an electromagnet is generally

Icied as initial pull times range or distance of travel. It has been theo-
eially proven that the maximum amount of work may be obtained
r I an electromagnet when the reluctance of the working air-gap is equa
ciat of the rest of the magnetic circuit* (Fig. 2). This is true for electro-
Dnets with their coils and cores rigidly fixed, relatively, but is not true
c 'lectromagneta with movable plungers, especially when the air-gaps are
and the m.m.fs. are of high value, owing to the "solenoid effect.
i .ever, the rule holds for all types of electromagnets so
far as the air-gap
) , is concerned. (See Par. 62.)
>. The maximumwork In the air-gap (initial pull distance) is X
) lined when 5g<l>f,, that is, the
product of the air-gap m.m.f. and the flux,
)'>mes a maximum. The expression for SFj.is

» the air-gap m.m.f., 61^ the reluctance of

rein JFjis the working air-gap,
F reluctance of the magnetic circuit exclusive of
;he the working air-gap,
k 5i the total m.m.f. The reluctance
) le air-gap is Si(,= Sii/<t>a- The general 100
joretical air-gap characteristics are
similar to the 90
iVn in Fig. 2. This is
•) for the maximum
wattage which 80
B'y be obtained in a coil connected in
70
res with a continuous-current line of
: stant e.m.f. As is well§60known, the
cdmum wattage is obtainable when "so
tresistance of the coil is equal to the
i 1 of all of the other resistances in P< 40
J es in the line. Likewise, when the
pper length of the air-gap is either in- "J
; ised or diminished, the maximum pull 2O
length of air-gap is diminished.
0. Electrical time-constant.
5 en quick action is desired, it is neces-
iv' that the current reach its maxi-
n m value as soon as possible. Refer-
r> to Sec. 2, it will be seen that a
i nite time interval, in each case, is
 Sec. 5-31 MAGNETS
ductance (Par. 81) in henrys, and t the elapsed time in seconds from
moment the circuit was closed. Solving the above equation for t,

*=-^?o,.(l-J) (sec.)

wherein L/R is called.the time-constant. From this it is seen that for a gii
ratio of instantaneous current to the Ohm's law or steady current
time-constant is the only factor which determines the time required
establish it. The time-constant is fixed by the magnetic circuit and by
ampere-turns (when iron is present), and is independent of the number
turns, since both the resistance and the inductance vary as the square'
the number of turns, for a given winding volume.
31. The approximate inductance of a magnet, in which the air-ji
13 not very long, can be found by assuming the magnet to be connected t
source of alternating e.m.f., of known frequency and having a sine-Wii
form. Let U be the length in cm. of the iron circuit; la the length in cei-
meters of the air-gap; N the number of turns; s the cross-sectional areoi
square centimeters of the magnetic circuit, and the maximum value of :

total flux. Then the alternating e.m.f. which must be impressed upon i

winding to produce a maximum flux <t>, is

£; = 4.44/A'^0lO-« (volts, effective)
where / is the frequency in cycles per second. The approximate relucta i

)
is.

=
(51
y (- + la^ (oersteds)

M can be taken from curves in Sec. 4. The m.m.f. is ff=1.257A'/ when

/is the effective (root mean square) current in amperes. It follows fn
? = 0(R that

and then
E
(henrys) {.
^^2Tfi
32. Effect of movable plunger. Magnets with movable plunfi
which are designed for quick and powerful action require careful study of )
initial conditions. At the first instant, the value of the current increfi
at such a rate that the flux interlinked with the winding will generate
counter-e.m.f. equal to the impressed e.m.f. The pull produced by )
flux due to this current will start the plunger, and the sudden decrease!
reluctance due to the closing of the air-gap will produce a correspond!
increase in flux and thus decrease the rate of change of the current, thai,
the current will be retarded in reaching its final and permanent va .

Because of this phenomenon it is usual to design such magnets (for instai

those used on automatic starters) for a much lower impressed e.m.f. tha J
actually used at the start; in order then to protect the winding, a hijr
resistance is automatically inserted in series with it at the moment l
plunger arrives at the end of its stroke. This resistance limits the currt
to that value necessary to maintain the required final pull on the plungei
33. The action of the plunger in reducing the reluctance of )
magnetic circuit may be approached from the energy standpoint; thus, »
total energy which is supplied to the magnetic field up to any instant it

W-E \ td<= ?^-f-0.113Fi (watt-seconds) (

-.f.
wherein t is the instantaneous value of the current in amperes, L the •

stantaneous value of the inductance in henrys, F the average pull on )

plunger in pounds, and I the distance traveled in inches.

 MAGNETS Sec. 5-34

il. Current-time curves for plunger electromagnets. Referring

ti ^'ig. 3. the current-time curves* for a certain
magnet are plotted for
i-rent stationary positions of tlie plunger, each curve a representing
r n air-gap. If the plunger moves forward before the current has reached
it nal and
permanent value, the reluctance decreases and the current drops

0.05 0.1 0.15

Time
"iG. 3. — Theoretical current-time curves for a plunger electromagnet.
(
(i 1 one curve to the next, corresponding at each instant with the air-gap
El the time. If, for instance, after 0.02 sec. the plunger closes the air-gap
ti"..") cm., it is probable that the current will have the same
value as though
it id increased from zero along the curve corresponding to
the air-gap 1.5
c and it cannot have a greater value. In Fig. 4, the current-time curves
a given for maximum and zero air-
gi\ assuming the current to increase
a g the first curve until a is reached,
b re the pull becomes sufficient to
Tome the friction and start the
p iger, the latter then moves forward
». 1a rapidly increasing acceleration to
t{ end where the air-gap is zero, and
t^eifter the current follows the curve
ci.ssponding to the zero air-gap to 6,
w re the magnetic circuit becomes sat-
u'ed and the current rises rapidly to
tli value determined by the resistance
of ,e winding. If an external resistance
bdserted by means of a short-circuiting
s\ oh actuated by the plunger, the cur-
re may be limited to any desired value,

i. Energy stored in the magnetic

Ciult. The current curves in Fig. 4
Cf also be chosen to represent the ir
i in the winding; then the difference
'

bi een the final value I max, and the

lEintaneous value i, represents the
cciter-e.m.f. of inductance, that is,
tl counter-e.m.f. generated by the flux
e\ ing the turns of the winding. The Time
cciter-e.m.f. ofinductance multiplied Fig. 4. —
Current-time curves for
maximum and zero air-gaps.
b; the current in the winding is the
P' er supplied to the magnetic cir-
C'i. These power curves are plotted above the current curves in Fig. 4.
C ,-e cdef is the power curve for the maximum air-gap; eg hf ia that for
« air-gap, and cdihf that for the varying air-gap. The areas under these
Calculated and plotted by Mr. O. A. Kenyon; 3rd edition, Standard
H dbook.

349
Sec. 5-36 MAGNETS
curves represent the energy transferred to the magnetic field, in each
With the moving plunger, the total energy input to the magnetic field ine
area cdihf, while that left as stored energy at the end of the stroke and »
must be dissipated when the circuit is broken is the area cghf. The difTer'xJ
between these two, cdihg (cross-hatched) represents the energy transfoiid
into mechanical work and dissipated by friction and impact of the pluw
during its travel, iron losses being neglected.
36. Impregsed e.m.f. The final permanent value of impressed e f.
in continuous-current magnets is determined by the resistance.
37. The speed of the magnet action also depends upon the secom
7
losses (eddy currents. Sec. 2). These losses tend to reduce the flux ime
core and thus retard the attainment of the maximum pull. This e:t
can be reduced ly laminating the core and frame and by avoiding le
use of a metallic bobbin. It can also be reduced by using fewer turns ,d
larger current.
38. Slow-speed magrnet action is obtained by increasing the t*
constant and the secondary losses. The secondary losses can be grtlj
increased by dividing the winding into aeciji
10 and short-circuiting more or less of the sect'i
Fig. 5 shows the effect of short-circuiting a it
tion of the winding. * The total numbcal
turns was 8,400; in curve (1), only 2,165 tti
were energized, while in curve (2), 2,165 tj«
06 were energized and 6,235 turns short-circu 1.
1
In the first case it required about 2.5 sec !«
to reach the maximum current, while ime
second case, 4 seconds were required.
39. Inertia of moving system. When*
1 2 S 4
Time In Sec. speed of action is an important factor, thj
ertia of the load to be moved must be conaidd
Fig. 5.- Showing the ef- For the same pull and range, a quicker
feet on the current-time will be obtained in overcoming the ten.
curve of short-circuiting a a spring than in moving a mass whose
portion of the winding. is equivalent to the tension of the spring,
total mass to be moved is the sum of that o(|
plunger and the external load.
40. The selection of the type of electromagnet for specific »k
depends upon the nature of the e.m.f. (whether continuous or alternati)
the range or distance of travel, and the rate of travel or the quickneof
action. In general, the iron-clad solenoid type is mechanically the bi;r
protected and is the best adapted for a long range and a strong pull, b it
IS slow in action. The horseshoe type has the quicker action, but is if
adapted for short ranges. The plunger-electromagnet type has an a(«
intermediate between the above-mentioned types and may approziiil
one or the other according to the range and the dimensions of the pluit.
The clapper type is extensively used on control apparatus, since it acts y
quickly and has a strong sealing pull. The general rule is that what is*
in time is gained in pull and vice versa.
41. The required dimensions of an electromagnet are proportiil
to the load, the range, the duration of excitation and the interval heU a
excitations. The cross-sections of the plungers, cores and frames 11
depend upon the flux required to produce the desired pull. In long-r ;»
electromagnets of the solenoid type, wherein the pull is proportional tc «
product of the magnetizing force and the flux in the plunger, the i

rnay be of small cross-section, if the duration of excitation is to 1

since the magnetizing force of a comparatively small coil may 1
great for a short period without danger of injury from overheatiiu'
does not hold for a clapper type, since the main pull is dependo:
the flux which the cores are able to conduct, and is only slightly affecti I

increase in the magnetizing force after the cores approach saturation.

42. Electromagnets designed for continuous service must hnvo n I-

ings of such volume and radiating surface, and wires of such cross-H' '

* Lindquist, D. L. " Alternating-current Magnets;" Electrical

1906. Vol. XLVII, p. 1295.
 MAGNETS Sec. &-43

it' lecoils will not become overheated, but the proper pull will be main-
ji even after the winding haa been in circuit continuously for many
ut The designer should
allow too much space, rather than too little,
•
i winding and the insulation of the coil, because,
while the coil may be
a^ely small for intermittent service, it is often found necessary
or
silile to leave the coil in circuit longer than originally
intended,
t! The air-gap pull of any electromagnet is

f'=^_'li! (lb.)
^
(13)
72,130,000 '

F= (kg.) (14)
8xX 981,000
i^ <&' and arc the flux densities in maxwells per square inch and per
(B
u centimeter respectively; s' and s are the cross-sectional area of the
n •
plunger in square inches and square centimeters respectively.
4\ Curves plotted between the pull per unit area of core and the
n.ensity are shown in Fig. 6. The pull is plotted with maxwells per
u centimeter, but maxwells per square centimeter are also plotted
t: iiaxwells per square inch so 200---
a. ull can be read off for either
le
4 Relation between pull
H.ir-gap. In designing mag-
it an approximate idea of the
 Sec. 5-48 MAGNETS
ing force has a high value as compared with the cross-sectional area tk
plunger, the maximum pull may occur for a considerable distance o :st
side of the middle of the solenoid. On the other hand, with veryia
solenoids, the maximum pull may occur at or near the end of the sVioi
opposite to that at which the plunger enters.
48. Characteristic pull with solenoid and plungrer. Fig. 8 ok
the approximate pull diagram for different positions of the plunger, Pb
expression for the maximum uniform pull is

.=c.^ (lb.)

where I the current in amp.,

is N
the number of turns, s the cross-sc^ ,iu
area of the core or plunger in square inches, I the length of the solen 1 i

inches and C the pull in pound per isi

K—e.61- 6.4 r-4 inch per ampere-turn per inch. C

o.m upon the proportions of the coil, the
saturation, and the length, physical c!
and chemical purity of the plunger. ] . {
gives values for C for various solenoids ;te
by the author.
49. In magnets with long air-gai,t|
path through the iron can be consideij
having no reluctance. Therefore the ts
Fia. 8. —
Diagram of plun- ration characteristic can bo assuir

> ger pull for simple solenoid a straight line, and the ampere-tun
and plunger.

60. Maximum
air-gap directly proportional to the
sity.
Full per Square Inch of Core for Solenoidsit
!:

Open Magnetic Circuit*

Length Length of Area of Total Amp- Max. Lb. per S'.n.
of coil plunger core amp- turns pull, lb per 1,000 <p.
(in.) (in.) JCsq. in.) turns per in. per sq. in turn per-.v

Long 15,000 2,500 22.4 9.0.

Long 11,330 1,260 11.5 9.li
Long 14,200 1,580 14.6 9.2
10 10 40,000 4,000 40.2 10.0:
10 10 60,000 6,000 61.6 10.31
10 10 80,000 8,000 80.8 10.11
12 Long 11,200 930 8.75 9.4'
12 Long 20,500 1,710 16.75 9.8i
18 36 18,200 1,010 9.8 9.75
18 36 41,000 2,280 22.5 9.8
18 18 18,200 1,010 9.8 9.7,
18 18 41,000 2,280 22.5

—
Note. These tests indicate that little is gained in maxinium
making the plunger considerably longer than the coil.
51. The diameter of the coil should be about three times thai -
plunger, and the length of the coil should be at least two or three tii i'

outside diameter whenever possible.

62. The range is directly proportional to the length of the coil, regi lef

of the ampere-turns.
63. The pull in an iron-clad solenoid, with or without a stop, if^
posed of two components; one is the pull between the end of the sllll
frame and the phmger, and the other is that between the winding aijfl
plunger. The latter is all important at the beginning of the stroke, hii el

the end the stop-pull becomes predominant. The expression for th'

-( Niy
iac'y
+
sCNI
I
sNilU^c^'^ I-
(lb

• Underbill, C. R. " The Practical Design of the Solenoid; "

World and Engineer, 1905, Vol. XLV, p. 796.

652
 MAGNETS Sec. 5-54

vY ^
s is the cross-sectional area of the core in square inches, I the current
n ip iV the number of turns,
,
the length of the air gap in inches, I the
L
coil in inches, and c and constants, which depend on the pro-
C
Bi! h of the

)0 )ns of the magnet, the materials used and the degree of saturation.
Vtoximate values for ordinary soft-iron cores are c 2,600; for
lengths=
)f ilgreater than 10 times the diameter of the plunger, C = 0.0096 (see
?( 60 for values of 1,000 C).
'

Formula for pull characteristic. Referring to the pull diagram

F 8) it will be seen that the
solenoid pull is assumed to decrease as a
It) 'ht-line function, commencing at a point
about OAl froin the end of
,h oil.
• From this point on the total pull due to the plunger electromagnet
!a.)e expressed thua:

K. ein the distance in inches which the plunger is inserted in the coil,
V is
r^ constants are the same as those given in Par. 53.
Tost data on pull characteristics. Fig. 9 shows curves from
ictvl test.* Curve (1) is that of a simple coil-and-plunger; (2) that of a
ic ind-plunger with stop; (3), that of
an iron-clad coil-and-plunger; (4)
\ii (5) show the same iron-clad
!c with different lengths of stop.
4 these curves were made with
ih amecoil, which was 12 in. long
iithad a total of 10,000 amp-
tu3, or 834 amp-turns per linear
.D.

. Analysis of test data (Par.

Sf Referring to Fig. 9, the pull
w. the iron-clad magnet, curve
(4 corresponding to the position 5
(t 2 in.) of the plunger, is
1^,5 lb., approximately. Refer-
ri Par. 49, the pull due to the
';o
cc alone is about 9.7 lb. per square
ir ,
per 1,000 amp-turns per inch,
d: 7X0.834 = 8.1 lb. Next refer-
Sec. 5-60 MAGNETS
 MAGNETS Sec. 5-62

Bj-e-turns about 50 per cent, to allow for leakage, depending upon the
I of the air-gaps.

[
CONDITIONS FOE MAXIMUM WORK
(The work in the air-gap (pull X distance) of a magnet becomes a
Qtmum when the air-gap reluctance is equal to that of the rest of the
irft (Par 29) In Fig 14, F, is the solenoid pull, Fg is the air-gap pull,
the total pull as ascertained by actual test* of a plunger
is
electromag-
n( I
 Sec. B-63 MAGNETS

T
I
I

I I

-A-

-H-

»
-K*
1
No.
 MAGNETS Sec. 5-63

No.
Sec. 5-64 maOnets
64. Continuous-duty electromagnets may be excited at full voli«
continuously without dangerous heating of the coils, but the pull beco-i
somewhat reduced when the windings reach full temperature, due to.e
increased resistance in the coil.

4 8 12 4 8 1!

Watts per Sq. In. Watts per Sq, In.

Fia. 23. —Test curves on pull of
standard type of plunger electro-
Fia. 24. —Test curves on pulf,
standard type of plunger electrom>-i
magnet No. C in Fig. 20. net No. 22 in Fig. 20. 1 i

66. Intermittent duty is an arbitrary rating and, in general, tllii

magnets may be excited at full voltage for not over 7 min. during if'
half-hour, without dangerous heating.
66. Momentary duty is aLso an arbitrary rating which represents i

C 1 M
 MAGNETS Sec. 5-68

( The performance curves are plotted on the basia of watts per

jqve inch of cylindrical surface. Reference lines for the three classes of
lu are given as 0.7 watts per square inch for (C) continuous duty; 2.8 for

-A—

sa "T \^
i'T
I

Z^ZT-
l--J--i C-
-H
No.
 Sec. 5-69 MAGNETS
69. Two forms of plungers are shown; one is conical, and the othi
square at the ends. 1 he curves show the former to be preferable on mo
of the lonK-stroke types, as the tendency is to increase the starting pullari
reduce the final pull. For short strokes, the square-end type is preferabl

U 7Ti--*l

M^s-'i K-- ^ ^* " ~^ Watts per Sq. In.

— Standard type plunger
Fig. 30. of Fia. 31. —
Test curves on ii
electromagnet with fiat-end plungers. standard type plunger electrons
(See Fig. 31.) in Fig. 30.
PORTATIVE ELECTKOMAGNETS i

70. Lifting magnets. Large iron-clad magnets called lifting magni?

are now extensively used for the handling of materials in all branches of 1'
iron and steel industry. They are used for handling pig iron, scrap, castin
billets, tubes, rails, plates and crop ends; for loading and unloading ci
and ore vessels, and for handling skull-cracker balls and miscellane(
material.

Fig. 32. — Cross-section of a standard lifting magnet.

71. Operation. All lifting magnets, of whatever make, are suitable

use on continuous-current circuits only. It is not customary to operate
magnets on very high voltages, owing to the difficulty of securing insul
ing material that will withstand the high inductive reaction that
when the circuit of a magnet is suddenly opened. Standard magm :

designed for operation on 220-voU continuous-current circuits.

72. Lifting load. It is quite impossible to calculate the load which n
be lifted, owing to the varying contact of the load, but Par. 73, givin
>

table published by one of the leading manufacturers, shows the approxinn

lifts for various magnets and materials.

360
 MAGNETS Sec. 5-73

a C
03 ?

o a an O ^ n
a <s
C3 g !

'p.'d
S =^^
m o a o*>
•

3 OS o 0}
at a
O a
*" M-^ «
a c 0! _S © 5 c •

<u 01 a
bC
<oog .2>>a t. C tc

-^ "3 ^^ " § "

J30 13"" 0-3 5?
c5 si >
0)^*0
a o o ^^ Ssl
mS o
fl to
a c
.
^~ s .5^2 o C 2 Da >
0)

CO
-S C 3 fi si f

® O S
^ SV
-a a
to
-2 a *

12.^
£03
W2S"
a

•a.s>.

ft— s

E >
0-° ag> 0.0
C80
E^ a E^
.2 fc; ffi £ oSO
3 a•-
-»^
a g « 3
O c3
Sec. 5-74 . MAGNETS
74. General construction. These magnets are very rugged in constr
tion, aa they are subject to exceedingly rough usage. The iraine or body
the magnet is made, in one instance, of a special grade of dynamo sf
which combines great strength and ductility with excellent magm'
qualities. They are designed to withstand heat without injury and
waterproof. Fig. 32 shows the construction of a lifting magnet made by
Cutler-Hammer Clutch Co. The Inland Stool Co. reports that ah.
4,000,000 lb. of machine cast pig iron wore unloaded in 10.5 hr. by two 62-
magnets. The average lift per magnet was 3,427 lb. j

76. Magnetic clutches and disc brakes above general cli<

are of the
but they attract armatures in the forms of discs. In both cases, the mo
ments of the armatures are small. In magnetic clutches the clutch meml
are engaged when the magnet is energized, whereas in magnetic disc bral-,
a spring presses against a disc brake when the magnet is deSnergized, t
stopping rotation by means of friction.
76. Holding magnets. Portative magnets called magnetic chui;
are extensively used for holding tools and materials in grinding and ot,-
machinos. The no-load release magnet is of this type. In a general w',
magnetic separators also belong to this class.
ALTERNATING-CURRENT TRACTIVE ELECTROMAGNETS
77. The design of an alternating-current magnet involves calci
tions which are essentially the same as those for an ordinary transforii.
The total flux is determined by the number of turns, the supply voltage ;1
the frequency; thus

^^ 2irfNi,„„, ^ iA4N<t.„ax 10-» (volts, effectiv,

V2 10 8

and
E 10» „ ,
»""= 4.44/iV
,
(maxwells)

where / is the frequency in cycles per second, N the number of turn-<, i

E the impressed e.m.f. in volts.

Taking / and A'' as constant,
0m<ii = s(Bmai = iCB (maxwells)
and
," K — (gausses)

That for a given impressed e.m.f. the flux density will

is, vary inv"^
as the area of the core.
78. Flux density. Since the air-gap varies approximately
pxill
square of the flux density, it would appear that the fiux density sin i

be as great as possible. However, the iron losses also increase with the i
density, so that the maximum possible flux density is not the most effici;.
79. Iron losses. The major portion of the total loss takes place in •
iron rather than in the copper. The hysteresis loss (Sec. 2) is calculi!
in the same way as that of a transformer, and denoted by P\. The ed-
current loss (Sec. 2) is denoted by P«. Then the total core loss is
P„=Pk-\-P, (watts)

80. The quadrature exciting watts are expressed thus:

li
-2.r,f^-^^ (la + )\0-* (watts)

wherein la is the length of the air-gap in centimeters, U the mean lengt'B

centimeters of the magnetic circuit in the iron, and s is the cro.ss-secti u
area of the core in .square centimeters. Expressing this in terms
volume of the air-gap and of the iron, which quantities must be kn
determining the core losses,

P, = 2.5/rt5'„ax(T^a+ ") 10-« (watta)l

362
 I

MAGNETS Sec. 5-81

v rein Va and Vi are the volumes in cubic centimeters of the air-gap and
t iron, respectively. Values of permeability may befound in Sec. 4.
I. The total exciting current may be found as follows: The wattless
c iiaanetizing component is

Ix=^' (amp.) (26)

he energy component, assuming I'R losses in the winding to be neg-

1 -lie, i.s

Ir= ^~^ (amp.) (27)

iie total exciting current is

I=\/lr^+l7 . (amp.) (28)

'he copper loss in the winding is

J Pc = im (watts) (29)
lidding this to the core loss, we have approximately for the total loss
P=PA + Pe+Pc (watts) (watts) (30)
>rhen the energy component of the exciting current is

/'r= (amp.) (31)

J
,1 the total exciting current is

lich is approximately correct.

1)per loss, and the calculations
/' = V'/V+/»2 (amp.)
This current can be used to find a new
(32)

can be repeated as far as it is thought worth

i
;ile.

1)2. Eftect of temperature on iron losses. The losses in the core

:Tease with a rise in temperature, and since the core losses form the
'jor portion of the total losses, the efficiency will increase with a rise in
fiiperature.
Lamination of magnetic circuit. The magnetic circuit should
13.
be laminated; this may be done in a way similar to that used in
rurally
asformer construction; or the core can be made solid, and slots in. ^
[ie and i in. or more in depth milled lengthwise in it. The magnetic cir-
i;t can also be constructed by winding iron ribbon spirally about a spider.

|J4. Pulsation of pull. In single-phase magnets the pull varies from

jo to a maximum, and back, twice during each cycle. This causes a
')ration of the armature against the core and gives rise to a considerable
\ ise. The latter may
be largely overcome by means of a shading coil,
iked with a portion of the flux in the end of a core or in an armature. This
i its the phase so that flux is always present in the sealed air-gap, and the
ill is never zero.

f86. Air-gap pull. If there was no reluctance excepting in the air gap
'
d also if there were no iron losses, the mean effective air-gap pull* would be
nstant regardless of the length of the air gap. In practical electromagnets,
|ie presence of reluctance and iron losses prevents the current from falling to

ro when the air gap closes, so that, for a very short air gap, the pull charac-
istics are somewhat similar to those for continuous-current electromagnets.
B6. Calculation of pull.
For a given number of effective ampere-
the laws stating the pull with alternating-current electromagnets
rns,
3 with those for continuous-current electromagnets (barring
identical
re losses); but, since in constant-e.m.f. electromagnets the current is re-
iced as the reluctance of the air-gap is reduced, during the travel of the
[mature or plunger, the characteristics of alternating-current electro-
ignets are different from those for direct-current electromagnets. How-
er, the true ^ull may
be determined, for any length of air-gap, by calcu-
I ing the effective ampere-turns for all lengths of air-gap and then calculating
e pulls with the ampere-turns so deduced,
by the equations given in Par. 63.
,' IJnderhill. C. R. "Alternating-current Electromagnets;" Electrical
[frid, 1914, Vol. LXIII, p. 260.

363
Sec. 5-87 MAGNETS
POLYPHASE ELECTROMAGNETS
87. Test data on two-phase electromagnet. Fig. 33 shows the rr
tion between volt-amperes and pounds puli for a two-phase magnet designj
and tested by D. L. Lindquist.* The magnet contained four coils, ea
wound with 220 turns of No. 14 A.W.G. copper wire, the cross-sectioi
area of the core being 1.94 sq. in. The test was made with the magn.!
winding connected to a tv,
;z phase 60-cycle system. T
,
.

^00 -1-g
- —..,,..
1

^—
1 1 1 1 ,

>--
method of connecting
is shown in Fig. 34.
the

-fr.i l
I I I I I I I I L ix] l^i -rTI I I I

^200
 MAGNETS Sec. 5-94

,h(
can successfully withstand. The temperature inside the coil
isulation
ni necessarily be higher than that on the outside.
t The watts per square inch for a series of standard magnets are
[iv in Par. 68. These values may be used for magnets within the range
If oportions shown in Fig. 17,
Fig. 20, Fig. 27 and Fig. 30.
'
Hot resistance. The approximate final resistance of a coil which has
tei in circuit for a sufficient length of time to become thoroughly heated is

,
Rt = Rc(.l + a,jt) (ohms) (34)

uti is the resistance of the coil at room temperature; Rt the final

Re
«gance; t, the rise in temperature in deg. cent, above room temperature;

in the mass resistance temperature coefficient at room temperature

«, is

8e5ec. 4). The standard room temperature is 25 deg. cent. Roughly,

t y be assumed that the resistance of copper will be increased 1 per cent.
01 ich 2.5 deg. cent, rise in temperature, or for each 5 deg. fahr.
'
Coils impregnated with high-melting and good heat-conducting
lo; ounds are able to withstand more applied power than untreated coils.
!n ;ernating-current magnets, the ferric parts also become heated (see Par.

MAGNET WI&ES
Wire insulation. Wires commonly used in the winding of electro-
ns lets are insulated with enamel, silk or cotton; or combinations of enamel
in otton, or enamel and silk.

98. Table of Diameters of Magnet Wires

(The Acme Wire Co.)
i
,Mze
Single- Enamel i Single- Enamel
vv. G.
cotton and silk and Enamel
covered cotton covered silk

.1069 .1088 .1038

.0957 .0975 .0925
.0858 .0876 .0826
.0770 .0787 .0737
.0691 .0708 .0658

15 .0621 .0635 .0585

16 .0558 .0573 .0523
17 .0503 .0517 .0467
18 .0453 .0468 .0418
19 .0409 .0424 .0374

20 .0360 .0372 0340 0352 .0332

21 .0325 .0335 0305 0315 .0295
22 .0294 .0305 0274 0285 .0266
23 .0266 .0277 0246 0257 .0237
24 .0241 .0252 0221 0232 .0212

; 25 .0219 .0229 0199 0209 .0189

k 26 .0200 .0208 0180 0188 .0168
I 27 .0182 .0190 0162 0170 .0150
; 28 .0166 .0174 0146 0154 .0134
"
29 .0153 .0160 0133 0140 .0120

, 30 .0140 .0147 0120 0127 .0107

31 .0130 .0137 0109 0117 .0097
32 .0120 .0126 0100 0106 .0086
'
33 .0111 .0117 0091 0097 .0077
•
34 .0103 .0109 0083 0089 .0069
35 .0096 .0102 0076 0082 .0062
38 .0090 .0096 0070 0076 .0056
37 .0090 0065 0070 .0050
38 .0085 0060 0065 .0045

365
Sec. 5-99 MAGNETS
99. Space factor. The most efficient winding is that which contains
maximum amount of conducting material hence a thin insulation of |,
;

dielectric strength is desirable. The space factor or activity coefflci,t

is the ratio of the space occupied by the insulated conductor to that occu| |

by the bare conductor. This is conveniently expressed in terms of turns r

square inch. The Tables (Par. 98, 102, 104, 106) show the relative va i
for the various wires. Enamel and silk, and enamel and cotton, are desigi
to replace double-silk- and double-cotton-covered wires, respectively; t
former two have higher activity coefficients and greater dielectric streuu
than the latter two.
WINDING CALCULATIONS
100. Winding formulas. In what follows let
d = diameter of bare copper wire in inch,
Ri =ohm8 per linear inch,
di = diameter of insulated wire in inch,
t" = turns per linear inch,
n" =» layers per inch,
Na «» turns per square inch,
R, =ohms per cubic inch.
Then the number of ohms per linear inch is

R( = 8,628tZ-n()-io
and t" = dr^ (or is found by actual count) j

For layer windings with no paper between layers,

n" = 1" (approx.) i

When paper is used,

n"=(di4-<p)-'
wherein (p is the thickness of the paper layer.
The turns per square inch and the ohms per cubic inch are ;;

Na = t"n"
Rv = NMi
The properties and dimensions of bare copper wires will be found ii

Furthermore let
T = thickness of wall of winding in inches,
L = actual length of winding in inches.
Pa = average perimeter or mean length of turn in inches, »
S = longitudinal cross-sectional area of winding in square inches, -f

V = volume of winding in cubic inches.

The winding cross-section and the winding volume are
S = TL
V = Sp.
In all usual shapes of coils, the thickness of coil- wall is T = n/n", W
n is the number of layers. For coils wound on cores or forms of the shapj
Fig. 35, the equation
Pa = 2(a-f-6-H.57ir-0.859r)

Fio. 35. —Core shapes and dimensions for electromagnet windings^!

isgeneral and gives the mean length of turn for coils with cores of a>j
these shapes. In the case of the perfectly square or rectangular core]
radius, r, is zero; whereas, in the case of the round core, it is, of course, «
to one-half of the diameter.
For a round core only,
Pa = r{Di + T)
where Di is the inside diameter of the coil. In all cases, the dimcnau

366
 MAGNETS Sec. &-101

he 3ulated cores are assumed, so far as the inside dimensions of the winding
le incerned.
1- total number of turns in a winding is given by
N = TLNaOT N = n"t"TL (45)
resistance of a winding is expressed by
R = VRv otR = paNRi (46)

1 . Formula for ampere-turns. The calculations of windings for elec-

ro'.gnets are generally controlled by the ampere-turns to be developed
no he energy loss in watts which can be safely allowed. This reduces
• problem of finding the size and kind of insulated wire which will give
•

be roper proportions of turns and resistance. For continuous-current

tetomagnets, the equation for the ampere-turns for a given e.m.f. ia

JV7= (47)

Jo'ersely, the size of wire isfound from the table opposite the nearest
'bI for Ri = E/NIpa. For the proper dimensions of a coil to radiate a
jv amount of heat see Par. 92.

102. Table of Turns per Square Inch; Solid Layer Winding

(The Acme Wire Co.)

iiize
W.G.
 Sec. 5-104 MAGNETS
then to make the final calculations after the turns per layer and number
layers have been determined from the preliminary data.
For a round winding, with given core, length, size of wire and resistanu
the outside diameter will be ]

The approximate thickness of wall of winding will be

The number of layers will be n = Tn", and a new value for T will
found for an exact number of layers, by T = n/n". The mean length
turn will be pa=ir(Di + T) and the outside diameter will now be D
Di+2T. The number of turns will be N = nt"L, and the resistanc
R = NpaRi. For round windings, the radiating surface is A =irDL, whe
A is |the cylindrical surface.

104. Ohms per Cubic Inch Solid Layer Winding

;

(The Acme Wire Co.)

Size

>
 MAGNETS Sec. 5-106

106. Table ofOhms per Pound

(The Acme Wire Co.)

Sze
^.W.G.
Sec. 5-111 MAGNETS
at the ends so that the fringes will overlap one another when bent at ri;
anglea to the tube. The coil is then mounted on the muslin-covered tv
and several oiled muslin washers are placed on each end. A slotted fil
washer is mounted at the end with the inside lead, and the lead is brou(,
out through the slot after being wound once around the tube; the ins
diameter of this washer should be sufficient to slip over the turn of the 1p
More oiled-muslin washers are then put on, and the fringes are fannofi
at both ends of the coil, after which heavy fibre end washers are put oi;
the ends of the brass tube spun over. This makes a very solidly constru .

and well-insulated coil. In alternating-current coils, the brass tube mi

be slotted lengthwise. When flat ribbon leads are used, it is not necessf
to use a slotted washer.
All splices should be soldered or brazed and thoroughly protected with ni'
muslin. The leads should be tied in position with stout twine.
111. Covering. Mounted coils are covered with cord, pressboard, ni
muslin, etc., and are often dipped in black air-drying varnish to give thr
protecting finish.
TESTING OF MAGNETS
112. Measurement of pull. The attracting effort of a small portati
magnet or a small tractive magnet, with the armature or plunger in cont;
with the pole faces or stop, may be measured with a spring balance. Lai
magnets may be tested by direct loading or by loading through a system
levers. The pullout >oint is not preceded by any warning and, in ore
to obtain accurate load readings, the load must be applied at a unifoi
rate and under perfect control.
A simple method is to hang a bucket below the weights and to pour wai
or shot into it until an amount equal to a weight unit is exceeded, when t
bucket may be removed and the equivalent weight placed in positic
then the empty bucket is again hung in place and filled, this cycle of opei
tions being continued until the pullout point is reached, when the total weig
is determined.
113. The pull tests, for various lengths of air-gaps, may be mn
by the use of brass discs or rings of thicknesses arranged in decades. Th
the first group may be 1 in., 2 in., 3 in., and 4 in. rcsoertively, with whi
any combination in thickness from 1 in. to 10 in. may be obtained. Tl
idea may be carried out as far as desired. Twelve spacers will give 1,<1
combinations. The measurement of the pull should be made as outli:
in Par. 112.
114. The heating test requires an ammeter, a thermorneter (or vo
meter), a watch and a rheostat. Fig. 36 shows the connections for a t(
where the temperature rise is dete
mined by the change in resistance (Sc
3). Instruments and general measui
ments are treated in Sec. 3. T
temperature
rise can be measur
by the resistance method
either
with a thermometer placed agair
?

tho outside of the winding. In maki

v^v,...^ „ „ .V,. «~ tbe test the current should bo ko
runi determinTngTe^mperatureris'rby »,* a con.stant value / by means of
t

resistance method. rheostat, and the thermometer (or,

Fig. 36, the voltmeter) read at regul
time intervals. While making the tost, either the temperature or the e.m
drop should be plotted with time; this will give the heating curve and she
when the final temperature has been reached.
115. The resistance test is usually made with a Wheatstone bridge
a modification* of the same designed to teat the coils very rapidly.
116. Test for short-circuited turns. Coils designed for use on alu
nating-current circuits are tested for short-circuited turns by placing the
on the core of a special transformer, whereby a high e.m.f. is induced in thei
117. The breakdown test for lirect-current coils is accomplished 1
placing them on a laminated core before mounting; then heavily overloadii

MJnderhill, C. R. " The Design of a Quick-acting Wheatstone Bridsr

Electrical World, 1910, Vol. LVI, p. 29.

370
 INDUCTION COILS Sec. 5-118

from coil to tube, of 3,500 volts alternating

B .da regular commercial test,

, stive value.
BIBLIOGRAPHY
i^Sxr'^^^^'M^cCn^Cr^ Magnetic Fields;- Trans.

York. McGraw-Hill
'f.J.f:.t:V^-^^T^T^^^
New York, Spon and Chamber-
^•HOMP8oi?S:P^^''The Electromagnet;"

^i'ndebLl, C. R.-"Solenoids, Electrornagnets and Electromagnetic

. J- /£ '
„j „ York, D. Van Nostrand Co., 1914.
^
tE^V-'zur^BerechLng d"r Ele^^
schinenbau, J906, Vol. XXIV, pp. 945, 973
and 993.
I
und Maschinenbau,
IssE E.— ''iJ ber Elektromagnete;" Elektrotechmk

\\Jscn P —"Bekrlge^iifr Berechnung der Zugkraft von Elektromagneten;"

'!l"::i±oSrf^:'K-'=TheDe.^^^^^^^
til World and Engineer, 1900, Vol. XXXVI, p. 125. r>.,*„."
for Specific Duty,
R.-"On the Design of Electromagnets
;iRTcHo;P, E.
5' Electrical World, 1894, Vol. XXIII, pp. 113
and 212.
Plunger Electromagnets;
H0MP80N S P -"On the Predetermination of
r

^^^^^''^''k^AS^^^c^n, Electromagnets;" Electrical

|SJE.''F.'^R-'^i"'Anti'nating^current Relay for Low Freauencies;"

^;SBB^W'Def"^irTung's"iJ''d^^^^^^^
4 ^e" Zeiischrift, ms";
Vol. X'XXIV. pp. 611
i Electromagnet; "reprinted in The Electrician 1913,
Vol. LXXII, p. --^^^^%JYlxilThs
^SS.
Engs., 1914, Vol.
'jnderhill, C. li.— "Solenoids;" Proc. Amer. Inst. Elec.
Alternating-current Magnets;" Electrical World,
i^DQUisx/D; L.-"
)!viIlE^R^R"-l-"The^Economical Design of Dire^^^^
1,
" Trans Amer. Inst. Elec. Engs.. 1911. Vol. XXX. p. 2019.
of Alternating-current Electromag-
r-VNDERHiLLCR.—"Characteristics
is;" Ehdrical World, 1914, Vol. LXIII p. 381.
FloktrntPch-
H^lektrotecn-
^FIFPNER E —"Die Berechnung von Lasthebemagneten;
KheZeitschrift. 1912. Vol. XXXIII. p. 57 T7i„„t,^,„„„npt •"
Electromagnet.
Jnderhill, C. R.— "The Design of the Marcel-Deprez
'

ixtrical Review & Western Electrician 1909, Vol.

L.\ .JP-^i^-
Electrical World, 1910. Vol.
(Electric Lifting Magnets in the Steel Plant;"
in Electromag-
l^TR^ATTON H F— "The Use
World. 1912, Vol.
of Naked Aluminum Wire
LX, p. 400.
f,s;" Electrical .

Wachod, C. p.— "The Design of Plunger Magnets;" Electrical World,

World, 1910,
.[JND^RHiL'L.^aR.— "Enameled Wire Windings;" Electrical
der Elek-
.ICHiEMANN, P.— "Energieumwandlungbeider Ankerbewegung
vmagnete und Permanenten Magnete;" Elektrotechmk und
Maschinen-
1, 1913. Vol. XXXI, p. 11.

INDUCTION COILS
BY CHARLES R. UNDERBILL
GENERAL
Induction coils
'.19. may be divided into two classes: those with
I primary winding only, and those with both primary and secondary wind-
371
Sec. 5-120 INDUCTION COILS
ings. The former are used extensively in connection with the ignition^
internal-combustion motors. The function of both types is to respc
to very sudden fluctuations of the e.m.f. in the primary circuit. For t
reason, they have open magnetic circuits, which partly accounts for tl
generally low efficiency.
In telephony, the function of the induction coil is to accurately transfo
the complex waves of e.m.f. and current corresponding to the sound wa*.
produced by articulate speech. It is, therefore, in this particular cai
simply a transformer with an open magnetic circuit. Induction coils
the secondary type are also used in radio telegraphy, internal-combusti
motor ignition, etc.; they operate on the principle of the gradual or p
gressive storage of energy, which is then suddenly discharged, and the cy
repeated.
The performance of the primary type of induction coil has an import r

bearing on the behavior of secondary-type coils of the jump-spark t>

and, for this reason, the primary-type coil is treated first and separate!)

PRIMAEY-TYPE INDUCTION COILS

120. Definition. A primary-type coil is a reactor (Sec. 6) designed
receive electrical energy, then convert it into magnetic energy, storing
much of the latter as feasible, and finally to reconvert it suddenly ii
electrical energy. The ultimate object is to utilize the heat of the resulti
spark, when the circuit is suddenly broken. The rupture of the circ
usually takes place in the cylinder of an internal-combustion engine
motor.
121. Theory. As commonly made, the primary-type induction c
consists of relatively few layers of coarse magnet wire wound over a c<
consisting of a bundle of soft-iron wires. When the circuit is closed throu
a battery, current flows through the coil and magnetizes the core; the count
e.m.f. generated by the magnetic flux cutting the turns of wire in the c .'

opposes the e.m.f. of the battery, so that a definite time interval is requiri>
to fully charge the iron core with magnertic energy.
The break is lesigned to have a snap-action which causes the circuit
be opened very rapidly, as soon as the flux in the core attains its most eflScie
value; thereupon the current and the flux decrease at a very rapid rate, a
at the same rate, to zero. This sudden rate of change in the flux indue
a high e.m.f. in the coil, proportional to d(j>/dt, in the same direction as t
battery e.m.f., tending to retard the decrease of the current, and thus pi
vent the sudden collapse of the magnetic field. Hence, at the point of ru
ture, or break, there results a bright spark or arc, usually varying frc
A in. to A if- ii length, the energy of which is the equivalent (barri
losses) of the magnetic energy previously stored in the core. The value
the current at the instant that the metallic circuit is broken is given '

Par. 30, Eq. 6, under "Magnets."

122. Stored magnetic energry. The magnetic energy, in joules, stor
in time ( is

Tr = "i;' Goules) (5

where L is the inductance in henrys and' i is the value of the current ,

amperes at the end of time t in seconds. This is the energy of the spa)
(less losses).

123. The inductance of the coil is expressed by

L = 80iVJdlO-» (henrys)
approximately, for cores having ratios of length to diameter betwr.
and 15, where N is the number of turns in the coil, and d is the diameu r

the core in centimeters.* The time, t, required for the current to ntia
63 per cent, of its final value is the time constant (Sec. 2) of theoircm
it is numerically equal to L/R. By assuming that the rate of current im-
is nearly uniform between O ixndL/R seconds, which is approximately c
the value of the current strength may be estimated for any correspi
time after closing the circuit.
* Armagnat, H. " Induction Coils " (Translated from the French by '

Kenyon); New York, McGraw-Hill Book Co., 1908.

372
 INDUCTION COILS Sec. 5-124

1 In Fig. 37 are shown the test character-

Test characteristics.
,i,'
a coil with circuit constants oi R = 9 ohms, and L = 0.02 henry.
of
of 8 volts, the
h the circuit was closed for Q.02 second, with an e.m.f.
O^i (or spark energy) was 0.025 watt-second.
energy The curve for
;
shown. It will be seen that the current at any instant is
ts is also
r^ y proportional to the e.m.f.
T time required for the current to rise from to 63 per cent, of its ulti-
a value may be lessened by
d ng the inductance or in-
e; ig the resistance. In 1.4
nil, a gain in time causes a
ri ponding loss in energy jji.a
01 The voltage should be
.

ffimt to overcome varia- «!l.O

)r of the resistance of the
in''ts, but not great enough
d the arc too long after
;

e ntacts are separated. In

a 36, battery e.m.fs. of from
tc' volts are employed, but
g«l rule isto keep the e.m.f.
V as possible. a When
initor is used instead of a
it y, the resistance and the
d ance of the generator
u; 36 added to the constants
i rest of the circuit.
Instantaneous current
 Sec. 5-128 INDUCTION COILS
SECONDARY-TYPB INDUCTION COILS
128. Theory. Fig. 39 shows the circuit diagram of a typical secoii
type induction coil. The circuit is closed at S and current establi^
O

-Secondary
Fig. 39.
for
—Typical diagram
circuit
secondary-type induction coil.
Fio. 40. —
Current and c.m.f. cu'«
of a secondary-type induction 5
without condenser.
the primary circuit; this current produces a flux in the core and whena
flux reaches a certain value the pull exerted on the interrupter contact i

r primary Cnrr
Seconda
E.M.r,

—
Fio. 41. Effect of loading the
secondary. (No condenser.)
Fig. 42. —
Curves of current an<l
in an unloaded secondary-type c.
condenser.
is sufficient to overcome the pull of the spring, .', and opens the cirom
The circuit being open, the flux quickly decreases to zero and thus ni
a high value of e.m.f. in t;
ondary winding, which cotisi.-jf
many turns.
When no condenser (Par. KiJ
used and the secondary cir
open, no current flows t

the secondary and, consri;

the effect of the second.ir;.
the primary is nil, cxoppi
the negligible charging cur
Time largo coils. All actions in
•

mary take place exactly a.-;

the secondary were not ;

Fig. 40' is the same as Fik

the secondary e.m.f. curv< >
The effect of loading the e
dary (without condenser) is ^i "
Fio. 43. — Current
curves of a loaded in Fig.
41.
129. ESect of condenser. I-
secondary-type coil with condenser.
42 shows the effect of thocon
• Bailey, B. F. "The Induction Coil;" Electrical World, 1910, Vol
943.
374
 INDUCTION COILS Sec. 5-130

39) with an unloaded secondary, while

Fig. 43 representa the effects
1
43) are taken
ding the secondary. These curves (Figs. 41. 42 and with the local
,; oscillograms
made by Prof. Bailey. The condenser,
primary, constitutes an oscillating circuit 1 he self-
H ance of the
rate of oscillation is high. The
4 ion in the primary is small; hence the
c^ tions in the
primary react upon the secondary, producing an oscillation
,R
mposed upon the logarithmic current-time curve.
be so designed
I Ooeration of interrupter. The interrupter should sud-
increase to its proper value and the circuit then
* he current may
a
in order that the time rate.of change in the flux ma^
open automatically,
great as possible. The interrupter is usuaUy made adjustable for this
;
brief duration
When it cannot be relied upon to give a sufficiently
;

II se
resistance of the primary and thus de-
.itact, it is safer to increase the
e' the time-constant,
rather than to increase the e.m.f. of the battery.
have just sufficient capacity to prevent
h condenser (Par. 169) should
)a ing.

of induction coils is largely empirical, there

being
1 The design
,a upon which there are no definite data. Prof Bailey and othei^
'points
from
». published some excellent papers n the theory of induction coils,
Bibliography ).
h part of the foregoing data have been taken
(see

Core design. Fig. 44 shows a curve plotted* between

flux in
J .

inch per ampere-turn per inch length of cod («^/^Ji).

and
n.per square
cross-sectional area of core (io/A„). It must
16 tio of core length to net
Bjted that the net area is used; this is given by

A„ = o— =0.7-^
.rf2
[(sq. in.) (52)

and o is the space factor (Par 134).

tti'.dia the core diameter in inches,
^ curve was plotted from data taken from tests made on cores of com-
16. il annealed round
'o-are 0.062 in. in dia- 200
le . In every case,
_
180
W iciting coil was 3 in.
)E iind consisted of 191
ai of No. 16 A.W.G.
o\iT wire wound in 4 __^,
i>?. The flux was g 5
aeired with an explor-
as il of 20 turns placed
D f centre and outside
I '! exciting coil. The
Wji.s plotted on the
luji (Fig. 44) are for a
B< f cores 1 in. india- ,
-

n«r and of different 6 8 10 12 14 16 18 20 22 24 26

4
le.'ths; the circles Length
'
led on the curve are Het Area

ftif
iBCfc of cores 4 in.
various diameters.
long piQ 44. — Curve for estimating ampere-turns,
.... j
r;i3 well to note that the same ratio of length to diameter can
correspond
Mny ratio of length to net area, and that the flux density produced per
»ni:re-turn per inch length of coil varies with the latter ratio.

'J. riux density. Based upon the tests plotted in Fig. 44, the flux
Je ty along the middle section of the core of a straight-core coil is. accord-
ini ,0 Mr. O. A. Kenyon,
= ^^-^-^^ (6.1— -f-35)
(Bmo» (maxwell'aper sq. in.) (53)
An I

wl e iV is the number of turns, / the maximum current in amperes, the I

lei h of the coil, h the length of the core, and A„ the net cross-sectional
ar: of the core. All dimensions are in inches.
Sec. 5-134 INDUCTION COILS
134. The space factor of the core is that per cent, of the total area w \
isoccupied by iron. In the cores tested by Mr. Springer, the space fan
varied from 0.675 to 0.70 and averaged 0.687.

136. Table of Core Dimensions from Practice

*
(Ehnert)

Spark length
(cm.)
 INDUCTION COILS Sec. 5-140

Limiting the secondary e.m.f. If too many secondary turns are

1
« the of e.m.f. can be limited by connecting the terminals
maximum value
lark-gap, the length of which corresponds to the maximum permissible
I

It

not vary greatly. For coils giv-

1 The size of secondary wire does
.

g ong sparks, Ehnert

a* that in practice the
ir varies in sizes from
lO equivalent to No. 35
I
38 A.W.G.; and for
;
.

10 coils giving short hot

«3, it varies from No.
)';No. 34 A.W.G.
Arrangement of
i.
ii'ings 1 .yer method. ;

h are two general

le )d3 of arranging the
i lings, namely, the
tjf method and the sec-

oDr "pie" method

144). Fig. 45 shows
?i
leiyer method; the up- Fig. 45.
of coil.
— Distribution of flux and general form
Bi alf shows the theo-
!til form of the major
ist.tion and the secondary coil, while the lower half shows the
»r^
practical
The curve at the top shows the e.m.f. generated per turn in the sec-
ondary coil at different positions along
This curve shows that turns
i
the core.
near the end of the core are very much
less effective than near the middle.
differ as to the proper length
1 L5mm Designers
™ph5^ of the secondary coil, but as a rule it
varies from 0.25 to 0.50 of tte length
of the core.
143. Construction of secondary-
type coils for ignition. Immense
quantities of iaduction coils are used
in internal-combustion motor ignition.
These coils usually have secondaries
consisting of two sections mounted on a
tube over the primary. The coils are
wound evenly in layers, by automatic
machinery, and several sheets of thin
40. — Coil proportions.
paper are inserted between successive
layers during the winding process.
'h -
poils are subsequently treated with paraffin or some compound.
Arrangement of windings; "pie" method. Figs. 47 and 48
the "pie"
1 1. Coils giving
, ! -k longer than 5
m (2 in.) generally [^^^s^s^^ss^?
ec re the secondary
'to be made in
sections. In
!

the inside of
,

in pie" is connected
p le outside of the
[d, ent "pie," etc.,
m in Fig. 48, the
Rjent coils are con- Fig. 47 and 48. Methods of connecting and dis- —
ffi' d alternately at tribution of e.m.f. in pancake coils.
"
Mp
and outside.
In the_^ first.
the cross-sections are shown the e.m.f. diagrams. ^_ .

pies
xiraum e.m.f. which can exist between two adjacent coils or
3 ai to the generated in one coil and is the same
e.m.f.
aU parts ot tne m
377
Sec. 6-145 INDUCTION COILS

coil; in the second, the difference in potential between two adjacent

zero at the points where they are connected (alternately inside and ou. ,

and increases from that point to a maximum value equal to twice the eif!
generated in one coil.
At first sight it appears that the first system would require only haliie
insulation between sections or "pies" that the second would, but in ij.
tice the connecting wire, which must run through the insulation betweei*
coils, is ran straight out through the middle and requires sufficient insul;
on each side to resist the coil e.m.f.; thus it will be seen that both sys »
require the same insulation.
145. Details of winding process. The pies are wound in thirV' —
varying from 0.0625 in. to 0.25 in. As a rule, silk-coverod wire is use
98, 102, 104, 106). The core of the winding form is given a bevel, i:
to tell the polarity of the coil at a glance, provided, of course, that;:

are wound in the same direction. When cotton-covered or silk-covcri

is used, it is passed through a bath of melted paraffin wax or compoun
winding; the amount of wax retained by the wire ia controlled by paasi
wire from the bath through several paper slits, varied to suit the req *•
ments; in this manner the wax is scraped off the wire to any desired ex t
Care should be taken to have the temperature of the wax sufficiently hii o
prevent cooling before it is in place, since the wax serves to hold tlv
together. Before winding, the wire should be thoroughly dried out
oven.
146. Table of Dimensions of Induction Coils

Authority
 INDUCTION COILS Sec. 6-148

K etween the sections or "pies" of large secondaries there are discs built
J some treated material. The core wires should also be insulated by
pig them in some kind of insulating varnish.

J
INTERRUPTERS
Types of interrupters. Interrupters for induction coils may bo
li.
V'id into two distinct classes, namely; mechanical and electrolytic.
hcimpler form of mechanical interrupter (Fig. 49) is suitable for so-called
ecal coils. It is also used on small spark coils. This type of inter-
ip: is not easily adjusted to different speeds, since it has a natural fre-
16 y of its own, and possesses coisiderable inertia.
t. An atonic interrupter is one that can be ad-
s to operate at any frequency within very wide limits.
.

8 :e3sf ul interrupter of this type is shown in Fig. 50.

[c ications of this type are used on nearly all ignition
\\\

hi.ammer
as well as on large and powerful induction
attracted by the core and hits the spring
is
)irH, making a very sudden break. The duration of
»n H is regulated with the spring, s, and the duration
The
coils.
*
'

t break is controlled with the screws, r and r'.

iri;, s, is so attached that it produces a pull which is Core
a eally uniform throughout the range of action and
lu lermits the magnetic force to accelerate the hammer p^jQ 43 Sim-
jr rapidly. The space between the hammer and the pjest form of in-
iD-H spring permits the hammer to attain an appreci- terrupter.
)li.-elocity and strike the spring a blow that breaks
le rcuit very suddenly. The contact spring is light and short, and has
i
V,' high natural frequency, thus making the "lost time" very small,
hi interrupter can be adjusted to operate on alternating-current supply,
re ing the circuit when the maximum value of current is reached.

150. Oil-immersed interrupter. When the

e.m.f. of the source exceeds 20 or 30 volts, the con-
tacts are usually broken in an insulating liquid, which
will extinguish the arc.
161. Mercury interrupters. For high-speed
work, mercury interrupters are extensively used.
There are two distinct kinds, namely; the recipro-
cating type and the turbine type. In the former,
a reciprocating contact-point is plunged into and
withdrawn from a basin of mercury, thus making and
breaking the circuit. The plunging contact may be
operated in a variety of ways, most usually with a
small electric motor. The maximum speed of this
type is limited by the tendency of the mercury to fol-
low the plunging contact when it leaves the surface.
In the turbine type, a stream of mercury is made
to play on a number of saw-like teeth, by revolving
SrciiO. — Atonic
either the nozzle or the teeth.
in- When the stream
passes between the teeth the circuit is interrupted,
_

'
errupter.
and while in contact with the teeth it is closed. This
rp 8 almost invariably driven by an electric motor and is excellently
aaed to very high-speed work.
1 Motor-driven interrupters can be adjusted to operate with
.

Iteating current, and are conveniently driven by synchronous motors for

lisurpose.
1'. Electrolytic interrupters differ greatly in their characteristics
pi the mechanical interrupters described above. No condenser is used
It -his class. The best-known type is that due to Wehnelt, which con-
st )f a cathode, generally a lead plate, immersed in a dilute solution of
iunric acid together with the anode, which is a small platinum wire pro-
set i into the electrolyte from
a porcelain tube. The interrupter is ad-
Bt by moving the anode up and down so as to change the amount of
irt in action.
ven a certain current density at the anode has been reached, the gas
ieed at the surface of the anode increases the resistance at that point

379
Sec. 5-154 CONDENSERS
to such an extent that the circuit becomes practically interrupted. As s i
as the current density falls the resistance decreases and the current agi
rises to its original value.Experiments show that electrolytic interrup-ji
will operate in synchronism when connected in series or in parallel.

BIBLIOGRAPHY
—
164. Keference literature pertaining to induction coils.
Armaqnat, H. "Induction Coils;" Translated by O. A. Ken>,
McGraw-Hill Book Co., Inc., New York. 1908.
—
Ehnert, E.W. "Theorie und Vorausberechnung der Funkeninduktore ^
Elektrotechnik und Maschinenbau, 1907, Vol. XXV, pp. 337, 361 and
B. F.
B.\.iLEY,
— "Induction Physical Review, 1908,
Coils;'* XX Vol.
;

Bailet, B. F. — "The Induction Coil;"

p.358.
World, 1910,
Electrical Vol. i'

Springer, F. W. — "Electrical Ignition in Internal Combustion Ensinff

pp. 943 and 1005. ^
'

World, 1906, Vol. XLVIII, pp. 995, 1111 and 1242.

Springer, F. W. — "The Design and Operation
Electrical ,

Spark Coils;" f^ of

Edwards, E. — "Contact Method

trical World, 1907, Vol. L, 1163. p.
J. Gas Engine Ignition;"
of Elertr I

Eddy, W. O. and Casthorn, M. — "The Design

World, 1907, Vol. L, 705. p.
Induction of '

Electrical
—
World, 1906, Vol. XLVIII,
Eddy W. O. "The Design a
1197. p.
Induction Coil;"
of 12-in. Elcctr.l
World, 1907, Vol. XLIX,
Eddy, W. O. — "The Construction
40. p.
Induction Coils;"
of Electrical Wtl,

Collins, A. F. — "The Induction Coil;" New York, Munn and

1907, Vol. XLIX. 244.p.
,,

NoRRiE, H. — "Induction Coils;" NewYork, Spon and Chamberlam,

1908.
S. I'l.

"Questions and Answers." Electrical World, 1906, Vol. XLVIII, p. 1,1

CONDENSERS
BY CHARLES R. UNDERBILL
TYPES
j

1B6. Types and properties of condensers. There are three princu

types of condensers. The most familiar one is the ordinary plate condeiir
used with induction coils, telephone and telegraph apparatus, where a jr

large capacity is not required. The plate type is also used for labora y
standards (Sec. 3) in measurements of various kinds. Where a very ;« 1

capacity is required, the synchronous condenser (synchronous motor

synchronous converter with overexcited fields) is employed; such appara
is outside the scope of this Section and will be found under Sec. 7. The t d
type is the electrolytic condenser which is treated later under its own Id
(Par. 175). '
The properties of a condenser are covered fully in Sec. 2, but in bri
chief function of a condenser is to store electrical energy for sul^
usage. Such storage of energy may take place in a variety of ways, a.
to circumstances: thus it may be constant, if the condenser is connoc
source of continuous e.m.f ., or it may be intermittent, as in the case
denser in a telegraph circuit (Sec. 21); or it may be transient; or, in '

of alternating-current circuits, it may be periodic. In consequent

property of storing electrical energy, condensers can be used in lui
ways to alter or modify the characteristics of circuits in some desired i:

such as to change the relative phase of e.m.f. and current in an alterii^i ^

current circuit, improve the power-factor, or to prevent the flow of contin i»

current simultaneously in the same circuit with an alternating current.

PLATE CONDENSERS
Types and limits of size. Plate condensers are made com t-
1B6.
cially in anumber of types, usually designated by the kind of dielectric i-

ployed. The earliest type, still used in laboratory and cl.ass-rooin worU
the Leyden jar, which is merely a two-plate condenser with a glass di >
trie,constructed in the form of a wide-mouthed bottle or jar with tirjU
coatings inside and out. Other types of simple plate condensers are dW
380
 CONDENSERS Sec. 5-157

various dielectrics, such as air, mica or paper.

,h Increase of capacity
ribtained by building up alternate layers of conductor (plate or sheet) and
liectric; alternate sheets or plates are connected in parallel to the two
1 pective terminals. Rolled condensers are constructed as a rule of tin-
1 and paper, rolled or folded over a mandrel instead of being laid up in
sheets or stacks.
.

n the Mansbridge* self-sealing condenser, foiled paper is used which

5 kes it possible to obtain a high capacity for small volume. Before being
I embled into the condenser the foiled paper is tested out electrically by
inning the paper over a metal roll, with the foiled side uppermost, and
iilying a constant e.m.f. between the foil and the roller. Any weak spots
;'
thus burned out.
The capacity of a Leyden jar is only a very small fraction of a microfarad.
. te or rolled condensers are made in various commercial sizes from a few
J idredths of a microfarad up to several microfarads. Condensers having
tiacities as large as 100 microfarads, for experimental work, have been
! linged by connecting a large number of small units in parallel.
57. The seat of stored energy in a condenser is in the dielectric. The
I rage of energy is a consequence of the dielectric displacement, or elec-
i: charge in the dielectric, which accompanies or co-exists with a state of
I
?tric stress. This displacement is expressed
k
D = -r^E
4ir
(statcoulombs) (54)

'jBre D the electric displacement or charge, in statcoulombs per cu. cm.,

is
l\ the dielectric constant or specific inductive capacity, and E is the poten- (
< gradient in statvolts per centimeter; the prefix "stat" implies units in
1 c.g.9. electrostatic system (Sec. 1).
58. Limits of voltage. When
the electric stress is increased indefi-
i|3ly, a point is reached at which the dielectric becomes unable to sustain
f intensity of stress, and electric rupture occurs, that is to say, the dielectric
1 aks down. The rupture limit is termed the ultimate dielectric stre igth.
';
L3 limit is not a constant quantity under all circumstances, for a given

1 terial, but is affected by the shape, size, physical condition, temperature,

< , and by the manner in which the stress is applied. The properties of
( ectrics are treated in Sec. 4, under "Insulating Materials." The follow-
i table (Par. 159) gives the properties of some of the dielectrics com-
ijaly used in condensers.
159. Table of Properties of Condenser Dielectrics
(Phillips Thomas)

Specific Per cent, Breakdown

Material of dielectric inductive power- strength,
capacity factor volts per mill

ica 5.5- 7.5 0.05-0.11 700-1200

ra. paper. . . 2.0- 3.3 0,10-3.00 400-700
.kelized paper 4.5- 6.0 0.10-4.20 300-700
Uuloid 4.2-16.0 0.70-8.00 400-900
eto-cellulcse 4.5- 6.5 0.70-1.10 400-700
Ratine 4.0- 6.0 0.77-8.00 400-800
irosene 1.9- 3.6

s'hese values hold only for sine-waves at 60 cycles per second, at about
'deg. cent.
60. Calculation of required dimensions of plate condensers. The
c lensiona of a plate condenser are determined by the formula
CL,
10 (sq. in.) (55)
V:2.2iNk
Mansbridge, G. F. "The Manufacture of Electrical Condensers;"
'mi of Proceedings of the Institution of Electrical Engineers, 1908, Vol.
, p. 535.

381
Sec. 5-161 CONDENSERS
where Li is the dielectric thickness in inches, after impregnation, betwi,
each pair of metal strips; A^ is the number of such dielectric strips in the c,.
denser; C is the desired capacity in microfarads; k is the specific inductji
capacity of the paper after impregnation, and I is the short dimension of li!
foil (Fig. 51). This construction insures the lowest possible internal ohii.
resistance and also permits the use of extremely thin metal foil.
161. Internal losses and leakage. A condenser may have inter!
losses of two kinds. The first is due to the resistance of the plai
themselves, and this is most prominent in rolled condensers of very thin
foil, inasmuch as each plate is one long continuous strip and the resistance!
the whole strip from outer terminal to inner end may be appreciable, 'i
second kind is the loss in the dielectric itself, due to dielectric hystere ,

so-called (Sec. 4) this loss can bo expressed as an equivalent series resistai,

;

which should be added to the resistance of the plates. Both forniff

resistance absorb energy and reduce the normal angle of lead of eurit
with respect to terminal e.m.f. from 90 deg. to some lesser angle; thii
equivalent to saying that the power-factor is increased from a value wl i
is theoretically (or in the ideal case) zero to some definite value, althoi
not usually large.
Besides these two forms of loss, there also may be a pure conduction cunt
flowing through a condenser, in phase with the terminal e.m.f., which resj
from the lack of perfect insulation, or the presence of leakage. The resistn 3
of the condenser to a continuous e.m.f., after the steady state has bi
reached, is termed the insulation resistance. The value of insulai
resistance, of course, should be as high as possible.
162. The power-factor of a condenser determines to what extent
will be heated when used in alternating-current circuits. The power-fa t
is the cosine of the angle by which the current leads the impressed volt :,

with simple sine- wave forms. It varies with the frequency and inipreJ
voltage, with the temperature of operation, and with the dielectric ul.
The power-factor of a condenser may be determined by measuring the emy
loss or by measuring the variation from 90 deg. phase angle direct
The specific inductive capacities, power-factors, and breakdown stren I
of some materials suitable for condenser dielectrics are given in Par. I.

The constants of kerosene oil are included for comparison. The values k n
hold only for 60-cycle circuits, at about 20 deg. cent. The breakdown ti-
wave strengths are in effective (root-mean-square) volts per mil thicknes'f
dielectric. In connecting condensers in series for use on high-voltage "•

cuits (static voltmeters and the like), it is important to know the se\il
power-factors, aa the distribution of voltage is affected thereby. The I-

tage distribution among the several condensers will be proportional tc

product of capacity by power-factor, for small power-factors.
163. Absorption of charge. Many dielectrics do not become fji
charged instantaneously, nor do they, when fully charged, give up tu
complete charges instantaneously. The time lag in receiving full or (i-
plete charge is usually referred to as absorption. It is noticeable in tes |
such dielectrics as glass, rubber, gutta-percha, etc. The effect of absuri c
on the phase of the current is equivalent to resistance in series with <

164. Glass condensers are made both in the form of Leyden jar-
flat plates. Glass-plate condensers are commonly made of the besi i<
glass with sheets of tin-foil shellaced to each side of the plate. The edg,
the surface of the plate, not covered with the tin-foil, are varnished to prej
leakage. The finished plates are mounted in a rack and connected tow
by flat springs which touch the foil of adjacent plates. Condensers ofl
class are employed on the transmitting side of wireless telegraph appaq
.L. W. Austint summarizes tlie results of his tests as follows: The w
in the compressed air condenser used, at a pressure of 15 atmospt
amount to an equivalent resistance of between 0.1 and 0.2 ohms. Conaei
in which "brushing" (brush discharge) is prevented by the nature of
'

construction show no change in resistance between the limits of observai

• Grover, F. W. " Simultaneous Measurement of the Capacit.v and T{

Factor of Condensers;" Bulletin of the Bureau of Standards, 1907, Vol,
P- 371. . ^. ,i

t Austin, L. W. "Energy Losses in some Condensers used in Ilieli'*

"^
quency Circuits;" Bulletin of the Bureau of Standards, 1912, Vol. I

382
 CONDENSERS Sec. 5-165

I to 20,000 volts, indicating that the internal losses are independent of

)

th'voltage. Leyden jars of commercial types immersed wholly in oil

jh losses but slightly greater than those of the compressed-air condenser.
r paper and micanite condensers measured show very much larger losses.
r resistances of the different Leyden jars in air vary between 1 and 1.8
ol? at 14,500 volts. Between 10,000 and 20,000 volts the equivalent
re tance increases approximately in proportion to the square of the voltage.
Piling Leyden jars in series parallel, the capacity remaining the same, does
nr liniinish their brushing losses below 20,000 volts. Immersing only the
_

the conducting
• coatings of Leyden jars in oil gives an equivalent
midway between that observed when wholly in air and that when
!'

„ in oil.
... Brushing losses are much increased by any semi-conducting
m rial on the surface of the glass at the edges of the conducting coatings of
Le.en jars.
'5. Mica condensers.Those condensers in which mica is employed
io lie more constant in their properties than those made with
dielectric are
par. mica condensers
Therefore, are used as laboratory standards
}l pacity; and also where high voltage is used, on account of the greater
ii jtric strength of mica. H. L. Curtis has shown* that with good mica
joensers the capacity as measured with continuous e.m.fs. does not differ
W the capacity as measured with alternating e.m.fs. more than 0.1 per
;e for any frequency; the difference is usually less than 0.1 per cent.
,

Fi he effect of temperature on mica condensers, see Par. 167. R. Apple-

ysi has shownf that with mica condensers the capacity remains con-
itj with increasing temperature, but the safe voltage limit decreases.
'5. Paper condensers. According to Mr. Phillips Thomas, plate
sorensers are made most conveniently and economically as follows: strips
i
rf|3tal foil and squares of unglazed paper of close texture and short fibre

(1)
Showing the process of building up a multiple-plate condenser.

lied up in alternation, allowing the metal strips to project on all four

of thesquare centre portion. These projecting ends are folded down
lelted into one solid bar. The whole is then vacuum dried and impreg-
with parafBn, beeswax or the like, and cooled under a pressure not
-ding 10 lb. per sq. in. Fig. 51 shows the method of placing the
A» of foil and paper. The paper sheets are best made in square form,
IS edge being slightly wider than the narrow dimension of the metal
.,
,.S- 51 shows four fibre or wooden upright pegs forming a jig, used
n ilding such condensers. A strip of metal foil is laid one way between
fn' ri;s, then a square piece of dielectric (paper) is laid over the strip
of
pegs are recessed to fit) and next a second piece of foil is laid be-
0 pegs, at right angles to the first. This constitutes one element
Mss,H.L. "Mica Condensers as Standards of Capacity;" Bulletinof
uu of Standards, 1910, Vol. VI, p. 431.
pieyard, R. " Dielectrics;" Philosophical Magazine, 1896, Vol. XLII,
>. i.

383
Sec. 6-167 CONDENSERS
of the condenser. This process is repeated until as many sheets of diele i
as desired have been used, after which the projecting sheets of foil are r*
up and melted into a solid bar, as in (2). The condenser is then readiiO
impregnation.
167. Effect of Temperature on Paraffin-paper and Mica Condensi '

(Abst. from Proc I. E. E., 1896, Vol. XXV, p. 723)

Temp. deg. cent

 CONDENSERS Sec. &-171

I,condenser* for correcting comparatively small loads having low power

ict -, in a manner similar to which synchronous condensers (Par. 166)
re o'd in large systems. The resistance rods very quickly drain off any
ha ' may be in the condensers when disconnected from the line.
that
g-;ic condensers may be obtained for installation on circuits ranging in
ret'ncy from 40 to 125 cycles and in voltages from 220 to 2,300 volts,
1 (.lacities from 60 kv.a. to 300 kv.a.
The efficiency in all capacities is
t I-t 99 per cent. At normal capacity the temperature rises of the con-
fir: section and reactors are not over 10 deg. cent, and 50 deg. cent.
I»(;tively.

100

^90
Sec. 6-174 CONDENSERS
volume per microfarad is 4.5 cu. in. The rated voltage limit is 400 volts «
nating; one of these condensers failed on test at 650 volts, alternating' h
energy loss was from 1 per cent, to 2 per cent. Another condenser c*
paper type,* built to stand 10,000 volts (alternating), occupied 2 cu. ftli
microfarad. Generally speaking, the ordinary paper condensers of the iS
type used in telephony and telegraphy are built to stand about 500 (j
alternating, and range in size from a few hundredths of a microfarad
«
4 mf. to mf.; some of these condensers are built to stand 1,000 volte
r
nating. The higher the voltage limit, the more bulky and expcu-
condensers become. The table (Par. 168) gives the sizes, dinien.'^ii
age limits, and approximate costs of rolled paper condensers used in t.
practice.

174. Table of Dimensions of Condensers Used with Induction ili

(Ehnert)t

Spark-length, cm
 CONDENSERS Sec. 5-179

: I.The capacity of this condenser depends only upon the voltage

if rmation and the material of the anode, and is independent of the nature
f > electrolyte. Fig. 53 gives the capacity as a function of the formation
oi^e for aluminum, tantalum and magnesium. The abscissas are the
voltage of formation, the ordi-
nates, the capacity per square cen-
timeter of surface. The second
set of curves in Fig. 53 shows the
increase of the calculated ratio
(.t/k) of thickness of the gas layer
to the specific electrostatic capacity
with increasing formation voltage.
By passing from lower to higher
voltages the thickness of the gas
layer increases and assumes its new
value within a few minutes. In
passing back from higher to lower
voltage, however, it requires
months before the thickness of the
gas layer is reduced again to its
former value. For short experi-
ments the thickness of the gas layer
may be considered as constant as
long as the voltage remains below
200 400 the voltage at which the anode
Voltage oi Formation was formed. In this case the elec-
condenser behaves like a
53.-Capacity of electrolytic con- *''°'X*'''
,

le.rs, and ratio of the thickness

with interchangeable
co^^^ejiser
^"''^""^==' of gas
"\ B'la However, if the forma-
dielectric.
•v f ^^.T^o«;fi« o„„ „:*
aytospecificcapacityCpersq.cm.).
^^^^ ^.^^^gg j^ increased, the ca-
>a^/ is inversely proportional to the formation voltage.
}i. Capacity with reversed currents. An electrolytic condenser has
10' ecessarily the same capacity in opposite directions of the current. To
ns equal capacity in both directions, both electrodes must have an equal
;

lur ;e in the electrolyte and must be formed at the same voltage.

: Precautions in manufacture. In the practical manufacture of

.

lie olytic condensers, attention is paid to the fact that the oxide film and

.he as layer adherent to it cover only those parts of the aluminum elec-
Tc which are in the electrolyte. From those points of the aluminum sur-
ac vhich are just above the electrolyte, the electricity tends to jump or
iro om the aluminum plate into the electrolyte, causing considerable heat
in« orrosion of the aluminum. It is, therefore, important to make this
Ju num boundary line between electrolyte and air as short as possible and
;o 'ulate it very carefully.

M. Electrolytic condensers for alternating-current circuits

ih( d be formed' with continuous e.m.fs., equal to the maximum value of the
ilt- ating e.m.f.
J. The energy
losses are small at low voltages and do not increase
>pf:ciably when the condenser is connected in the circuit for a long period
)f but as the voltage is increased the losses increase with time at an
ae,
ncising rate. In cases where condensers are to be used continuously, it
8 i.isable to connect several low-voltage condensers in series. Dr. Gun-
'''-^hulze* carried out an extensive investigation of electrolytic condensers
ichsanstalt which was described and discussed in an article: " Alumi-
ftrolytic Condensers of High Capacity," published in Electrochemical
-.' tallurgical Industry, Vol. VII, p. 216 (1909).
-1
'

BIBLIOGRAPHY

' RTI8, H. L.
—
U. Reference literature pertaining to condensers.
"Mica Condensers as Standards of Capacity;" Bulletin of
aKureau of Standards, 1910, Vol. VI, p. 431.

. h;hulze, G., "Kondensatoren Grober Kapazitat;" Elektrotechnik UTtd

mtninenbau, 1909, Vol. XXVII, p. 247.

387
Sec. 5-185 RESISTOR.^
—
Grover, F. W; "The Capacity and Phase Difference of Paraffined Pa
Condensers as Functions of Temperature and Frequency;" Bulletin o«
—
Bureau of Standards, 1011, Vol. VII, p. 495.
Austin, L. W. "Energy Losses in Some Condensers used in High;-
i

quency Circuits;" Bulletin of the Bureau of Standards, 1912, Vol. IX, pj

—
Appleyard, R. "Dielectrics;" Philosophical Magazine, 1896, 1
XLII, p. 148.
—
Ehnert, E. W. Theorie und Vorausberechnung der Funkeninduktor
Elektrotechnik und Maschinenbau, 1907, Vol. XXV, pp. 337, 361 and
;'

—
ScHULZE, G. "Kondensatoren Grober Kapazitat;" Electrotechnik
;

id

Maschinenbau, 1909, Vol. XXVII, p. 247.

—
R08A, E. B., AND Grover, F. W. "The Absolute Measuremcrol
Capacity;" Bulletin of the Bureau of Standards, 1905, Vol. I, p. 153.
"Construction of a Condenser for a Jump-spark Coil;" American 1>
trician, 1905, Vol. XVII, p. 576.
—
Grover,»F. W. "Simultaneous Measurement of the Capacity and Pof'
factor of Condensers; "Bulletin of the Bureau of Standards, 1907, Vol I

MoRDEY, W. M. — "Some Tests and Uses

p. 371.
Condensers;" Journal
of of »

Mansbridqe, G. F. —"The Manufacture

ceedings the Institution
of Electrical Engineers, 1909, Vol. XLIII,
of p. 8
Electrical Condens
of ;*

Journal of Proceedings of the Institution of Electrical Engineers, 1908, )1

XLI, p. 535.

RESISTORS AND RHEOSTATS

BY LEONARD EEBLER
TYPES OF RHEOSTATS
185. Plate-type rheostats have a resistance in the form of a refliJ
metal wire or ribbon attached to a plate of porcelain-covered iron, it(
a plate of in.sulating material such as soapstone, by means of a coatiioi
fused enamel or by cement. They are used almost universally for iil
field rheostats, theatre dimmers, small motor-speed controllers, battery c g
ing rheostats, etc.
186. Box-type rheostats have a resistance' in the form of wire-\rr i
enamel-covered porcelain tubes; cast-iron grids; coils of bare wire: r
ribbon; carbon discs, or a conducting liquid. They are used for m 1

rheostats, motor starters, large motor-speed controllers, battery-r

rheostats of the larger sizes, etc. (Also see Par. 199.)

FIELD RHEOSTATS
187. Field rheostats are used in series with the fields of dynamc oi
regulating the field strength and in turn the voltage of the dynamo, or i h(
fields of motors for varying the field strength and in turn the speed.
188. Generator field rheostats for direct-current machines usuall n
provided with such a value of total resistance that it is about equal to«l
of the field to be regulated, thus giving a variation in field strength H
maximum to one-half iiiaxinuun with a constant exciting voltage. i

Alternatingr-current generators have field rheostats whose resis'Hi

is usually about twice that of the field, thus giving a variation in field am «
from maximum to one-third maximum, at constant voltage.
189. Motor field rheostats have resistances of a value determim
control desired. The resistance is about equal to that of the field
per cent, speed increase is wanted and may be eight or ten times tli
field when about 400 per cent, increase is wanted.
190. The current capacity of a field rheostat should change by an i

amount as each additional step of resistance is inserted. If I max is ('" ''

rent when the rheostat is short-circuited, Imin the current when all '' ''

ance is in circuit. A' the total number of steps and IN the chanter
peres per step, then
iAf =— -r= . (amp.)

and the current In when n steps are in circuit is

In = Imax-nIN
')
(amp.)

388
 RESISTORS Sec. 6-191

ri total resistance of the rheostat when n steps are in circuit is

.'
'

«n = -^ ^—7- (ohms) (58)

infivhen (.n — l) steps are in circuit the total resistance of the rheostat is

i?„-i = ~P 7^-tTt- (o^o^s) (59)

Imax—{n—l)In
ri resistance of the nth step is therefore Rn—Rn-i ohms. In each
ua E is the e.m.f. in volts at the terminals of the field circuit.

1.maximum number of watts to be dissipated by any one

The
It; be approximately constant, if the change in amperes per step of
will
re'tance inserted is constant, and the resistance of each step is figured as
ate.
2. The maximum
allowable temperature rise for field rheostats
is deg. cent, when measured by a thermometer placed against the re-
jii-e conductor. The limiting observable temperature rise for the is-
8u ; air is 175 deg. cent, measured one inch from the enclosure about
th esistor.
3. The automatic-release feature on motor field rheostats is
90 'times provided. This usually consists of a magnetic device connected
ac JS the armature terminals which short-circuits the rheostat resistance
w 1 the motor stops, so as to prevent starting under weakened field.

MOTOB SPEED-REGULATING RHEOSTATS

Speed-regulating rheostats for main armature circuits have
4.
i
v&ing amounts of resistance for varying conditions.
:5. The required resistance for a certain per cent, of speed reduction,
w: a constant-potential shunt-WOUnd motor, is determined as follows:
L« 5 be the normal speed in r.p.m., Sr the reduced speed in r.p.m., £ the
li? voltage, I the current taken at reduced speed, R the rheostat resistance

in ims required to secure the desired speed reduction then

3. Motor current requirements at S E

ffiiced speed. For pump, machine duty, -^ = p_fB (^0)
et> the current taken at reduced speeds is
f>r .o J«
apoximately that at normal speed. For p_ri? _ ^^'
la-ventilatingfans the torque varies as the
fgi)a in ^ k i-)

Bc.re of the speed, but for ventilating fans „, „

oiss than 20 h.p., the current will vary ^nd ij=— ' (l — — ") (62)
n)|ii nearly as the speed. I ^ S /
i7. Temperature
rise of plate-type rheostats. For each watt
di pated per sq. in. of free radiating surface, the rheostat plate will rise
alit 60 deg. cent., and usually but one side of a plate-type rheostat cao
rfate freely. Therefore where A is the area of one side of the rheostat
(s in.), I the current flowing (amp.) and R the resistance of the rheostat
(ens) in circuit, the temperature rise will be 60 {I^R/A) in deg. cent.
l^)rox.).
•8. The maximum
allowable temperature rise for speed regulat-
ii rheostats the same as for field rheostats given in detail in Par. 192.
is

19. Calculations of resistance, current-carrying capacity, etc.,

f( box-type rheostats, regardless of the use to be made of them, may
b' arried out in the same manner as for plate-type rheostats.

)0. Automatic features on armature speed controllers consist of

n 'oltage protection, overload protection and overload circuit-breaker.
^ voltage protection and overload protection are secured by the use of
c< act arms which are held in the operating position against the action of a
Bvng. On no-voltage or overload the spring is magnetically released and
n es the arm to the open-circuit position.
n overload circuit-breaker on armature speed controllers consists of
a parate switch arm held closed by a latch. On overload this latch_ ia
ti ped by a magnet, the switch is opened by a spring and breaks the main-
li circuit irrespective of the movement of the resistance controlling arm.

389
Sec. 6-201 RESISTORS
201. Speed regulators for series-wound motors. For series moto
the calculation of the exact resistance for a definite speed variation requir
a curve of the motor characteristics. Lacking this it will be found that I

controller designed as above for a shunt machine (Par. 196) will giv
approximately the same regulation for a series machine running under co.
stant-torque conditions.
THEATRE DIMMERS
202. Theatre dimmers are made of a number of platea mounted in
bank and each plate controlled by its own lever. A master lever is usual
arranged with cams so that it may control all or any number of the plat

yl = Master Lever
B" Individual Plate Lever
D=Bod
C Plate
Connecting Lever with Contact Asm
Fig. 54. — Bank of theatre dimmers.

at once. A typical bank is shown in Fig. 54. The circuit operated by oi;
plate seldom carries more than 50 amp. except in the case of the dimm^'
for the auditorium lights. The latter often carries 300 to 400 amp. '

203. For dimming carbon- filament lamps a resistance equal to abo

3.4 times that of the lamps in the circuit at full candle-power will dim suf
ciently so the lamps have no illuminating power. In order that the diim !

may be done smoothly and without flicker, 50 steps are required.

204. For dimming tungsten-filament lamps to a point whrri
filament is just visible in the dark, a resistance equal to 3.6 times the i

sistance of the lamp load at full candle power is required. This reduces t
current flowing to 25 per cent, of normal. To dim the lamp to blackness,
resistance equal to 4.0 times the resistance of the lamp load at full canc^
power is required, which will reduce the current to 18.7 per cent, of normi
In order that the lamps shall be dimmed smoothly and without flicker, t
dimmer must have at least 110 steps.
205. Free ventilation of theatre dimmers is essential, as the amou
of heat radiated by a complete equipment is often large.
206. Overloads caused by using too many lamps, or lamps of Isrg
candle-power than the dimmer is designed for, must be carefully avoided.

RESISTORS FOR MOTOR STARTERS

207. Motor-starting resistors should bo so proportioned that t
total resistance and the resistance per step admit sufficient current to sta
the motor, but not to exceed certain limits.
208. The normal current is that necessary to keep the motor armatu
turning over after it is once started, and is less than the current requir
to overcome the torque plus the friction of rest in starting from standsti
209. The starting current is equal to the normal current plus a curre
necessary to overcome the friction of rest at starting, overcome inerti
and produce the desired rate of acceleration. In general the starting c\
rent is assumed to be one and one-half times the normal current.

390
 RESISTORS Sec 5-210
The current flowing at the time the starting rheostat establishes the
rcuit, is limited not only by the resistance of the motor starter but also by
le resistance of the armature of the motor, the resistance of the line, the
iductance of the motor armature, etc. During the time the inductance of
le motor armature is dying down, the motor armature itself is speeding up
nd generating counter voltage, so that the resistance necessary in a motor
arter is in general 70 per cent, of that which would be necessary if this
!sistance were the only factor to be considered.
1 aiO. Eating of resistors for motor starters. The resistors of motor
' arters are in general rated as for light starting duty or for heavy starting
uty.
211. Light starting duty resistors must not exceed the temperature
363 of Par. 192, if used for starting up a motor once every four minutes for
1 hour, taking 15 seconds each time for starting, with an average current
125 per cent, of normal current.
212. Heavy starting duty resistors must not show a temperature rise
eater than that in Par. 192, if used for starting up a motor once every four
inutes for an hour, taking 30 seconds each time for starting, with an
>'erage current of 125 per cent, of normal current.
213. The resistive conductor is usually in the form of wire, ribbons, or
ist iron grids, and mounted in some substantial manner as next described.
214. Supports for resistive conductors are tubes of porcelain or
ibestos or other insulating material when the resistive conductor is wire or
bbon, and usually under these circumstances the resistor is enclosed in a
leet iron case. When cast-iron grids are used they are usually mounted
a separate case and connected by cables to the starter face plate.

BATTEBY-CHARQINa RHEOSTATS
216. The resistance of a battery-charging rheostat, for charging
orage batteries from a constant-potential source, may be determined aa
Uows: If E
is the e.m.f. of the charging circuit (volts), E„i„ the lowest
. na.f of the battery during charge (volts)
. Imin the lowest value of charging
,

irrent, then the total rheostat resistance will be R

pj RJ "'" •

R = ^ (ohms) (63)
t certain amount of this resistance must carry the maximum charging current
.naxi this amount is
•

R= ~ """
(ohms) (64)
fhebalance of the resistance will have a ciurent carry ing capacity varying
Som I max to Imin.
216. Lead-cell batteries normally have a voltage per cell of at least 2
ilts after charging is started, so that in calculating rheostats for lead cells
'iii» referred to in Par. 215 is equal to the number of cells multiplied by two.
. 217. Edison-cell batteries normally have a voltage of at least 1.40 volts
'r cell after charging is started, so that in calculating rheostats for Edison
ils Emin referred to in Par. 215 is equal to the number of cells multiplied
V two.
218. Carbon battery-charging rheostats have a resistance that varies
versely as the pressure and may be increased to any extent desirable by
osenmg the pressure on the carbon discs. For this reason the total amount
resistance necessary in the rheostat need not be considered in designing
:carbon rheostat.
MISCELLANEOUS RHEOSTATS
.219. Wire rheostats.Wire can be wound in coils, or stretched over
sulated frames. Wires larger than No. 6 A.W.G. are difficult to wind
spiral form and wires smaller than No. 21 A.W.G. must be wound upon
•1 insulating core. When it is desired to increase the current capacity of a
'il resistor beyond that of No. 6 wire, several
coils may be connected in
ultipie. The table in Par. 220 gives the mechanical dimensions of coils
laae of dmerent sized wires.

391
Sec. 5-220 RESISTORS

220. Table of Dimensions of Wire Coils for Rheostats

Size,
Max. Feet lurns
mandrel, per
A.W.G. inches tvirn

6-8 1.25 0.38

9-11 1.00 0.30
12-14 0.75 0.23
15-18 0.50 I
0.16
19-21 0.25 i
0.082
22-30 Must be wound on insulated core
 RESISTORS Sec. 5-227

it srfectlycontinuous, but unless there is a provision for short-circuiting the

e trodes outside the solution it is impossible to cut out the resistance
e:rely.
J7. Electrodes for liquid rheostats. The electrode material is not
ifortant so long as it is a
g 1 conductor and is not 1.0
a eked by the liquid. .

L d or carbon plates are a .8

ul with sulphuric acid, P
c jer with copper sul-^ 6
pte, and iron in most »'
;r cases. The current ^ ^
d sity should not exceed _g
•

1 np. per sq. in. o

28. The solution de-"-*-
pis upon the voltage and
un the quantity neces-
8 to radiate the heat.
'
1 234 5678
Strength o£ Solution^ (by Weight)
I,e water is seldom used
ft pressures under 1,000
For voltages below
Fig. 55. —Conductivity of solutions.
v,-3.
t, sulphuric acid, or some salt is added to the water to increase its conduo-
t,ty.
55 shows the relative conductivity of various solutions expressed in
ig.
iiies between the plates with a current density of 1 amp. per sq. in.
Cinary water gives a drop from 2,500 to 3,000 volts per in. gap at this
c/ent density.
i
RESISTOB UNITS
29. Resistor units are used wherever a resistor that is not varia-
b is desired. These units are made in many forms and types for the use of
tse who desire to purchase the units and assemble them in rheostats; for
iJ in the speed regulators of desk and ceiling fans; for testing purposes, etc.

-30. The resistance material is usually of German silver or some simi-

IJ material of low temperature coeflScient. This is usually wound on tubes
£ is then covered with
8 tement-like coating or
va a fused vitreous en-
^il.^ The tubes on which
t wire is wound consist of
f tery, asbestos paper,
1 I, etc. Pottery tubes
E used when the resist-
ive wire is to be hermeti-
c y sealed in a fused
> eous enamel.
31. Carbon resistance
lits are sometimes used
\^Te exceedingly high re-
eances with a very low
\tt dissipating capacity
t, desired.
32. The watt dissipat-
i •
capacity (I^R) of such
t ular units as are com-
1 a 1 1 y manufactured
r ci
e! listed, varies from 1 to
£' watts. The resistance
c/ihese units can be made
FlQ. 56. —Large resistance unit.

fliigh as 16,000 ohms on an enameled wire wound tube 4 in. long and
diameter.
}i.

33. Large resistor units are made of cases enclosing a number of

t tubular units described in Par. 230, or enclosing cast-iron grids, German
E er ribbon, etc. (See Fig. 56.)

393
Sec. 6-234 RESISTORS

234. The temperature rise of resistor units is as discussed in I

192.
236. Mountedresistor units are manufactured with various atta.
ments for readily mounting in special apparatus or for giving various c(.

57. — Mounted resistor units.

binations, etc. Units designed to replace resistance lamps in order tha

resistance may be secured that does not change with time, or on acco
of heat, are so made as to screw into a standard Edison socket. (See A, I
58.) Other units are made with ferrules on the ends, so they may be reac
inserted in the conventional type of fuse clips (See B, Fig. 58) still others ;

mounted in brackets (See C, Fig. 57); on porcelain bases See D, Fig. 57), i

236. BIBLIOGEAPHY
James, H. —
D. "Controllers for Electric Motors;" D. Van Nostn
Company, New York,
Ali.kn, a. H. — 1919.
"Compression Rheostats;" Jour, of the Engineering C
—
of Phila. (Philadelphia), April, 1918.
PopCKE, A. G. "Electric Controllers for Direct Current Imi
Motors;" American Machinist, Vol. XLVII, p. 151 (New York), 1917
Anon. —
'Standardization of llesistors;
' Electrician, Vol. LXXl
'

346 (London), 1917.

Rudolph, G. E. — "Data on Design Wire Rheostats;" Eleclr
of Iron
World, Vol. LXIX, p. 412 (New York).
K.\asoN, C. L.
—
"Construction of a Water Rheostat Capable of Cn-
700 Amperes;" Electrical World, Vol. LXVII, p. 1306 (New York), 1
—
Garrard, C. C. "Apparatus for Starting and Controlling EK
Running Machinery;" Electrician, Vol. LXXVI, pp. 772, 837, 873 (Loiki
Waller, A. E. — "Dimmers
1916.
Tungsten Lamps;" Trans. A.
for I. K.
Vol. XXXIV, 349 (New York), 1915.
Knioht, C. D. — "Principles and Systems
p.
Electric Motor Contrc
of
Vol. XXXIV, 2915 (New York). 1915.
Jaqoer, C. a. — "Generator Field Rheostat Control;" General
Tran.'<.A. E.
I. E., p.
!'
Vol. XV,
Moore, C. R. — "Generator Field Rheostats;"
Reviexv, 299 (Schenectady), 1912.
p.
Electrical Revi>
Vol. LX,
Ekern, E. a. — "The Water Rheostat as
Western Electrician, 672 (Chicago), 1912.
p.
Load Artificial for Elcctr
Installations;" Stone & Webster Pub. Vol. IX, 312
Ser. Jour., p. (>

Hallock, F. D. — "Notes on Rheostat Design;"

York), 1911.
Journal, Electric Vol.
p. 105 (Pittsburgh), 1907.
Ki.nzbrunner, C. — "The Testing Continuous Current Machines;"
of Ji
Wiley & Sons (New York), 1905.
Krause, R. — "Starters and Regulators;" Translated by Kinzbrunnci
West, Harper & Brothers (London), 1904.

394
i

ri
SECTION 6

TRANSFORMERS AND RECTIFIERS

BY CHARLES LE G. FORTESCUE
inter. Transformer Div., Westinghouse Electric and Manufacturing Co.
Member, Amer. Inst, of Elec. Eng.
I CONTENTS i
{Numbers refer to Paragraphs)

TRANSFOBMEBS
I -oduction
( leral
C'leral
Theory
Design
L ign of Insulation
1
14
27
35
Multiple Operation
Polyphase Transformations
Constant-current Transformers
Auto-transformers
127
132
170
180
i
Systems
C iling 54 Instrument Transforhiers 189
J?hanical Design and Coil Transformers for Miscellaneous
rouping 78 Uses 200
1 nsformers for Power Service 85 Transformer Testing 212
i nsformers for Distribution Installation, Care and Operation 229
vstems 115
BEGULATORS
I ential Regulators 245 Current Regulators 256

BEACTOBS, 260
BECTIFIEBS
^ lor type Rectifiers 274 Mechanical Rectifiers 294
I I'trolytic Rectifiers 287

BIBLIOGBAPHY, 301

395
 SECTION 6

TRANSFORMERS
INTEODTTCTION
1. A transformer a device for transferring energy in an alternati*-
is
current system from one circuit to another. It consists essentially of >
independent electric circuits linked with a common magnetic circ.
Thus energy at low voltage may be transformed to energy at high voltage r
vice versa. In like manner, current of a given value in one circuit maji
transformed into current of another value in a different circuit, i

winding of the transformer connected to the supply circuit is referred tu

the primary windiriE^, and those windings of the transformer that j

connected to the receiver circuits are referred to as secondary windings.

_
2. If a transformer with open secondary winding has its primr
circuit connected across alternating-current supply mains, only a si 1

current will flow through the primary. This current is alternating and ]-
duces an alternating magnetic flux in the iron core of the transfon
which interlinks both the primary and the secondary windings and byj
rate of change induces an e.m.f. in each. If the two windings are clo /
associated with each other, the e.m.f. induced in each will be proportiii

^ winding
or
numbers of turns. The e.m.f. induced in the priir/
to their respective
is known as the counter e.m.f. of self-induction of the prim
back e.m.f., and is equal in magnitude to the e.m.f. of the mains i
the IR drop due to the current passing through the winding. Th
fore, if the pernleability of the magnetic circuit of the transformer is li
,

and the resistance of the primary winding is low, the counter e.m.f. 1

be very nearly equal in magnitude to the e.m.f. of the supply circuit, I

it follows also that the secondary induced e.m.f. will be nearly equal to j

e.m.f. of the supply circuit multiplied by the ratio of the number of turn !

the secondary winding to that of the primary winding.

S. If the secondary circuit is completed through an impedanci c
load, current will flow through the secondary and the load; this will teni)
demagnetize the core, so that the effective impedance of the primary wind
is at once lowered and more current flows into it. The extra current. '^ '

just sufficient to overcome the demagnetizing effect of the current '.'

m the secondary winding, will have the same time-phase as the sci
current and the ratio of the magnitudes of the two currents will be cii,.. .

the reciprocal of the ratio of the numbers of turns in the respective windi .

4. The secondary current causes a drop in e.m.f. In the seoondr

winding, partly due to the resistance of tlie winding and partly duD?
magnetic leakage caused by the fact that all of the flux which interlinks*'
primary turns does not interlink all the secondary turns.
5. The primary current likewise produces a drop of e.m.f. in )
primary winding, due to the resistance of the primary winding and to ;
fact that there u portion of the magnetic flux which interlinks som'
i.<*

the primary winding without interlinking any of the secondary windii

6. The induced e.m.f. will therefore be proportional to the e.m.f
supply circuit, less the drop in the primary winding; and the sd
terminal e.m.f. will be equal to the secondary induced e.m.f. less the d
the secondary winding, the drops being taken in their proper phase n!
The total drop from supply e.m.f. to secondary terminal e.m.f. is usuall.\
email in power transformers, so that the product of the secondary cur t

and terminal e.m.f., measured in kilovolt-amperes, differs from that of »

primary by 2 or 4 per cent., only, at full load, while the ratio of the oui'

39U
 TRANSFORMERS ScC. 6-7

to e input, or commercial efficiency, may be as high as 99 per cent, at full

lo.

The ratio of transformation is the ratio of primary voltage to

Be ndary voltage, or very approximately the ratio of primary turns to
BC' idary turns; it is also approximately the same as the ratio of the second-
ar urrent to the primary current.
Constant-potential transformers, or transformers having nearly
CO :ant ratio at all loads, are most generally used for transmission and dis-
tri tion of power; they are then designated power transformers (Par. 86).
W n used for the purpose of raising the voltage they are referred to as Step-
and when used for lowering the voltage
Ul ransformers, are referred to as
Bt-down transformers. If it is desired to call attention to the windings of
ai nsformer without considering their relation to the supply circuit they are
te ed the high-voltage winding and the low-voltage winding.
Constant-current transformers are those in which the current in
th econdary or receiver circuit is automatically maintained constant when
tb primary is connected to a constant-potential source of supply. The
m lal inductance varies with the load.
Instrument transformers are those employed to connect measuring
.

in uments or relays with power mains, the primary being connected to the
m 13 and the secondary connected directly to the instrument. When their
fu tion is to transform from the voltage of the supply circuit to a voltage
BL'i.ble for operating instruments or relays they are termed shunt-type or
ptmtial transformers. When their function is to transform the curreiit
in e supply circuit to a suitable value in the secondary or instrument circxiit
tb are termed series-type or current transformers.
I. Auto-transformers are those in which the primary and secondary
ci;its are electrically connected so that part of the load in the receiver
cii.itis supplied directly from the supply circuit through the primary
w? ing, the remainder being supplied indirectly through the secondary
w* ing by electromagnetic induction.
'
. Transformers may be conveniently classified as follows:
) Power transformers for the transmission and distribution of rela»
tiy large quantities of energy.
;) Instrument transformers for use with measuring instruments and
rers.
_^i Auto-transformers for general power purposes, balancing electric
ci.iits, etc.
') Constant-current transformers and regulators, used for street
lif ing.
; I Voltage regulators, used for regulating the voltage of alternating
elrric circuits.

All these different classes of transformers have the same

.

" ineral Theory," which will first of all be discussed: certain considera-
in design common to all will next be taken up; and finally the character-
ti s
b pecuUar to each class will be presented in the order given, together with
.s

ccmercial data.
I
GENERAL THEORY
;:. The magnitude and direction of the induced e.m.f. in a circuit
a^iriven in the two laws known as Neumann's Law and Lenz's Law
(^.2). If these laws are applied to the case of the transformer on open
the following relations are obtained.
ci lit

d 1
/Zito-|-—-(Zviio) =«! I
''
(')
a
— (Mio)=e2 J

're (Lito) and are the numbers of interlinkages of tubes of induction

(Afio)
w the primary and secondary windings respectively, to is the primary
Oil-circuit or exciting current, K\ is the resistance of the primary winding,
fi, the e.m.f. impressed on the primary winding, and et is the e.m.f. induced
>nie secondary winding.
'• Practical formulae for transformers. If it is assumed that
a^he turns of the primary and the secondary winding completely encircle

397
 Sec. 6-16 TRANSFORMERS
a magnetic circuit of uniform cross-section and infinite permeability, i
that d, the instantaneous value of the e.m.f. impressed on the primarii
a simple harmonic time-function of the form
eis.lO'XV'SJ&i cos ut
where Ei is the root-mean-square or effective value of the impressed
and 01 is equal to 27r/ where f,is the frequency of the alternatiii>;
to becomes zero, and the resulting solution of these equations will giv

(Lxio) "niAiB sin ut

(Afio) =nj^ijB sin ut
El ^ Ex
ni
where m, m are the number of turns in the primary and secondary winri»i
respectively, Et is the effective value of the secondary voltage, ^i is the c j.
sectional area of the magnetic circuit and B the maximum instantanu
value of the induction in C.G.S. lines per unit area. The relations bet\|
El and B are given by

o„ " y/2ExX\Q* = -^-.-.~.

wniAi
.
£iX10»— — .
, ,.
(c.g.s. lines per unit area)/
.,

l)

wniAiB
El- 4.44 (volts)
V'2X10«
These are the equations used to determine the value of the open-ciH
secondary voltage and the induction in power transformers. Even iiit
reluctance of the magnetic circuit be taken into account the value of it

not materially altered, and since exigencies of manufacture may cause h «

errors in this quantity than that due to the assumption of infinite perme I-

ity, greater refinement is useless. The error in the value of £i due toil

^ assumption is not of consequence in most commercial transformers.

16. The primary open-circuit characteristics of power transfom
may be obtained with sufficient accuracy by means of a curve givi
loss per unit mass
and another giving the
tions (Sec. 4),
of iron at different
e>
.

volt amperes per unit mass at li

 TRANSFORMERS Sec. 6-18

n fave. but has harmonic

components. This is due to the variable per-
,eility of iron at different
inductions and to its retentiveness. The
;u of the wave
distortion due to iron
etic circuits assumes importance
in ^'
ia
18 iment transformers on account of
le jssibleintroduction of error thereby.
l)wledge of the properties of different
ir, of transformer steels is therefore
jstial to the design of instrument
ra' formers (Sec. 4).
: The secondary open-circuit
Referring to Eqs. 1, Liio and
oi;e.
f re variables of time, but Li and
i
M
he d also be considered as
variables de-
ei ng on the instantaneous value of the
K tion. Then assuming unity ratio of
iriiry and .secondary turns,
e2=-ei+fiiio+^ {(Li-ilf)ij (5)
at
 Sec. 6-20 TRANSFORMERS
20. The short-circuit characteristics of a transformer are obt
ai
from those of the loaded transformer by making Ro and La equal to «
It is usual to consider the quantity uM
in the resulting equation i,^
finite in which case the short-circuited transformer may be treated
*
simple impedance so that the effective reactance of a transformer of a
ratio when short-circuited is the sum of ui{Li — M) and u(Li — M).
J'J
over under load conditions the effective transformer impedance differs
«
the short-circuit value only on account of the influence of the normal iiM
tion on the permeabiHty of the core, and since the effect of uM
may be igiil
in the short-circuit reactance, the effect due the difference of uM \.
short circuit and when there is normal induction in the iron being ol
smaller order of magnitude may also be ignored. The quantities \.
in transformers under load are the equivalents of the short-circuit cc'
loss and impedance have been measured with varying inductions in the
and have been invariably found to be practically constant.
21. The current in the secondary winding of a transformer supp
a load may be obtained by means of the simple alternating-current ei
shown in Fig. 4. But since the admittance Y is not readily expreasib
is inconvenient to use this circuit. Moreover the quantity (Li — M) cb
be evaluated very exactly and therefore more or less error is introduced '

it is used. The following formula derived mathematically from I

and 7 with the assumption made in the preceding paragraph has the s(
tage of great simplicity

where Rb and Lt are the effective resistance and effective inductance

load current is circulated in the secondary with the primary short-cirot

22. With sine-wave secondary open-circuit voltages Eq. i

comes that of a simple reactive circuit having resistance equal to the
of the load resistance and the secondary effective short-circuit resist

^ and having reactance equal to the sum of the load reactance and the ai
dary short-circuit reactance. The secondary current may then be n
plied by the ratio of transformation to obtain the primary load our
and from this the primary current is obtained hy adding the equiv
sine-wave exciting current in proper phase relation. Eq. 9 under
circumstances may be represented symbolically as follows:
f2= I (ro + r.) +j(xo+^,) ]I2 I

where E2 and I2 are both vectors. The vector diagram and current lot

all loads are given in Fig. 6.

23. The construction may be explained as follows: OA V
of Tig. 6
or the primary impressed e.m.f., reversed in time phase. OB = E\fi^
secondary open-circuit e.m.f. The radius of the heavy-line circle wi
as centre represents the secondary short-circuit impeclance of the t
former, drawn to the same scale as OB. To obtain the loci of the seoOB
terminal e.m.f. for any load, bisect OB, at Ci and draw the lineiC;
C> at right angles. The locus of all loads having a given power-faotoj
circle passing through B with its centre at some point on the line C]
C>. The unity-power-factor centre Ci, is obtained by making Ci, C«
to CiB multiplied by the ratio of the secondary short-circuit reeistalu
the secondary short-circuit reactance; the centres Cs, Ct, Ci, etc., f or loi
other power-factor are obtained by making cos at, cos a4, etc., equal totl
spective power-factors, making the angle Lag behind or lead the phase <at
according as the power-factor is lagging or leading. The loci are the!
tained by describing circles passing through B with these centres. Th<
for different load currents are concentric circles having B as centred
radii proportional to the respective short-circuit impedance drops at 1

loads. Thus the secondary terminal e.m.f. with full-load secondary oa

and 90 per cent, leading power-factor is represented in time-phase ai4l
nitude by the vector drawn from O to the point C where the 90 ptt]
leading-power-factor circle intersects the full-load impedance-drop cirdfei
obtain the loci of the current vectors, describe with centre O a <aW
radius to represent the effective full-load secondary current on any rail
scale; with the same centre draw another circle of radius equal to thatdl

400
 TRANSFORMERS Sec. 6-24

re- liemultiplied by the ratio of one-half the secondary open-circuit voltage

} secondary short-circuit impedance volts at full-load current. Take
Biual in time-phase and magnitude to the secondary open-circuit voltage,
ra-9«2 at right angles to OB and make the angle eiOei such that its cosine is

ni; to
r I
short-circuit reactance
. —
:
,

short-circuit impedance
i
draw also v
alinei
i- i x ^i.
eteia tangential to the
;
.

II drcle at the point ei; this line is the locus of the

centres of the circles
g through O, which are the loci of the secondary load currents for
nt power-factors, ez
centre for the circle "^Vv
a^ig through which is
iescus for the currents
)r loads of unity-power-
ic the other centres
;

re und in the same way

i r the secondary vclt-
ge3ci. The loci for dif-
irt, values of secondary
>a urrent are circles with
I
» centre and radii pro-
01 mal to the effective
ftls of the load currents.
'h vector for any given
al of load current and
OT-f actor of load is
\a fore the line drawn
:o to the point of in-
sr'ition of the load-cur-
;r circle and the power-
icr circle. The approxi-
l& primary current is
lie obtained by combin-
ijj his vector with the
ei r OE representing the
p< circuit exciting cur-

The short-circuit
er-lo88 with full-load
u nt circulated in the
B( dary winding is not
hirue copper-loss, but a
Drction must be made on
cunt of the I^R loss
a d by the exciting cur-
M Part of this extra
>es practically constant Fig. 6. —
Vector diagram showing voltage and
t loads and is included current relations in a transformer at all loads.
1 le core-loss measure-
Ms; the other part varies with the load. If be the angle corresponding
Oue secondary power-factor, a the angle of hysteretic lead, Jo and Iz the
fi:ive values of the exciting current and the component of the primary
tt'nt corresponding to the secondary current, respectively, then the cor-
eion to be added is
Correction = 27o/3i2i sin (fl-h a) (watts) (11)
nibstituting values of Ri the effective primary resistance should be used.
i"Icorrect value of induced e.m.f. at which to take the core-loss is the voltage
«i3 the admittance Y, Fig. 4, and it can be found in the usual way by
^< 10 after {Li — M) has been obtained. But it is not usual or necessary
B actice to go to such refinements. The core-loss measured at the rated
'cige plus the secondary IR drop is sufficiently close for practical work.
The efficiency may now be obtained by the usual formula
.

„_ . Output
Output
Efficiency = ^—^—, =7t
,,-.
(12)
Output -f- lossesInput
Hi. The regulation may be defined as the difference between the full-load
ijthe Bo-load secondary voltage of the transformer, for the same primary
26
401
 Sec. 6-27 TRANSFORMERS
voltage, expressed as a percentage of the full-load secondary voltage,
is also the rated voltage. If IR/E and JX/E are respectively the effei
short-circuit ohmic and the reactance drops expressed as fractions
rated voltage, then
(-g-cose- ^« •
.y
sin B)
IR IX E
Regulation '-I-
'
E
GENERAL DESIGN
37. The desigrn of successful commercial transformers require be
selection of a simple form of structure, so that the coils may be easy tn 4
and the magnetic circuit easy to build. At the same time the meai^
of the windings and of the magnetic circuit must be as short as
for a given cross-sectional area, so that the amount of material :

and the losses shall be as low as possible. The form of constructii i

permit of the easy removal of heat by means of ventilating ducts, it

admit of being insulated in a simple and economical manner, and tl
ings should be of such forms as may be easily reinforced to wr
mechanical stresses.
28. Two types of transformers are in comzQon use. Wbenti
netic circuit takes the form of a single ring encircled by two or more groL
primary and secondary windings!
tributed around the periphery ol
termed a S
ring, the transformer is
type transformer. When the pri j
and secondary windings take the]
of a common ring which is enc"
by two or more rings of magnetic!
terial distributed around its periM
the transformer istermed a shell t

^ Fig.
Blmple R«jt»Dgul»r
BheU-Tjpe

7.
of
— Forms magnetic
of
transformers.
Blmple ReotongiOai

Core-Ijp.

circuits
'P^^'^
transformer.
29.
the core-tjrpe transformer ar
length of magnetic cinu
short mean length of winainjs-.
The characteristic tea.tv.< '•>

—
of the shell-type are short mean length of magnetic circuit and long .

length of windings. The result of these features is that for a givemoi

and performance the core-type will have a smaller area of core and I
number of turns than the corresponding shell-type. As a general nil
core-type construction is more economical for small high-voltage t
formers than the shell-type construction, the dividing line for sixe
dependent on the voltage. In the matter of relative weights of iroi
copper, the two types tend to merge into each other if steps are tdc<
alter the construction so that their features are more nearly alike. I
and Fig. 8 illustrate the forms of magnetic circuits that have been I
to result in the most economical and satisfactory designs.
30. Electrical desigrn.
The fundamental formulae in
the electrical design of a trans-
former are those given under
"General Theory," Par. 16,
Eq. 4. If a certain current-
density and induction be as-
sumed, the allowable thickness
of the coils for the proper cool-
ing may be predetermined.
The electrical stressbetween
layers and between adjacent
coils may
also be predicted '\
with sufficient accuracy to spec-
ify the amount of insulation
that it will be necessary to use
in each case.
The area occupied by Fio
31. 8. — Shell-type distributed
a primary or a secondary circuit.
 TRANSFORMERS ScC. 6-32

o .uctor, including the duct space and the insulation clearances necessary
.sure proper cooling and insulation respectively, and the proper me-
h-.cal allowances may be accurately calculated. Denote these two areas
ly and a2 respectively and the corresponding net area of the conductors
ly and -72. Then if P be the out-put of the transformer in watts and
1

find W2 the I-R loss per lb in the primary and secondary windings
4 ted output and temperature 6 centigrade
P O.OOuVl +0.004289 ,, ^
71 = ^ 7== (1*)

Irfyj be found by substituting E2 for Ei and Wi for Wi.

may If A\ and
ii? the gro.ss areas of the magnetic circuit and the windings respectively
tfiif So and Sb be the corresponding space factors the following
relations
w] btained _
m A
A 1/12
/1
= V2(giai+E8a2)X10« (15)
wm .' jy Q,

R s, =
p^±f^' (16)

icire the both windings is the same Wb the mean I^R loss
mean length of
i€b. will be VWiWi. If h and h are the mean lengths of one turn of each
iri ing to be determined when the dimensions are
known
„, EiyihWi+En^hWi ,,».
£171^1+ £272^2
is in general advantageous to have Wi = W2'=Wb. Denote the ratio
i4i,l2 by X
and let the ratio of the dimensions of the cross-section of the
iri ing space and magnetic circuit be Y and Z respectively. The area and
liinsions of the magnetic circuit and winding space will then be

*
Ai = /——') \ Dimensions = (^\ by (ZAi)^ (18)

A2 = (XA1A2) 4, Dimensions = (y\ by (FAj)* (19)

le volume of iron and copper for any type of transformer may be

ot ined from the formulae

Volume of ivon = SaUiAi)^ fi {

^
X,Y,Z, ^1 }
(20)
(AiAj)
^'
Volume of copper = S6(AiA2)* /2 { X,Y,Z, .
}
(21)
UiAt)*
w) e t'l and C2 are determined from the insulation constants and /i and /j
de-te that the quantities preceding it are to be multiplied by a function
of 16 quantities in the bracket. The
quantities in the brackets are not
di nsional quantities and therefore /i and h
will be independent of the size
of le transformer but will vary with different forms. If conditions for
m.mum are introduced, Y and Z become definite functions of
cost and lo.ss
th :emaining variables so that the functions /i and fi may be plotted in
se,o f curves having X as the independent variable and C\l "•J A\Ai and
CiJ A\At as parameters.
The relations between the output of a transformer and Its
.

diensions, weight, and cost of copper and iron, derived from the above
fo ulas, assuming no change in the space factors, densities and proportions,
w provided that the insulation clearances between windings are very small,
ar ipproximately as follows:
Area of core varies as P\
-Area of winding space Pi
Weight
Cost (22)
Per cent, loss
Volts per turn pi
403
 Sec. 6-33 TRANSFORMERS
33. Core material. Silicon steel is used almost entirely for pn
and distributing transformers. For the first class of transformers ckg
on account of its non-ageing characteristics. For the second class on ace
of its extrernely low hysteresis and eddy current loss. A great deal o
vestigation is being carried on by various manufacturers witlr a vie:
producing steels having characteristics suitable for different classes of »
A complete discussion of various classes of sheet steel for electrioa!
paratus will be found in Sec. 4. ,

34. Insulation, cooling and mechanical stresses. These f^

will have a large influence on the form and dimensions of large power ti
formers and are taken up in detail under separate headings below.
DESIGN OF INSULATION '

36. High insulation strength is one of the most important requiren

of a well-designed transformer. However, provided that the p»
strength is obtained at every point, the less insulating material need
better, because the insulating material is the chief factor limiting the]
peraturo at which it is permissible to operate and it is also the main fi:
in producing the rise of temperature of the windings.
36. The electric stresses to which a transformer is subjecte s
service may be transient in nature, or they may be steady. BeLi:
the former class are surges set up by switching, breaking down of lin'
ors, arcing grounds, and short-circuits. Steady electric stresses ai'
by such accidents as the grounding of one line of a transmissioi!
and will be preceded by a surge or transient wave due to the
> the electric field brought about by the new condition of stre.'->
high electric stress to ground, in a transformer, may be preceded by 4
< i

stresses between coils and turns of the high-potential parts of the i

ings. A breakdown between turns in a high-voltage transformer may t
fore be due to a combination of the two forms of stress. Another foi
stress that may cause breakdown of the low-tension winding is like!

^ occur when the electrostatic capacity between the high-tension andj

tension windings is high in comparison with that of the low-tonsion ]
ing to ground, in which case a dissymmetry of the high-teusion c;
such as that due to a ground on one line may cause a potential elevtti
the low-tension winding sufficient to break down the insulation, or to
loss of life.

37. The transient stresses are difficult to estimate with any d

of certainty and the designer usually has to satisfy himself with n
obtained by experience with transformers in service. !

38. The steady stresses may be easily calculated, and the usual pr^
is to design the insulation so that it will withstand a difference of pott
between the low-tension and high-tension windings and between cut
high-tension winding, ranging from two to two and one-half times the pO|
steady stress under service conditions.
39. The insulation between adjacent coils and adjacent Utt\
the transformer must be capable of withstanding with an ample n
of safety the normal and transient stresses that occur. It is custom^
large transformers to give an overpotential test of double voltage, Br,
for the purpose of making sure that there are no weak spots in Hi',
insulation.
40. Effect of polarity of windings. Polarity in a transformer d^
upon the relative direction of the induced electromotive forces in the pr|
and secondary windings con.sidered with respect to the two adjacent^
the two windings. * In a single-pha.se transformer under normal conoj
of service, the middle points of both primary and secondary windingf ^
ground potential; but the maximum difference between adjacent primtw
secondary coils may be half the sum of the primary and secondary vm
or half their differences according to the polarity. This factor becon
extreme importance in the design of transformer for interlinking two
voltage systems.

• A full discussion of this question will be found in an article by '

escue. Electric Journal, 1907, and also one by Wm.

McConahev,
Journal, 1910.

404
 TRANSFORMERS ScC. 6-41

I Methods of insulating. The methods employed in insulating a

itJrmer will depend largely upon the type, upon the
high-tension
te and upon the method of cooling, employed.
Small transformers
crate on 2,200-volt circuits are usually insulated between the high-
loi and 'low-tension windings with a cylindrical barrier of mica and
Tif material about ^
in. thick. The usual way of applying this barrier
t( rap it over one winding;
the second winding is then wound on top of
ne company uses a tube of mica with a pure shellac bond which has
Biaoulded from a circular cyhnder under heat to the proper form with
lif to insulate the high-tension and low-tension windings from each
it The adjacent ends of the two windings are insulated from each other
ans of collars or spacing pieces and heavy paper corner pieces. The
m^te coil may be vacuum dried and impregnated with a compound in-
lu> in oil, before the iron is built in, or the iron may be built in
first

d whole transformer impregnated.

le

1! Insulation between turns and layers. In small transformers

ich round wire is used, and where the volts per turn are small,
d:ie windings are not subjected to high stresses, the cotton cover-
% sufficient for insulation between turns, and with proper subdi-
ii< of the coils only a little additional insulation
need be used between
re In larger transformers where round wires are used, the layers must
bvily insulated. In high-voltage transformers the line coils are sorne-
n( wound with cord between adjacent turns to secure high insulation
et.h. In large transformers where the conductors are copper straps,
B-'ils are wound spirally with the conductor flat, and the conductor is
h. heavily sleeved with cambric or cloth, or, according to the practice of
eimpany, the adjacent turns are insulated from each other by micanite
i
if The turns of the coils next to the line are always heavily rein-
re; In wire-wound coils the voltage per layer rarely exceeds 150 volts
t inner coils and is much less than this in the coils nearest the line.

4; Coil insulation. In order to reduce the stress and thereby obtain

areffective insulation, the windings are subdivided into coils.
J£ at coils may be insulated Jrom each other by taping,
is
The
or by insulating
and edge strips or angle pieces. For insulating the coils of small
ir irmers and air-blast transformers the former method is used by some
i
U icturers, the coils first being impregnated with an oil-proof gum. For
ju ing the coils of large oil-insulated transformers the oil spaces between
ic md one or more J-in. fuller-board washers are depended on.
4<The insulation between the high-voltage and low-voltage
inngs in large transformers of the shell-type is constructed of sheets of
lit! )oaid about i in. thick and angle pieces of the same material. The
B^of fuller board and the angle pieces are arranged in the form of a box-
it rrounding each group of high-tension or low-tension coils; all joints
B pped and in high-voltage transformers the corners of the coils are
sued by specially formed angle pieces so that when the insulation of
g:ip of coils is completed, it forms a boxing around the group which
mtely isolates it from the adjacent group.
4« Heavy cylindrical tubes of paper are used between the high-
lit' and the low-voltage windings in large core-type transformers,
leimpany uses a paper tube rolled with shellac as a bond; another com-
.nuses fibre or fuller-board tubes. Small high-voltage core-typo
M'ormers may have their high-voltage winding wound directly on one
the tubes; this furnishes a cheap and eSective method of manufacture.
4) The insulating value of the oil, in oil-insulated transforn^ers,
d.ended on very largely to help insulate the transformer; this is done
' i'^rspersing the oil and the fuller-board in all the barriers. At the ends
t high-tension coils the insulation is effected mainly by oil spaces rein-
re with corner pieces of fibrous material.

4' In air-blast transformers the same general method of construc-

3n used, but in addition the coils are heavily taped and treated with
»t')roof compounds. In air-blast transformers the insulation clear-
tctare very much
larger than in oil-insulated transformers, particularly
t? ends of the coils where distance insulation must be used to a great
te

405
 Sec. 6-48 TRANSFORMERS
48. Outlet terminals. The outlet terminals in general use axe
'
Iji

condenser terminal (Par. 49) and the oil-filled terminal (Par. 60).
49. The condenser-type terminal consists (Fig. 9) of alternate cy'-
ders of thin tin-foil and shellac-treated paper, rolled hot on a central bi
j
rod of the proper diameter: they are so arranged that the capacities -
tween adjacent tin-foil cylinders are the same throughout, and the tin-
cylinders differ in length by equal steps. The potential stress is distribul
evenly over the whole length of the ternii .

The addition of a disc at the top of the term 1

and an external cylinder of insulating mate!

extending between the flange and the disc, a
space between the condensers and the cylirj
being filled with gum, complete the outlet It).
60. The oil-insulated terminal (Fig.j
depends upon oil as an insulator and a'l
means for insuring equal distribution of hea-
the terminal. It consists of segments of po-
lain or moulded material cemented togetbe')
form an enclosure for the oil; a conducting i
extends from top to bottom of this enclos'.
The oil space is subdivided by insulating !-
inders to prevent lining up of particles in )
oil.

61. In transformers for hiffh-Tolt i

transmission the coils adjacent to the line •

minals are more heavily insulated from one -

other than the rest of the coils. In large trs-

f ormers the normal stress between adjacent c»
is seldom permitted to exceed 15,000 volts, i
the size of a transformer is increased, keepings

> current density and the coil thickness thcsii)

the voltage per coil will vary inversely as i
fourth power of the output. Since the thickH
of the coils and the spacing between them »
usually determined by the cooling requireme,
a large transformer ia more easilyinsulatedti
a small one.
62. Groundingof the neutral point.'.
considerable saving in cost of insulation i'
be obtained if transformers are desiprn^'! •

operation with the neutral point of tl

circuit grounded. The insulation stn
Oil-filled Condenser which a transformer may be subjected in
TeVmin"^ type"terminal "^ thereby greatly reduced and the d;u
V n cii J breakdown of low-tension insulation diii
J
9.— r\-i
Oil-faUed andJ effect described in the latter part of 1
condenser-type terminals, ig entirely eliminated, in polyphase ti
mations.
63. The effect of insulation on cooling. The fabrics which .u
fof insulating the conductors deteriorate when subjected to hi(jh tempi
This is true also of cooling fluids such as oil. The temperature at n'-

is permissible to operate is therefore limited by these factors. Thes( :

tions are particularly emphasized in small transformers and those of t

blast type where the heat must pass through thick barriers.

COOLINa SYSTEMS
64. Methods of removing heat. The losses in a transformer np;
heat in the windings and the core. Meansmust therefore be provil
removing it: otherwise high temperature will result, which will desti
fibrous materials used for insulating the various parts of the trausU.
Methods of removing heat may be classified as follows:
(a) By natural convection of air and radiation. This metho<t
employed in certain special cases for small distributing transformers \t\ •

406
 TRANSFORMERS SeC. 6-55

15 .--a. It is the method generally used for cooling instrument and emal
iw hboard transformers. ,.,,.. _ ., , .

By forced convection of air. Transformers in which this methoa

s ;d are commonly called air-blast
transformers. They may be built
in' ratings as large as required and
voltages not exceeding 35,000 volts.
By natural convection and radiation with two fluids. Oil-
•
.1 air-cooled transformers are cooled in this manner. This method
ipplied to transformers for all voltages and for ratings up to 8,000

By a combination of natural convection of a fluid medium

forced convection of cooling air. This method has not been used
iri> _

n country to any great e.\tent, but is in great favor in Europe.

is
By natural convection of an insulating fluid which is cooled
iricially by another fluid. This method is used in oil-insulated water-
!b;d transformers.
By forced convection of an insulating fluid which may be cooled
nay convenient way. This method has been employed to cool large
ji formers by forcing the cooled fluid through the windings.
oil circulation with the oil cooled by air-blast may be
i
employed
- If-contained unit.
. Conduction outward to the surface exposed to the coolinf
n ium step in the removal of heat from the winding of a trans-
is the first
o; er. will partly be through copper and partly through
This conduction
D! ation. The flow of heat between parallel faces of any material for a
licence of temperature of 1 deg. cent, may be given in watts per sq.
n' nd in this work it is convenient to expre.ss it in this form. The tena-
}e ture gradient at any point of the coil will therefore be opposite in
ii: tion and proportional to the maximum value of the heat flux (expressed

n itt.-i per sq. in.) at that point.

. The maximum temperature rise through a coil at any point
d le the line integral of the temperature gradient in the direction of the
If fiow to that point.
rise through a coil at any point of its
The average temperature
the weighted average temperature rise of all the portions of the
-.

irs contributing to the heat flow at that point.

. Cooling by convection is the next step in the removal of heat
!o ucted to the surface of the coil. Convection currents are caused by
:h ipward motion of the heated fluid, thereby permitting unheated fluid
Therefore, it is essential in order to obtain efficient cooling
<i)lace it.
A surface, that the windings be so constructed that they present
r coil
le cal surfaces, forming paths free from obstructions to the flow of these
lection currents. After the heated fluid has risen to the surface it must
iioled, and in order that this may be done efficiently its temperature must
) high as compatible with the limiting value set for the maximum tem-
;iure of the transformer. The winding must therefore be so constructed
_

no part of the fluid flowing past a surface shall be far removed from it;
lermore, the difference in velocity between the fluid in intimate contact
the surfaces of the winding and that furthest removed must be kept as
I

1 as possible.

The structural requirements are

fulfilled by arranging the wind-
that the exposed surfaces are concentric cylinders with vertical axes
iSO
vertical planes.
ferallel The thickness of the coils is determined by the
S^jnt-density in the copper and the permissible maximum temperature-
tii through the coil.

The physical characteristics requisite in a cooling fluid in order

._

lb it shall be an efficient cooling agent for transformers are:

) It must be a good insulator.
It must have good thermal conductivity.
)

It must have high specific heat.

It must have a high coefficient of expansion.
Its viscosity must be as low as possible.
It must be capable of withstanding the operating temperatures without
;

cr onizing or producing gummy deposits on the coil surfaces.

It must be stable, difficult to ignite, and free from acids or any other
)

luedient that will attack fibrous materials, iron, copper, or varnishes.

407
Sec. 6-61 TRANSFORMERS
The reason for most of these requirements are obvious, but (b), (c), (d) ic
(e) some explanation, which is given in the next paragraph.
require
61.Explanation of heat transfers in coolingr fluid. Consider v^
adjacent surfaces of a winding taking the form of two parallel planes a sJi
distance apart, and assume that all the heat is emitted in a direction no a
to the planes. The fluid directly in contact with the surface will fi:
•

come heated and expand, thereby tx

lighter and rising. It thus .i:
will
point ofits passage assume a teiiiijirart
which will increase progressively along le
vertical. At the lowest point of the h
the oil nearest the surface will perforn.ll
I the cooling, but as it rises the tempera r«
gradient through the fluid normal to k
surface will increase, thus permitting ic
conduction of heat to the fluid fur^'i
removed from the surface. The temperare
gradient through the oil at the top of le
coils will therefore depend upon the velc y
of the fluid and its distance from the surle.
The more nearly uniform the velocitii
the fluid at each point, the less will be le
temperature gradient. The velocity oiie
at each point depends among osr
fluid
things upon the viscosity of the fluid b g
more uniform the lower the viscosity. 1 h
specific heat is important because it perm a
given amount of heat to be removed !t
unit time at lower velocity and lower tcm r-
ature rise along the surface. High theiil
conductivity is necessary so that heat jy
Fig. 10. — Oil-insulated self- be transmitted through the fluid norraui
cooled transformer. the surface with a small temperature gradit.
It should be noted that where the fluid a
gas, a certain amount of work is absorbed during expansion, so that*
specific heat at constant pressure should be used.
62. The temperature difference between the
fluid at the top of the coil and that at the bot-
tom is a measure of the force required to circulate
the fluid. Part of this force is used up in overcoming
the friction offered by the surfaces and the viscosity
of the fluid.
63. In transformers cooled by free convec-
tion in air the remainder of this force is that
necessary to bring the velocity of the air up to the
required value to effectively remove the losses. In
oil-insulated self-cooled types (Fig. 10), where
the transformer is immersed in a liquid which circu-*-
lates by free convection, cooling the surfaces of the
"*"
windings and being cooled in turn at the surface of
the container by convection of the air, the hydraulic
force or head developed in the windings due to the
difference in temperature has to overcome not only
the resistance to flow within the windings them-
selves, but also that external to the windings due to
the sides of the case. In addition to this there is a
back pressure or counter-head which represents the
force required to overcome the friction resistance of
the external surface of the case to the convection
currents of air and that required to set them in
motion. Pjo ii._Air-blas
64. In the air-blast method of cooling (Fig. transformer.
11), instead of depending on free convection
.solely
of air to cool the transformer, pressure is used and air is forced thro^i
the windings. The temperature rise of the hottest part of the surfaces, ab»
408
 TRANSFORMERS Sec. 6-65

air, may therefore be made as small as desired by using suflS-

Iinooming by
itpressure, and the limits of this method of cooling will be set only
cost of maintaining a large flow of air at suflScient pressure, and by
t; temperature gradient through the coils and insulation.
5. Artificial cooling of the hot oil after it flows from the top of
t roils affords the same advantage in oil-immersed transformers (Par. 64).
1 water-cooled transformers (Fig. 12) this is done by placing a coil of pipe
I r the surface of the oil, through which cold water is circulated.
G. In forced oil circulation (Fig. 13), the liquid is circulated as
IS cooled artificially, and a still further gain can be made m
efficiency of
L', but it is only in transformers of large capacity that the gain in
<-< -^1— — cooling efficiency overbalances the in-
creased outlay.
67. Limitations in design on
account of cooling. As the size of
the transformer is increased, keep-
ing constant the current density, the

12. —
Oil-insulated water-
cooled transformer.
Fia. 13. —Forced-oil circulation system
of cooling.
i iction and the watts lost per sq. in. of effective coil surface, the dimen-
? •
will be proportional to the one-fourth power of the output. The
' ! area per watt lost will therefore become less, and the length of path
I ooling fluid must travel will be greater.
8. In transformers cooled by natural convection a larger difference
i emporature will be required between the top and the bottom of the
c^3 up the necessary circulation of air, the greater the capacity of the
to set
t isformer, on account of the decrease of the duct area per watt lost and
t mean length of flow path, with increasing capacity or
increase of the
r riH. Consequently, unless these factors are changed in proportional
r o with the losses, the temperature rise of this style of transformer will
i ease as the size increases.
9. In oil-insulated self-cooled transformers as the capacity or
r ng is increased there is more resistance to the flow of oil in the ducts on
' )unt of their greater length. Moreover since the dimensions of the
c ; are determined largely by the dimensions of the coils and these are

409
Sec. 6-70 TRANSFORMERS
approximately proportional to the one-fourth power of the output while ;j
losses increase as its three-fourth power, the additional surface necessi/
to dissipate the heat must be obtained by corrugating the tank aurfi
The air flow has therefore to encount-er a more constricted area of entry :i
a longer path of higher resistance. The volume of air per watt lost I
consequently decrease and the average temperature of the air flowing or
the surface increase, resulting in a higher average temperature of the ,

unless the gradient between the oil and cooling air has been sufficiently -
creased by increasing the tank area per watt lost. The maximum t<-
perature of the oil will tend to be higher, and therefore the maxim i

tempyerature of the windings which is the limiting factor in any electr I

apparatus will also tend to be higher. Accordingly in large transforiri
the difference between the average temperature of the air flowing o-
the surface and the average temperature of the oil must be kept lower foi
given temperature rise in the coils than in small transformers, and th<i.
fore a larger tank area per watt lost, will be required, or else the tempe-
ture gradient through the coils themselves must be decreased.

Fig. 14. — Oil-insulated Fio. 15. — Oil-insulatedself-oooled trai

Belf-cooled transformer (tu- former (radiator type).
bular type).
70. Tubular and radiator type tanks. The usual course is a comprom
between these two methods of keeping down the temperature rise in t
coils, but with very large transformers tlii.s becomes costly and more elficic
cooling tanks must be used, good examples of which are the tubular a
radiator types of tanka (Figs. 14 and 15) or else recourse niust bo had
artificial methods of cooling such as water cooling, forced circulation, etc.
71. The watts lost per sq. In. of coil surface for cylindrical cc
of large radius and for discoidal coils, may be obtained by very simple foric

410
j
TRANSFORMERS ScC. 6-72

Ifrom the current-density or the loss in watts per lb. at operating tem-
lature.
1^,= watts loss per sq. in. of coil surface at 6 deg. cent.,
TFt = watts loss per lb. of copper at 8 deg. cent.,
=
-)' area of bare conductor in sq. in.,
=
6o thickness or diameter of wire uninsulated,
=
6i thickness or diameter of insulated wire plus layer insulation,
n= number of turns per layer in layer-wound coil or number of
layers in cylindrical coil,
(io» width of rectangular conductor uninsulated.
bodo = y -\- c (for rectangular wire) 1

6<,2 = iy (for round wire) [

^^"^^

„ re c is the difference in area between a circle having a diameter equal to

ible the radius of the corners of the conductor and its inscribed .square.
i. The values of W, (Par. 71) for different types of layer -wound coils
c 1 one surface exposed are

Wi= 1
01
Wb (rectangular wire)
(24)
^
W,=
0.252 nbo'.
J Wb , ,
(round wire)
.

01
fen two sides are exposed the results given above are divided by two.
3. The temperature gradient through a coil having one surface
) osed may be obtained on the assumption that it is homogeneous,
i a thermal conductivity Xo and thickness So and that the insulation
("jring has thermal conductivity Xi aijd thickness Si. In which case

(25)

oils"with two surfaces exposed are considered as two coils of one-

{
l{ the thickness with one surface only exposed.
it. The equation of cooling for an oil-insulated self-cooled trans-
iner may be based on the assumption that the emissivity of the case is a
Vtant. The calculation is made in two steps: first, the calculation of the
ij n temperature reached by the oil above the mean air temperature;
» nd, the calculation of the mean rise of the windings above the mean oil
I perature. Let
I Po = total lo8s=Pi+P2, = iron loss -f copper loss,
ao = emissivity of tank in watts per sq. in. per deg.,
ai = emissivity of coil surface in watts per sq. in. per deg.,
Ao = area of cooling surface of tank in sq. in.,
.A. = area of cooling surface of coils in. sq. in.,
<ro= specific heat of oil,
<7.= specific heat of coils,
eo = initial temp, rise (cent.) of oil above air,
9i = rise of oil temp, (cent.) after time (i,
9a = initial rise (cent.) of coils above oil,
Si = riseof coil temp, (cent.) after time (i (hours),
Go = weight of oil (pounds),
6i = weight of coils (pounds),
(i ""time measured in hours to raise temp, of oil from 0o to 9i

P (-4-) -"»
9. = -^r - ^
Z° A , \
«eg. cent.) (26)
aoAo /0.823aoAo<i
10 1 Go^o )

b-1.215(-^-!!^) logio^^?"^^? ^ (hours) (27)

\a»Ao/ ( '^^ _fl ^
^aoAo /

411
Sec. 6-75 TRANSFORMERS

The same equations apply to 0a, and Bb if we substitute these value n

00 and 01 respectively; and also substitute P, Am, <ri, 0, and a, forPoAo, aa i,

and ao respectively; we shall then have the temperature rise of the 'ij

above the oil at the end of an interval h, starting with a temperature rit|.
75. In water-cooled transformers the length of coolingr coil requ d
will depend upon the rate of flow of the water. Using the same symb
before, except that the temperature rises will be measured above the i

ing water, we shall have, if radiation from the surface of the tank is neg,
and taking 6a as the temperature rise of the water, F as the flow in g;i la

per niin., L as the length of cooling coil in feet and aw the emissiviDl
the surface of the cooling coil in watta per ft. per deg. cent.,
.0038Po
*"= F
F
L = 606—
,
log 10
00
~ ''"
— ,,
(feet)
^
)
a» "o
Temperature above 1
rise q o038Po
entering water under \ = ~
'

steady conditions J FV\^ 1 (deg. cent.)

/O^OOlOSoO-x
L lol F /J
Denote the bracketed portion of the denominator of the above fr

by C; then,

(deg. cent.)

(hours)
2165FC

C constant for a given length of pipe and flow of water. The temper «
is
rise ofthe coils above the oil may be obtained by the formulas given hi i

last paragraph. The above formulas with some modification may b

for forced circulation.
76. The cooling surface required for a transformer having a
40 deg. cent., based on a room temperature of 25 deg., will vary :

per watt lost, to 8 or 9 sq. in., according to the size of the

sq. in.
former. The value of m
will vary from 0.008 to 0.004 watts, per sq. ii x.

deg. cent.
77. The following relations will be found useful to transfo «
designers. Energy dissipated in 1 lb. of copper at the rate of 1 wn
raise the temperature of the copper at the rate of deg. cent, per H
no heat be permitted to escape. Water flowing at the rate of 3.8 ^
min. will absorb 1,000 watts, with a temperature rise of 1 deg. cent
at atmospheric pressure, flowing at the rate of 1,650 cu. ft. per nn
absorb 1,000 watts, with a temperature rise of 1 deg. cent.

MECHANICAL DESIGN AND COIL QROUPINO

78. Mechanical stresses in service are due to the heavy currpi •

veloped in electrical apparatus under short-circuit, caused by the trem

amount of energy developed in modern electrical systems. Re:
in a transformer, on account of tko great length of the leakage paths ^
furnishes practically the same protection to connected apparatus |J^ M
reactance. M
79. Coil grouping and reactance. The reactance of a tranrfw
depends on the grouping of the high-tension and the low-tension win »
The same general principles apply to the grouping of the windings (>«l
type of transformer. The element of a given grouping is formed by
••

of high-tension and low-tension coils of equivalent number of turns. genjW

an even submultiple of the total number of turns, placed as near toget f

412
 TRANSFORMERS Sec. 6-80

h nsulation will permit. This is termed a group and ia designated thus:

hivLH. A grouping arranged thus, LHHL, is a symmetrical 2HL group-
ie a group
arranged thus, LHHLLHHL, is a symmetrical iHL grouping,
nso on. Given a stated number of turns, and a thickness of insulation
ejeen high-tension and low-tension windings very thin compared with the
ovpaces, the reactance varies approximately as the reciprocal of the square
{ 16 grouping. A convenient method ot calculating reactance is to
der both the high-tension and the low-tension coils in a given element
s'lch concentrated into a thin shell one-third of the combined thickness
f'le coils from the surface next to the insulating barrier between
the
il tension and low-tension coils.
Influence of mechanical stress on design of winding. High
.

B! ance may be obtained in three ways: (a) By reducing the grouping;

b y increasing the number of turns; (c) by increasing the spacing bet\yeen
o The methods (a) and (b) increase the mechanical stress for a given
a? of current, while the method (c) decreases it, but the latter is costly; a
o)romise between these methods is best. All of the coil groups are sub-
3< d to compressive forces during short-circuit, and must therefore be
irerly supported. In shell type transformers, to prevent buckling of the
o under short-circuit, one company uses two heavy T-beams, spread
ft by two end-studs equipped with threads and nuts for the purpose.
1 free ends of the coils in all types of large transformers should be held
iry in position by bracing against the end-frames or by clamping the
o together between heavy plates by tiebolts.
Formulas for reactance. The reactance in ohms is equal to oL,
.

ri e L is given in henrys.
n value of L may be ob- — \
a ;d by the following
ulas:
/y \
I) l-type discoidal coils 1

I. 16);
. lO.GnH^i +li)(2Nc-\-h)
^

\ JVHai-t-a2)X10»
f.
(henries) (33)
1 ;> 1 1-t y p e cylindrical
«i(Fig. 17);
10.6 7i.2;(2iVc -f a)

K 18);
JV26X10'
(henries)
rectangular-
concentric coils
(34)
 .

Sec. 6-82 TRANSFORMERS

N is the number of HL groups, c is the space between adjacent high-teii4
and low-tension windings, and oi, at, 61, 62, b and d are as shown in 1
16 to 18.
82. Formulas for mechanical force exerted on coils. In a tit

former the electrokinetic energy is given by

W=IlI^ (Joules)

where 7i is the primary current, and therefore since F = ,—

^"o-f'r'X^o'
2 ax1
(dynes) .

:
,

X being in the direction of the maximum force, that is, at right anglM t^
surface of the coila. For shell-type transformers with discoidal coila,
^r 1 4^nKh + h) -.
I

UAoXlO^N'iai + ai)!
2 ^ '

83. Mechanical design of cases. Where fluted cases are used '

should be made of ingot steel at least 0.079 in. thick, except for transfer t

below 100 kw., then i\ in. may be used. Cases for oil-insulated I

cooled transformers have the sides cast in a base of cast iron. Bci
iron cases such as are used for water-cooled transformers are usually ).t
anteed to withstand a pressure of 50 lb. per sq. in. The covers of large tii
formers are provided with vents to release the pressure if an explosion sh .1

take place. The tank is provided also with a large gate valve, so that tl li

may be drawn off very quickly. The cases of large transformers shoub
made as nearly air-tight as possible, as this prevents dirt or moisture fin ti

its way into the tank.

84. In the design of end-frames for large transformers sti

steel has come into general use. This affords a much greater latii
the designer, as he then has freedom to make the proportions of t i

anything he pleases. The cooling coils of water-cooled transforin

usually made of }- to 1-in. brass, copper or iron pipe and are tested
250 lb. per in. hydraulic pressure.

TKANSFOBMERS FOR POWER SERVICE

86. General consideration in design. The most important quali ii

a power transformer is durability it should be able to withstand the «

;

exacting conditions to be met in service without being sensibly weak(«

It is important that the insulating material shall not be subjected to excejj
tem{)eratures, and therefore every portion of the coil surfaces should bw
exposed to the cooling medium. The coils directly connected to the I
in high-voltage transformers should have reinforced insulation. Ij

86. The cheapest transformer consistent with durability that 'M

reasonably good performance, is what is generally required. Such feaJ
as efficiency and regulation are usually of secondary mportance. TheJ
density in the iron of such a transformer will be made as high as consiJj
with a reasonable exciting current; the loss per lb. at commercial frequ^
in silicon steels is so low that tlie core-loss is seldom a limiting feature. %
current-density, on the other hand, is limited chiefly by consideratioM
cost, because when the density is increased beyond a certain point, fl

transformer designed to operate at a given temperature rise, the cost bjl

'

to increase again.
87. Types and characteristics. Power transformers differ m 1;

in the methods used to cool them: the characteristics pertaining to diff n

methods of cooling are taken up under "Cooling" (Par. 64 to Vu
Transformers cooled by natural circulation of oil and air must be il'

on a more liberal scale than water-cooled transformers, or those co<

forced oil circulation, and therefore the losses will be lower in the ]<
>:

than in the latter. Air-blast transformers, on account of the heavy id •

tion and large insulation clearances needed, are not as efficient as other p
«

transformers of the same voltage-class.

 TRANSFORMERS Sec. 6-88

. Large transformers for general power senrice are usually built

Qiie of the following types: self-cooled in tubular or radiator tanks water-
;

ic;d: oil-insulated with forced circulation of air; forced-oil-circulation

y or ;
air-blast. Their characteristics are moderate efficiencies, low tem-
i« tare rise,
and durability. They may be either of the shell-type or the
ctype of construction, according to size and voltage; if of the latter
y cruciform cores and circular coils >.re used.
,

Three-phase transformers. Two types are in general use, via.,

.

bJore-type and the shell-type. The core-type is illustrated in Fig. 19.

t insists of a magnetic circuit having three "legs," each of which carries
hlux due to the winding of one phase; since these fluxes flow toward a
c non point the third harmonic must be practically absent. It is possible,
b !fore, to use a star-star connection with this typye of transformer
rout producing voltage distortion. The shell-type three-phase trans-
o,er does not differ materially from three single-phase transformers; Fig.
Ki ustrates such a type of transformer. It
fi be noted that a small amount of iron is

ad, but though the total saving in nia-

e over three single-phase transformers is
1

n 1, there is a decided gain in cost of in-

,1 Fia. 19. —transformer.

Core-type three-phase Fig. —
20. Shell-type three-
'
phase transformer; shell-type
single-phase transformer of one-
third rating shown for compari-
son,
it.ition of one three-phase transformer over three single-phase trans-
Oiers, and it occupies considerably less floor space. The performance of
in'-phase, transformers may be obtained with reasonable
shell-type
It, racy by taking the values for single-phase transformers of one-third
.D.atmg, the water rates and weights being multiplied by three. For the
!c type three-phase take a single
phase of two-thirds the rating and add
»Ver cent, to the water rate and weight.
Transformers designed for outdoor service. There is a large
.

tf increasing demand for these

transformers in large voltage transmission
iy;ms owing to the cost of buildings and wiring increasing very rapidly as
Jt;ransmission voltage increases.
The design of the outlet terminal for outdoor service is not
•

n djfierent from the design of an indoor bushing except that, on account

>r, e rain te^t
it must nteds stand, it is usually longer and in the condenser
IJ the terminal proper is encased in a sheath of porcelain petticoats or
w nesting into each other and sealed with a cement. The space between
ifltermmal and the porcelain sheath is filled with a gum of high specific
active capacity and high melting-point.
Voltage classification. Standard transformers are classified accord-
•

tt,o the voltage of the transmission

lines on which they are i ntended to
Wate. The voltages which are considered standard are as follows:
Lf ., 2,200 22,000 110,000
fc^fc.6,600 33,000 132,000
^Bl.OOO 44,000 154,000
m^Bi'^99 66.000 220,000
^16,500 88,000
W-down transformers designed for these voltages are usually provided

i^ 415
 .

Sec. 6-93 TRANSFORMERS

with taps giving four steps of 2.5 per cent. each. Step-up transform
provided with taps are considered as special. The usual secondary dist
uting voltages are considered standard. Transformers used for intet(l(
necting two liigh-voltage systems are considered special. j

93. A standard transformer is completely specified when i

method of cooling, the frequency of the circuit (either 23 or 60 cyclr-
voltage class, and low-tension voltages are given. Manufactuni
type numbers or letters for their standard lines, and in some casi
different linesmay "overlap for a few sizes. In general, however, nu
biguity will exist if the method of cooling is specified with the other <i
required.
94. Tables giving ratings, efficiencies, regulation and welgi
typical of standard single-phase oil-insulated air-cooled transfo;-
ers. These transformers have a guaranteed temperature rise not exor -

55 deg. cent, at continuous full-load rating. They are maximuni

according to the A. I. E. E. standardization rules, and the insulatin:
are in accordance with these rules (see also Electric Power Club Stuh
ization Rules). The tables follow in Par. 96 to Par. 102.
96. Single-phase —^60 Cycles — 11,000-volt Class
Kv-a.
 TRANSFORMERS Sec. 6-98

98. Single-phase —60 Cycles

 Sec. 6-103 TRANSFORMERS
103. Tables giving ratings, efficiencies, regulaition and weigh i

standard oil-msulated water-cooled transformers. The risf,:

temperature of these transformers above incoming water is 55 deg. i

with continuous full load. They are "maximum rated" units in ac(i
ance with the Standardization Rules of the A. I. E. E.

104. Single-phase — 60 Cycles—22,000-volt Class

Efficiencies Regulation
Net
Kv-a. weight
with
i load I load
Full 100% 80% oU
load p. f. p. f.

1,000 98.1 98.25 98.2 1.4 4.6 8,000 lb.

1,250 98.15 98.3 98.25 1.35 4.6 9,200 lb.
1,667 98.25 98.4 98.35 1.30 4.6 10,600 lb.
2,000 98.35 98.5 98.45 1.25 4.6 11,600 lb.
2,500 98.4 98.55 98.55 1.25 4.6 13,800 lb.
3,333 98.55 98.65 98.65 1.10 4.2 17,500 lb.
5,000 98.65 98.8 98.8 1.10 4.2 23,000 lb.

106. Single-phase — 60 Cycles —44, 000- volt Class

Efficiencies Regulation
Net
weight

^ Kv-a.
i load } load
Full
load
100%
p. f.
80%
p. f.
with
oil

1,000 97.7 97.95 97.95 1.45 5.5 11,300 lb.

1,250 97.9 98.1 98.1 1.4 5.5 12,500 lb.
1,667 98.05 98.25 98.2 1.35 5.5 13,700 lb.
2,000 98.15 98.35 98.35 1.25 5.5 15,000 lb.
2,500 98.3 98.5 98.45 1.15 5.5 17,000 lb.
3,333 98.45 98.6 98.55 1.05 5.0 20.500 lb.
5,000 98.56 98.7 98.7 1.00 4.5 27,500 lb.

106. Single-phase —60 Cycles—66,000-volt Class

Efficiencies Regulation
Net
weight
Kv-a.
with
load load
Full 100% 80% oil.
i i load p.f.
p. f.

1,000 97.65 97.85 97.85 1.55 6.0 14.700 lb.

1,250 97.7 97.95 97.95 1.45 6.0 15,500 lb.
1,667 97.9 98.15 98.15 1.35 6.0 17,700 lb.
2,000 98.05 98.25 98.25 1.25 6.0 19,000 lb.
2,500 98.2 98.4 98.4 1.20 5.5 21,000 lb.
3,333 98.3 98.5 98.5 1.20 6.5 25,000 lb.
5,000 98.45 98.65 98.65 1.10 5.0 32,500 lb.

418
Sec. 6-111 TRANSFORMERS
 TRANSFORMERS Sec. 6-117

117. The two types of transformers, viz., the shell-type and the
re-type are both used for distributing transformers. The form
shell-type shown in Fig. (8) has shorter mean length of winding and
lignetic circuit than the usual form. The dividing line between shell-
pe and core-type design depends both upon voltage and rating. The
-mer being more economical for low-voltages and large ratings and the
ter for high voltage and low ratings. It is usual however to have one
;pe for a line of transformers. The core-type is better adapted for direct
Dling in air than the shell-type.
118. Standard lighting and power transformers are designed for
eration on 60-cycle circuits and have a nominal primary voltage of 2,300
,!ts and secondary voltages of 230 volts and 115 volts, or 460 and 230 volts.
le temperature guarantees for these transformers are usually 45 deg.
it. above atmosphere after 8 hr. full-load run, and 55 deg. after continuous
: 1-load run. Some manufacturers guarantee a temperature rise of 60 deg.
It. at 25 per cent, overload for 4 hr., starting with the oil tem-
•ature obtained under no-load conditions. The insulation test is usually
000 volts, for 1 min., between high-tension and low-tension windings
,i ground; an overpotential test varying with different manufacturers
1 mdouble to five times normal voltage is also applied.
Batings and eflSciencies. The accompanying data (Par. 120 to Pars
il9.
:5) on standard lighting transformers have been chosen as giving a fair
uresentation of the general practice in the United States. Two type.
;: manufactured for 2,300-volt 60-cycle service, namely, a " High-efBciency

"pe" or (standard) and a "Low-efficiency Type." The former type should

1 used when the cost of energy is high and when it is desirable to operate at
h efficiency both all-day and underload.
1 The latter type is justifiable
installation when the cost of energy is low, and where it is not so es-
)

iitial to have a high-operating efficiency. The table (Par. 120) gives per-
Jmances of "standard" or "High-efficiehcy" lighting transformers.* The re-
i.ining 60-cycle transformers are designed for operation on circuits of
1 her voltage than 2,300 volts and therefore have correspondingly lower
iformances.
:). Performances of 60-cycle Lighting Transformers: Standard
Voltages 2,300 to 230/115 or 460 230

Per
Per cent, cent, Outline
efficiency regula- dimensions Approx.
tion net
weight
of
trans-
Floor formers
space
Height

29195 1 91. 3.1 9s X14i 11 80

30 52i96 8 93, 2.5 12 X16 13 120
,i 36 76 5195, 2.4 12 X16 14 150
5 44 99 2i95, 2.1 14 X18 16i 225
7.5 60 128 596 1.8 loi X19| 18 310
74 168 7 96 1.8 X19i 15i 21 360
5 103 222 1.6 X194 15J 28i 490
5 137 367 2 1.6 22 X24 30 i 790
7.5 200 490 3 1.5 24 X28i 37J 1070
'0 258 607 4 1.3 24 X28i 444 1280
5 460 825 398 3 1.15:2-. 55 301 X37i 39 i 1680
615 1120i98 3'98 3 297 3 1.20 2. 60 30i X37i 484 1820
840 1800198 298 3i98 2;97 5il.30!3. 15i34 X40i 69 2480
11301 240098 298 3198 2197 5|1.30!3. 15!34 X40i 75 2560

The iron loss is measured by wattmeter, and the copper loss is measured
vattmeter and corrected to 75 deg. cent.

421
 2

Sec. 6-121 TRANSFORMERS

121. Performance of 26-cycle Transformers: Standard Voltac

2,300 to 230/115

Per
Per cent, cent, Outline
efficiency regula- dimensions Apprc
tion net
weigl
of
trans
Floor foriiu
Height
space

1 22 48 90.94.9 5.2 12 X16 13

2 39 75 91.93.9 4.5 14 X18 16
3 48 100 93.2,3.4 4.0 14 X18 16
5 71 150 93.9 3.9 15JX19J 18
7.5 101 187 94.3 3.4 20 X23 22
10 124 240 94.7 3.4 22 X24J 22
15 154 326 95.5 3.0 22 X24i 31
25 250 438 95.7 2.6 24 X28J 37i
37.5 274 760 96.6 2.8 31 X33 39
50 325 955 96.9 2.8 31 X33 45i
75 450 1550 97.1 2.8 34 X40^ 51
100 580 2100 97.2 2.7 34 X40J 74
150 1520 2400 95.7 2.9 33 X33 81
200 1750 3500 96. 1.8 3.0 39 X39 71

)
122. Performance of 60-cycle Transformers: Standard Voltai
6,900-6,685-6,276 to 230/115 or 460/230

Per
Per cent, cent, Outline
efficiency regula- dimensions Appr
tion
weig
of
tran
Floor form
Height
space

1.6 34 55 3.7 4 Hi;X16}

3 48 87 3.1 3. 12
5 55 150 3.053, 13
7.5 79 200 2.7 15}
10 102 220 2.2 15}
15 123 314 2.1 17
25 172 476 1.95 21};
37.5 230 624 1.7512 23
50 270 787 1.65^2 24}
75 417 1035 1 1.45i2 30}
100 655 11.50 2 1.252 34
150 820 1960 2 1.40 2 34
200 1200 2500198.2 1.3 2 34
 "

TRANSFORMERS Sec. 6-123

a Performance of 60-cycle Transformers: Standard Voltages

11,600-10,926-10,350 to 230/116 or 460/230
—
 Sec. 6-125 TRANSFORMERS
125. Performance of 60-cycle Transformers: Standard Voltai
23,000-21,850-20,700 to 460/230 or 230/115 .

>
 . :

TRANSFORMERS Sec. 6-129

Pi Pi
ci' + diV' VP1+P2+P1 +:);'"=(cii+-drO- Pi+P2+Pj + (.

'^ '^ (39)

7V
({"Kct^+di^J' (Pi+P2+P. + J'
\Pi+P2+Pi ) '
"^
(
Vcj' + di^ / +)
+Pj+Pi+-^
\Pi+Pi+Pt
^'"
" (c^ + djV (p, +P2 +Ps + ;'"•"
)' WTdj'^'
Vc.J +dj'^ VPi +Pi +Pt +
(pi+P2+p7+)
r[ joint admittance Y is equal to the sum of all the admittances, or

Y = g-jb = gi+gt+gz + -jXbi + b2 + b» + (40)

!•loads taken by the first, second, and third transformers expressed, as

fitions of the total kv-a. are respectively

\/ g»« + b» '
(41)

T power-factor of the load supplied by the transformers when the power-

ttorof the combined load is cos a are respectively
cos(a + Oi - 6), C03(a Oi - 6), cos(a +02-6)+ (42)
vv re 9, Bi and Bi are given by

fl = tan-i 9i = tan- ej = tan-i etc. (43)

g2

19. When the transformation ratios of two transformers are

ilhtly different they may be operated in multiple, without incurring
m-h trouble. The currents /i and I2 taken by the two transformers will
it'nd upon the transformation ratios mi and mt, the two transformer
ittidances Zi and &
and the load impedance Zo. following formulas The
Bi be readily used by those familiar with complex imaginary quantities
miZ2-\- (mi — m2)Zii
(
ZiZ2 + Zo(Zi + Zt)-
(44)
mtZi — (mi — m2)Zo
^'
" ZiZt + ZoiZi+Zi) ^*

Fig. 21. — Vector diagram of two transformers operating in multiple.

.
0. Compensation
for differences in impedance may be made by
»<5ing external reactance and resistance to the transformers whose react-
or and resistance are too low. The amount to be added in each case ia
otoualy that which will make the percentage value of the reactance drop
*E the ohmic drop, at the rated currents, the same in all transformers.
Wife the ratio is different, compensation by external reactances cannot
i.,\ ^"^ resort must be had to balance coils or auto-transformers. This
ca will be dealt with under
auto-transformers (Par. 180). Auto-trans-
'o ers may be
used for producing proper distribution of load in all cases.
 , 1

Sec. 6-131 TRANSFORMERS

131. Explanation of vector diagram, Fig. 21, for multiple operati
In the above diagram AB is taken of any arbitrary lengtli to reprei
the combined impedance drop. ADi and ADi are each taken the a'l
fraction of AB that the resistance drops of the respective transformers 1

to their impedance drops. ACi is taken equal to the current that

Ad
;

produce the drop ADi in one transformer, and is taken equal to i

current that will produce the drop ADt in the other transformer, i

resultant AC is the combined current. The corresponding comhi

resistance drop is AD.' The line AC will then represent the comb i

load current on a certain scale, and ACi and ACi will represent the cum
in the respective transformers, in magnitude and phase, on the same sc
Since the currents are known, the value of the impedance drop is kn(.
and therefore the scale on which AB represents the impedance dro (

known also: we may take a certain length to represent the magni (

of the secondary open-circuit voltage on the same scale, and with B i

centre strike an arc EOF; then, extending CA to E, draw AO, making (

angle a with AE, where cos a is the power-factor of the load. OA repres i

the secondary terminal voltage and OB represents the secondary of

circuit voltage, or approximately the primary e.m.f. multiplied by i

ratio of transformation, and with phase reversed.

POLYPHASE TRANSFORMATIONS
General considerations. A polyphase system is classified
132. a

balanced n-pbase system when the e.m.fs. and currents in corresponj

> branches at every point of the system are sinusoidal, have equal effei
values, and differ in phase by 1/nth of a period. If Ei be one of the e.:i
_
i

and 1, ai, 02, are the n roots of the equation x" — 1 =0, the bala^
. . .

n-phase system of e.m.fs. may be expressed symbolically as follows:

Ei = Ei, Ei=aiEu Efat^i. .En^an-if!! . . <)

In such a system
> 133. A
symmetrical n-phase system of currents or e.m.fs. is oil
which the effective values of all the constituents are equal and when takjl
fixed order or sequence, they diflfer in phase by any integral multipll
2r/n from zero to (n— 1). That system for which the integral multil
is zero is termed a zero phase-sequence system; that for which the intH
multiplier is unity is called a system of phase sequence one. In a tliB
phase system the second phase sequence is the same as the first i
sequence reversed; it is convenient to call the first phase soquenctn
positive phase sequence and the second the negative phase sequei
134. An unbalanced polyphase system is one in which the e.n
currents in any part of the system are unequal in effective value
unsymmetrical in phase-relation. The unbalanced currents and
may be resolved uniquely into n symmetrical systems of zero, 1

3d . (n— l)th phase sequence, each of which may be considci

. .

dependently of the remaining systems, so that the problem reduces

solution of n symmetrical systems.
135. The resolution of an unbalanced system of 3-phase cun U
or e.m.fs. into its symmetrical components may be ofT-' •' ™
simply; thus if the currents in phase A, B and Che J A, JB and /(
and the zero phase sequence, positive phase sequence and my
sequence components in phase A be lAt, jAi and fAt respeclr. i ..>

1, a and a^ are the cube-roots of unity or 1, ( —-x+j^ o ) • *'**^

I
~5~-
respectively,
,, lA+lB>, Ic
3
jA+alB + a'-IC
lAu
r TA+ a^lB + alc
JA2
3

426
 TRANSFORMERS Sec. 6-136

\
 .

Sec. 6-139 TRANSFORMERS

Eot<i = /a(i = indefinite

\/3

Em= -jV^Pai I 1X2= -j--'I

\/3 J

139. The two-phase system is in reality a four-phase system

constrained that unbalancing does not involve components of zero t

second phase sequences, but where the two phases are intcrconnec
electrically through connections between transformer windings or in rotat
apparatus it becomes a true four-phase system and must be dealt w
accordingly.
140. In the simple two-phase system without interconnectic
if Jx and Jy are the currents in the two phases, they may be resolved intu
two component systems of positive and negative phase sequence for w!
the currents in the x phase are

The graphically carried out as follows.

solution is In Fig. 22(6) let
and OF represent in
magnitude and phase the currents /i and Jy respeotiv
Draw OP
equal to and at an angle 7r/2 in advance of OY; then thp
a line
joining O to the middle point of PA' represents in magnitude and phasr
member of the positive phase sequence component in the A' phase, nan
Ixt. Draw a line OQ equal to OY and lagging ir/2 behind OY. The ;

0X2 drawn from O to the middle point of QX will represent in magnit .

and phase 7x2, the member of the X phase of the negative phase seqii'
component of the two-phase system of currents.
141. The zero phase sequence component does not enter into p
phase transformations except where there are connections to grounii,'
where an ungrounded system has unsymmetrical admittance to groi
The zero phase sequence component of current will appear also in •

symmetrical delta or ring connections. When the zero phase sequ(i

components of current appear in the lines due to ground connection; r
unsymmetrical ground admittances, while otherwise negligible, t'
rnay give rise to inductive interference with near-bjr communica 1

circuits and they are commonly known to telephone engineers as resii 1

currents.
142. Except when considering- the effects of grounds on the systi ,

only the positive and negative phase sequence components of a thrcc-pU

system will be considered.
143. A convenient method of calculating simple unbalani
transformer connections is to consider the effect of each s;yrameti|
component in the system separately, expressing each member in teTmjS
that of the principal phase, and the currents in the delta connoctioni
terms of the line currents by means of the relations in Eq. 48 in Par. 'm
The e.m.fs. may then be resolved into symmetrical components with Plj
A as the principal phase by Eq. 47. For more direct methods see "SH
metrical Co-ordinates Applied to the Solution of Polyphase Network
by Fortescue, C. L. G., Trans. A. I. E. E., Vol. XXXVII, Part 2, p. 102t!
144. In this sub-section we shall confine ourselves to the unbalallj
ing effect of unsymmetrical transformation, and to a few ca»e|l
grounding. The general problem of unbalancing of polypha.se systii
belongs properly to Polyphase Networks.
145. Two-phase to two-phase transformation. The usual tr"
formation is effected in each phase independently by means of a transfori",
the four secondary leads are independent, forming the terminals of a f "^
wire non-interlinked two-phase system. If the middle points of the seC'H
ary windings are connected together the four-wire symmetrical interlii.4:
two-phase system is obtained. If two ends of the secondary windinpit
connected together the two-phase three- wire system results, whichichiS
if

428

I
 TRANSFORMERS Sec. 6-146

long
it inked unsymmetrical polyphase system not well adapted for
s ice transmission. In this system the e.m.f. between the other two ends
•

t V^
windings is times the e.m.f. across the windings. Fig. 24 illustrates
ic systems.
Generator Bus bars
"T~Pha.so A

lPha3eJ.g
m
hsvFr nnnnf

2 Phase, 2 Phase, 4-Wire, 2 Phase,

4 Wire Interlinked 3 Wire
Fig. 24. —Two-phase systems.-

(3». Transformations between two-phase and three-phase sys-

•II. The most usual arrangement of transformers is that shown in
Fhase X
System
Phase Y
i
x> f
iiiiiiiiiijiloies>iiv^C7

IP

Three-Phase
System

Fig. 25.
—
"Scott connection", two-phase
to three-phase or three-phase to two-phase.
?1(25. The two transformers DQ and BR are usually of like design, both
ici provided with a tap at the middle point of one winding and also one
tt ooint \/3/2 or 0.866 of the winding from one end, as shown at D and .4

«Bctively. When the transformers are supplying balanced currents, the

!tt; nt density in the working portions of the windings of both transformers

B V same. The transformer DQ has 13.4 per cent, less loss in the wind-
ny)E than the transformer BR. The unbalance due to the tap A being
nj urately located is best shown by expressing the transformation equa-
*o- in symmetrical components. Thus if ^Ai and Pa: are the symmetrical
wnonents of the three-phase e.ni.fs. measured from the neutral, and
Pi nd f!i2 are those of the two-phase system, and if m be the ratio of the
in ing DA to the whole, and p the ratio of transformation from RS' to BC,

m 1\
EAi +
:

^)-^(
V3 V3 2J (50)
JpA2
'[V3V^/3 2J
+^/^+
V3 V3

I
Sec. 6-147 TRANSFORMERS
Thus if the transformation is from two-phase to three-phase and if the (

phase side is balanced (^i2 = 0), the component pAi will be zero if to/v<
or m= \/3/2. Vice-versa if the three-phase side is balanced (^42 = 0'!|
will be zero if the same condition is satisfied. =

147. The condition of perfect balance will usually exist only whe'l
transformer is carrying no load. Assuming that the transformer J
symmetrical about D, but that the ratio m of the other transformer!
be in error, the positive and negative phase-sequence components of cuj
for a symmetrical load having impedances Zo and Zo' respectively to |
components may be found when the following impedances are known: ,:

Zx measured between A and D with PQ short-circuited ,

Zy measured between B and C with RS short-circuited I

Zz measured between D and B with BC short-circuited

The solution is

lAx =
^ r3{zi,Zo' + Zo(^Zx + Z, + ^Zy'^ ^j EAi-SZo^Zx + Zz-'^Zy'^EAi

?°[ ZoZo'+(Zo + Zo')(^Z. + Z. + ^Zy'j+3ZyiZ. + Zz)

J
["3
I
ZaZo' + Zo'{Zx-\-Z, + jZy'^ } EAt-SZo'(^Zx + Z,-jZy^EA

ZoZo'+(Zo + ZQ')(^Zx + Zz+^Zy^+ZZy{Zx + Z.)

The expression in brackets in the solution for jAi is the positive \i
sequence component of the terminal e.m.f, under load; and that i4
solution for /a 2 is the negative phase-sequence component c*J
terminal e.m.f. If m has the correct value, namely V3/2 and thejj
phase circuit is balanced, EA2 in the above expression becomes zerii
in addition to this '

Zy=^^(Z. + Zz)

J At will also be zero and the transformation will be symmetrical wit!,

to e.m.fs. between lines.
148. If a neutral point be provided for grounding which is <•
located for no load, it will shift as the load increases and the syslii ':

have a mean potential to ground given by the zero phase-sequence

ponent of the e.m.f. to neutral and is given by
Eao= --^Z,{lAl-\-lAi)

149. When the load Includes no rotating machinery 2o

have the same value; but when the load consists of induction or sy
ous motors or converters, Ze' becomes relatively small compared (o
consequently dissymmetry in transformation may lead to excessiN
ing in rotating apparatus. In rotating apparatus Zv' is a fixed quair
given speed, approximately equal to the locked impedance in the iii-
motor; 2o will depend on the load and in synchronous apparatus «
with the excitation. It may in every case be expressed in the foi
rw-\-rB-\-jxa, where 3Z4iVu, is the wasted work done against iron loss, ^^
and friction, and a small amount of work required to overcome the n
torque due to JAi. The total loss in the motor will then be
3|/Ai=(ru.-|-ro)+7X2Vo')
160. If the transformation is from three-phase to two-p-*
Ej\ and Ex2 should bo obtained in terms of Ea\ and ^,-12 the positivJI
negative phase-sequence components of the three-phat^o imp*
e.m.f. from equation 47, and if Jx\ and Jt2&tp the correspondine symmM
components of the two-phase system of currents and Zo and Zo' the resiw
impedances to these components of a symmetrical two-phase load,
430

I
 TRANSFORMERS Sec. 6-151

, .Z^ + Z^ Zy. ,Z^+Z, Zy

r 2[ZoZo'+Zo{^^^+P)E..-
Zy 4.Zy Z,+ Z,
L ZoZo'+(Zo + Zo')(f^^tll+i
' ' '
' \ {mp)^ ' ^J'^'^K
p (mp)^)
(55)

2
I

I
zoZo'+Zo'i-,
. • . \
—~+^)Ex2-2ZoU-,—fr-^)^'^
.Zx-\-Zz
(mp)^
Zy.
p2 / \
.Zr-^Zz
(mp)^
Zy.

p- J
Zt 7 7 '^,7 ^7>^f^'-^^' ^'\ 4.ZyZ.+ Z.
\ ZoZo + (Zo + Zo ) / J ;_ 4-_!_^ -J •—(s 1_ \
\ (.mp)'^
(mp)'^ p^
p'' J p' \ (mp)'
p^ Kmp)^ J
i xpressions in brackets are the positive and negative phase-sequence
ponents of the terminal e.m.fs. on the two-phase side. If m has the
31 tt value and the three-phase impressed e.m.f. is balanced, Exi is zero.
•
addition to this,
I Zx+Z.
i
Zy = - r- (56)

rtiill also be zero. This is clearly seen to be the same condition as that
iv by Eq. 52. A stable neutral may be obtained on the two-phase side
n r all conditions.
:'.. a corrective impedance is required to increase the value of Zy,
If
8 luivalent must be added on the two-phase side of transformer BR
^25), for if it were added to Zy on the three-phase side it would have
wffect of increasing Zz also. With properly designed transformers the
n 'ance due to the impedances is trifling compared to that arising from
tl causes, but there are occasions when it becomes necessary to use
a^formers designed for other purposes having incorrect ratios and high
afs for Z,; it is then desirable to be able to determine the extent of un-
bI ce due to these causes and if necessary correct them.

11. Two-phase to six-phase transformation. A double Scott (

01 ection is employed almost universally for this transformation; which
•d solely for supplying six-phase power to synchronous convertors
o two-phase supply systems. Two transformers are required having

k
 .;

Sec. 6-153 TRANSFORMERS

phase to three-phase transformation and the unbalance calculated
Eq. 50. The impedance measurements for Zi, Zy and Z, must be m
with equal currents in both windings; this may be done convenient!;!
connecting the two parts in multiple when making the measurements i

taking twice the values obtained in this way for the values of Zi, Zy an^
In the case of the synchronous converter the positive and negative pli
sequence impedances based on six-phase measurements or calculan
should be used, the proper value being that obtained from the currei!
one lead and one-half the diametrical voltage. As the rating of a re _

converter is very much affected by unbalance, it is important to see i

the necessary conditions given in Par. 151 are fulfilled so as to minimi: I

153. Three-phase to two-phase transformation with three tri

f ornMrs. These methods of transformation offer some advantagt
small installations where the cost of a spare unit is prohibitive, and i

desired to provide against the possibility of complete interruption of se j

due to the loss of one unit of a bank. They are also useful in installa
_
i

where it is the intention at a later period to change over from two-pha;

three-phase and it is desired to provide for standard three-phase coii

B 3 Phase "Lines B
c
ll~
V AJumJWiiMAaiaMJ jias2flAfiimfl7u!MJaJ

Taylor Connection 3 Phase to 2 Phase

3 Phase to 2 Phase with. with
'i Transformers 3 TranstormeiS
Fig. 27. Fig. 28.
Figs. 27 and 28. — Three-phase connections
using three transformers.

tions. That shown in Fig. 27 is known as the Taylor connection. Aru

of equal practicability is that shown in Fig. 28.
154. In all the preceding connections balanced currents ii Q
system will produce balanced currents in the other system.
are numerous connections which will give balanced e.m.fs. but v

^
 TRANSFORMERS SeC. 6-156

n ions may be used as step-up transformers for moderate voltages; the

[pier has the advantage of providing a good grounding point in the low-
VI age system which does not siiift with unbalanced load, and has the
El her advantage of being free
from third harmonic pulsation; the latter
h: the advantage of permitting
operation in " V " in case of damage to one
16 units. These connections are not suitable for transmission at very high
V age, but may be associated with other connections which
provide means
ft properly grounding the high-voltage system; it is better, however, to
B.id mixed systems of connections. The delta-star step-up and star-
ia step-down connections are without question the best for high-voltage

pmm m^
^^^^^ pnnnq p

C^-—^B ^^^
nnnsTj nRrinr|pwir|
Delta-Delta O "
la Tb \e Connection
Connection
Delta-Star
Connection
Fio. 30. —Standard three-phase to three-phase transfor-
mation systems.

t;ismission, as they are economical in cost and provide a stable neutral

w reby the high-voltage system may be directly grounded, or grounded
(
t (Ugh resistance of such a value as to critically damp the system pre-
v ting thereby the possibility of oscillation. The star-star connection is dis-
c ;ed in the following paragraphs.

56. Star-star connection. To render this connection suitable for

hi-volt<»ge transmission delta-connected tertiary windings must be
pv'ided. This arrangement of transformers is frequently used to inter-
c nect two delta systems and provide a suitable neutral for grounding
e I of them. Sometimes auto-transformers are used for this purpose^ in-
8' d of two-coil transformers. In either case the delta-connected tertiary
flding secures a two-fold purpose, as follows:
\) It permits a path for the flow of the third harmonic com-
Pient of the magnetizing current, which in a star-connected bank
o'ransformers is a zero-phase sequence system of currents and would, if
t. delta connection were absent, find a path through the neutral point and

ti capacity to ground of the transmission lines, and cause inductive dis-

t lances.
>) In case of a ground on the system it permits enough current
t' low to operate the protective apparatus.
37. The effect of the tertiary delta in eliminating the flow of third
Ta monic currents through ground, (a) First consider the neutral
pat isolated; then the third harmonic component of the magnetizing
c ent can flow only in the tertiary delta, and therefore encounters the
v ual impedance of this winding only. The limiting value for the third
n nonic e.m.f. of neutral to ground is therefore the product of the third
hraonic component of the magnetizing current of the tertiary winding at
n'.-nal induction, and its virtual impedance multiplied by the proper
tnsformation ratio.
>) Secondly consider the tertiary delta open and the neutral
pat grounded. Then the limiting value for the third harmonic current
ti will flow will depend upon the character of the external admittance
a may be considerably greater than the third harmonic of the magnetizing
c ent under normal conditions.
 Sec. 6-158 TRANSFORMERS
(c) Lastly consider the neutral pounded with tertiary delta cIob*
Then the action may be regarded as arising within the core in the form r
third harmonic e.m.f. causing current to flow both through the neutral'
ground by way of the external admittance to ground and around the terti:
delta. The equivalent simple circuit is shown in Fig. 31 and consists of
equivalent circuit of a transformer (Par. 18) short-circuited at the i
representing the tertiary and shunted on the grounded neutral side by
admittance representing the external admittance of the system to grou
The limiting value of the current that can flow in the joint circuit due to
internally set up third harmonic e.m.f. is equal to that of the third fci

monic component of the magnetizing current under normal conditici'

Wj
^'-(^i^li^a) Ri ^3 i<')(L.-^^AfO

This circuit This circuit

represents virtual represents virtual
Impedance of impedance of delta
grounded winding ^ cODDCCted tertiary
with adoiittauce "
2
of lines to grouudP o

Fig. 31.— Showing equivalent circuit illustrating

> source and flow of third harmonic current.

But a condition of resonance may exist between the tertiary virtual re-
ance and the circuit through ground and neutral due to the external capa i
to ground, such that the joint path may have a very high irnpedance toj
flow of the third harmonic current. In this case the limiting valuii

> the current that can flow in the neutral will be obtained by divi'S
the third harmonic component of e.m.f. obtained with tertiary delta (O
and neutral ungrounded by the sum of the virtual impedance of the w.-
ing to be grounded and the external impedance of one wire to ground.
(d) Where two-coil transformers are used and both windiiu-
grounded there are three possible paths for the flow of the third ha;
magnetizing current, namely, the delta tertiary and the two paths tl,
the neutrals of each winding.
158. In star-star connected core-type transformers the third harm t
component of the e.m.f. becomes very small on account of the mutual ind:-
ance between phases, but it is advisable to provide such transformers b
delta connected tertiaries.
169. The second function of the tertiary winding. It is impor^
to be able to estimate the amount of current that will flow through gr(|
in case one of the high-voltage lines becomes grounded. Take the simjl
case and suppose a step-up star-star transformer is supplied by a generii
Let the ratio of transformation be p and let the positive and negative p«
sequence imped; nee of the generator be Zai and Zai, resprctively i
1 et the internal generated voltage be f:Ai. Lot the hi«h-voltage anii
voltage neutrals of the transformer both be grounded, but let that •

generator be free. Two impedance measurements will be required !

transformer; the ordinary short-circuit impedance measured on tin

voltage side with tertiary open, and the short-circuit impedance with i

closed, the low-voltage winding being o{)en. Denote these by Zt an

respectively. At the point of short circuit we shall have the ground ci.
i n the high-voltage phases U, V, Wrespectively /, and 0, which n
into its symmetrical components gives

juo^l-. lu^^y lu^-i'

We obtain for the value of 7/3
/
_ pEm
3 " ZTo + pHZax + Zai)+2Zt
434
 .

TRANSFORMERS Sec. 6-160

F i a value of /'/3 of 7/3 for a tentative value E'Ai of Eai. Then the e.m.f
a^ss phase AB of the low-voltage winding will be

Ec'=jV3[aEAii-^(.ZAi-ZA2^) ]
(59)

'

Ec be the effective value at which the voltage across AB is held,

i\ Eax = 4^^Ai^ (60)

a' from this the true value of 7/3 may be obtained. The currents in the
h:i- and low-voltage windings of the transformer and in the tertiary winding

1 . 32. — Showing distribution current in star-star transformer with

of
when line becomes grounded.
dc-ltii
tertiary

n then be calculated. They are shown in Fig. 32, the tertiary winding
,'

b igassumed to have the same number of turns as the low-voltage wind-

ii If the supply system instead of being a generator is a transmission
li fed from generators through step-up delta-delta transformers, the
ii edance of the transmission system should be added to Zai and ZAi after

tU have been multiplied by the proper transformation factor.

50. If the transformer is a three-phase core-type, the value of
(
2 should be measured with all the high-voltage terminals connected to-
g ler and the tertiary in delta, ZTo being one-third the value obtained in
t. manner.
61. Delta-delta connections are widely used for moderate trans-
nsion voltages. The case of unbalanced banks is of interest. If Zot
%and Zc be the short-circuit impwdance of the individual transformers

Delta connection with "V connection limit of

unlike transformers Delta with unlike trans-
formers.
Fig. 33.

Za+Zb + Zc Za+aZb+a^Zc Za+a^Zi + aZ,

jank, Fig. 33(a), let and
9 9
b-epresented by Zao, Zai and ZAi respectively. If the impressed e.m.f.
h components represented by EAi and EA2, and if Zo and Zo' be the im-
pances of a symmetrical star connected load to the positive and negative
p 36 sequence currents, multiplied by the proper transformation factors,
« if lAi and Iaz are the component currents in the line,

435
 Sec. 6-162 TRANSFORMERS

ZAiZAi\
„ /„ ZAi
{Z, + ZA0-^-^),A.-,(ZA.-^)eA ,

The positive and negative phase-sequence components of the dt'f

currents are obtained by the transformation in Eq. 48. The zero pha
sequence current Jao is given by i

jiAl ZAi lAi ZAi

--
',

jr„0= +j~- .^— (;

V3 Zao VJ Zao
162. The open-delta or "V" connection is an unsymmetrical conr:^
tion which is used when one of a bank of a delta-connected transforn;*
fails. It is sometimes used as a temporary connection with the intentj;
of completing the delta when conditions of load warrant by the additjj
of a third transformer. Since the line currents pass through each trs^
former the rating of each should be 0.577 of the total kv-a. of the load,
may be considered as a limiting case of the unsymmetrical bank of de
> connected transformers. If both transformers are alike and have impeda'
Z (Fig. 336) we shall have 2^Ai = Za2= Zao = Z/S and Eq. 61 when Za
made indefinitely large reduces to

(Iz+zt'^eAi+lzeAi
/4i =

^ (I'Z+ZB^SAi + ^ZflAl
IA2 =
(^Z + Zo)(^Z + Zo')
9
If an impedance equal to Z, the impedance of one transformer, be plf I

in the line lead A on the primary side, the system will become symmeti 1

and we shall have Pai

_.

lAi =
]

Z + Zt
PAi
JA2=^
Z + Za' ,

JA2 becoming zero when EAi is zero. j

163. Delta-star and star-delta connections. These arc the |
connections for use with high-Tolta^e transmission systems. The si
actions take place in the delta as in the delta-connected tertiary of <
star-star connection (Par. 156), but on account of the low virtual imped; <
of these windings there is no possibility of resonance, and therefor
'

neutral of the star may be grounded without introducing any troublr

164. Thesolutionf or transformers of unequalimpedanceconnci
a delta-star bank may be obtained from the solution for delta-delta coniici c

(Eq. 61) by making ZaiZai/Zao, Zai'/Zao and ZaiVZao all zero. The i

impedances Zo, Zo' are the star impedances multiplied by the proper tn
formation constant. If p is the ratio of secondary to primary this trs-
formation constant is l/3p2. The zero phase sequence component of i

currents in the primary delta is purely a magnetizing current and is neglin

The terminal e.m.fs. of the secondary circuit are given by the symii"
component e.m.fs. EUo, EUi and EUi where
Euo = pSjdAiZAt- IAiZai)
Bui = pV^3}TaiZo
EU2= -pV^jlAtZo
436
 —
TRANSFORMERS Sec. 6-165

1 zero phase sequence component is absent if the transformers are

ik The secondary positive and negative phase sequence components <rf

ir It are _ ,
/al jAl .
)

V3p (66)

m^^-'-
Vsp
I If the neutral point of the star secondary
.
is solidly grounded,
giind on one line will be equivalent to a short-circuit across one pair of
rinals of the generators through an impedance equal to that of one
81 ormer measured across the secondary terminals plus the line and
•od-return impedance up to the point of short-circuit multiplied by
'l

1 .
is not extensively used.
The "T" connection It has an ad-
" connection in being more nearly symmetrical if the
"V
u ge over the
rcr taps have been provided. As in the case of the "V" connection
transformers of a bank of delta-connected transformers, one of which
lEiiled, may be connected in "T
" and if the 10 per cent, taps be used
ir 18 teaser transformer the transformation will be more nearly sym-
le cal than if the "V" connection were used. Where "T " connected
a formers are installed they may later be changed to delta with the
ifion of one more transformer and an incrt^ase in rating of the bank of

(a) Correct Way (6) Wrong Way

Fig. 34. "T" Connected Transformers.

i cent.
r In the "T" connection (Fig. 34) the transformer known AD
9 "teaser" transformer may be a duplicate of the main transformer so
3

) be interchangeable with it, and it may or may not be provided with

n .B per cent. taps. Its rated capacity will then be 15.5 per cent, more
10 than actually necessary. The main transformer operates at a power
kc of 0.866, and therefore if the two transformers are duplicates their
-

rt' rated capacity will be 15.5 per cent, greater than the capacity of the

«. n kv-a., or each transformer must have a rating of 0.577 of the kv-a.

el;red. If the transformers are not interchangeable the teaser may
e iuced to a rating of one-half the kv-a. delivered.
,
K\ is the impedance of the teaser transformer with the secondary short-
ir- ted, and if Z2 is that of the main transformer through one-half of the

Jcdary with the corresponding half of the secondary being short-circuited,

Dif Zo and Zo' are the positive and negative phase-sequence impedances
f 3 symmetrical star-connected load referred to the primary.

Z1+2Z1
Zo>-f- )^.i-^ -Ea,
lAi =

(67)

7aj =
(^,+iii^)(z..+-±-)-(£i^)
437
 ! «

Sec. 6-167 TRANSFORMERS

In connecting transformers in "T " care should be taken to keepi
relative phase sequence of the windings the same, other-wis(i
impedance of the main transformer may be excessively high and cau»|
due unbalance. Fig. 34 illustrates the right and the wrong way. |
and Zi are equal the system will transform symmetrically.

Fig. 35.
—'Ihree-phase to six-phase —
Fig. 36. Three-phase to six--'
transformation, double delta. transformation, double St'
16T. Three-phase to six-phase, double delta. If two delta-conr •
banks of transformers be taken, and the polarity of one bank be rev »
the two banks together will furnish six-phase e.m.f. The relations be e
the secondaries is indicated in Fig. 35. Instead of using two banks o
formers, it is usual to place two equal secondary windings on eai
former and connect one set so as to, give opposite polarity to the ot
168. Three-phase to six-phase, diametrical. Similarly, if the
sets be connected in star, one set having its windings reversely conr
with respect to the other set (Fig. 36), we shall have six-phase e.m.f 1

is not necessary in this transformation when the neutral connection a

quired, to have two secondary windings; instead a middle tap m b
brought out, all the middle taps of the three transformers being com «
together to form the neutral.
169. The interconnected-star con-
nection shown in Fig. 37 is used in
connection with direct-current three-
wire distributing systems. This con-
nection permits continuous current in
the neutral wire to flow through the
transformers without magnetizing
them.
CONSTANT-CURRENT
TRANSFORMERS
170. The constant- current
transformer depends for its regu-
lationon the force of repulsion
between the primary and the
secondary coils which carry cur-
rents that are in opposite time-phase.
Referring to Fig. 35 and Fig. 4, as the
I oad impedance decreases, the current
will first increase, if the quantities
(Li — M) and {Li — M) remain constant,
but if the latter increases in the right
proportion the current will remain
constant. As the load impedance Fig. 37
To-^jxo isdecreased,the total reactance
in the secondary circuit will decrease, _ _

and the short-circuit reactance of the primary circuit will more

spending amount. The ratio of current transformation will thereio
practically constant throughout the range. The apparatus may
considered as a device to maintain a constant effective primary ir
independent of the load. The short-circuit impedance with full-L
separation should be us low as consistent with a reasonable cost or
-

tory operation, but with no-load separation it should be high enij

limit the current to its normal value. .Sometimes the transformer is otM

437a
 TRANSFORMERS Sec. 6-171

portion, only of the load

take care of the cutting out of a
i'^regulation to
odance, in which case the short-
j«it impedance voltage of the
rary circuit for normal current
i'be less than the primary
im-
r.ed voltage.
1 In the design of
constant-
uent transformers for tung-
t^ lamps, requiring
a given total
.UDer of ky-a., a smaller trans-
irfer is required than that for arc
MS of the same kv-a. rating, on
I! ant of the low power-factor of
h irc lamp. The design may be
m along the same general hues as
01 ower transformers, except
that
h hort dimension of the coil space
ri )e determined from the
effective
hi -circuit impedance of the regu-
at with full-load coil separation,
v\ the long dimension will be dc-
•

,ei ined by the no-load

short-circuit
m dance required, and the length
)f le coils. The transformers are
liiooled, the nature of the design
ifi'ding free access of air to all
m'ing parts.
2. Mechanical design and
ic stments. The design usually
BO arises one stationary coil and a,
m< ng coil, the latter being the pri-
m /, with a suitable counter-
(
W(ht, as in Fig. 38. both When
CO are movable they are usually
ar ig3d to counter-balance each
ot r by means of lever arms or
wlls. In both types, adjusting
W( hts are required to obtain proper
baice; adjustment also may be
Fig. 38.
tor transformer.
—
Constant-current regula-

nessary in the relative lengths of

le^ arms at different positions. dash pot should be provided to prevent
A
puping of the regulator and flickering of the lamps. Ten per cent, primary
voltage taps above and
below normal are some-
times provided.
173. Types and char-
acteristics. The one
general type now in use,
which experience has
shown most efficient, con-
sists of a shell-type mag-
netic circuit of rectangular
or cruciform cross-section,
^ witha movable coilsystem
^10.3 9. — Magnetic _, ^„
Fig 40.— Cross-8 e c-
^ described in Par. 172.
^lit of constant cur- tion of cruciform core oi j^^ Formulas for
Ter regulator. constant current regu- constant-current
f
lator. transformers. The for-
m the effective primary inductance and repulsive force are given below:
is for
th symbols refer to the dimensions shown in Fig. 39 and Fig. 40. The
iri'ctance for a rectangular-core 5egulator is

2b (henrys) (68)
] \
a+b

4376
 Sec. 6-175 TRANSFORMERS
The inductance for a cruciform-core regulator ia
, 4xCW2 / 7.6
(henrys)
(0.23 + log ^J
For each case the repulsive force F is
lOOL
(pounds)
^ V4.45X2.54XC.
The value of C
obtained by adding to the coil separation the insula
is 1

clearance between coils plus 0.45 times the length of each coil. All dir-
sions are to be measured in inches.
176. Regulation, of constant-current transformers for arc-ligh)
is usually guaranteed over a range from full load to no load. If projj
adjusted, the current should be within 0.1 amp. of the normal valuj
current for any number cf lamps between full load and no load.
176. The satisfactory working: of alternating-current arc laj
demands a certain amount of reactance in the lamp circuit. This is provj
in the transformer by its own effective reactance. The full-load operai
power-factor of an alternating-current arc-lamp system seldom ei|
70 per cent.; at small loads the power-factor is very much less. A tali
efficiency and rating is given in Par. 178.
177. Constant-current regulators for series tungsten lamp ligh |
are similar in design to the alternating-current series arc lamp const
current transformer, except that the dashpot is omitted. Ratings and r
ciencies are given in Par. 179.
178. Constant-current Transformers for Arc-Lighting; Ratings d
Efficiencies
60 Cycles
Secondary amp.

)
No. of lamps.
No. of lamps.
No. of lamps.
No. of lamps.
No. of lamps.
No. of lamps.
No. of lamps.
No. of lamps.
 TRANSFORMERS Sec. &-180

1< above values of performance are based on constant-current trans-

rirs designed to operate on a 2, 200- volt circuit; the number of lamps
wising the secondary load will depend upon
ie;)perating current and voltage.
Impressed
AUTO-TRANSFORMEKS T E.M.F.
1 Qeneral principles. The auto-trans-
.

f>r is nothing more than a transformer so

meted that part of the load current is sup- Primary
ie by the primary current, and part by the
iC'lary current. The relative amount sup-
is by each wiU depend upon the ratio of
ormation. If the ratio of transformation
Secondary
a;
the current in the secondary will ba
ge,
xj compared with that in the primary, and 551
wroportion of the load current contributed —
Fig. 4 1. Transformer
^.le primary current will be small; on the shown connected as an auto-
^ hand, if the ratio of transformation ap- transformer.
re hes unity the primary current will be large
)rared with the secondary current, and therefore the primary current
il apply the greater portion of the load. Fig. 41 illustrates the connec-
o:;of a transformer for use as an auto-transformer, and gives also a phjsical
)tption of the current relations in the latter. The primary voltage
1 difference between the voltage of the supply circuit and that of the
sc dary circuit. The load current is supplied from the primary and the
ic dary in approximately inverse proportion to the respective number
1 ns in their windings.
1 Therefore, the lower the ratio of transformation,
le nailer will be the transformer required to deliver a given load, and the
10 efficient will be the transformation. The method of connectior may
B odified from that shown in Fig. 41, but the principle is unchanged.
s le load on the secondary is increased the primary voltage becomes
re3r, so that the regulation of an auto-transformer is very much better
than when used as a simple
Bus-bar transformer.
181. Types and charac-
teristics. Auto-transform-
ers may be used for every
purpose for which transforna-
ers are used, but there is
little to be gained by using
them for large ratios of trans-
formation, and on high-vol-
tage work their use requires
a grounded system for the
sake of safety in operation.
?^42.- -Use of auto-transformers for par- 182. Auto-transformers
alleling transformers. for power purposes may
be used instead of trans-
Wirs to step-up or step-down the voltage of a grounded transmission
n^ Such an arrangement is found very convenient when supplying
o'j to a grounded system from a grounded supply circuit. A good
it'ple of the use of auto-transformers for power purposes is afforded by
liei'ew York, New Haven and Hartford Railroad system, in which the
I,' )-volt trolley circuit is supplied through auto-transformers at each
»<;>n from the 22,000 volt-feeder circuits. Auto-transformers may also
e «d as a means of interlinking two systems of different voltages; the
Bi -phase auto-transformer is commonly used for this purpose.

}i. Auto- transformers or balance coils are often employed to ob-

Urthe middle wire, or neutral wire, of a three-wire alternating-current
r^m. The size of balance coil used is ordinarily one that will take care of
St cent, unbalancing of the system.
n. Auto-transformers or balance coils for three- wire direct-cur-
•I systems. The connection shown in Fig. 23 of Sec. 9 is sometimes used
p (itain the neutral of a three-wire direct-current system.

li 439
 A A A ;

Sec. 6-185 TRANSFORMERS

185. Auto-transformers for producing a proper division of the lo
between transformers operating in parallel. There are several wii
in which auto-transformera may
be used for this purpose; one of these,
which a group of any number of transformers of one design may be connec
so as to operate in multiple with a group of any number of transformers'
^^^^^___^_^_____ another design, is illustra
M by Fig. 42. The illustrat
shows only single-phi
groups, but polyphase gro'i
may be paralleled in a si-
j^i^iia ilar manner.
jS ]S |g \S Another method of pa'-
2 00 KT 2 00 KT sooKVA 200 KT leling two groups of tra'-
rz rZ" TZ
formers is illustrated in ]
rir
II ]^ P 43. P
In this method it;i
t'^
necesssary to have an av-
Fig. 43.- -Use of auto-transformers for par- transformer with a num •

alleling transformers. of taps, so that the pro

tap may be used for e i

combination of groups. When paralleling two transformers of unequal •

pedance drop at their rated currents, the voltage across the whole windinK
the auto transformer will be ij

V(Iin - IlTi) 2 + (/l Jl - 7212) 2 C

The winding should be designed to have the turns in each portion inver:
proportional to the rated current of the transformer connected to it.
186. The regulation of an auto-transformer is illustrated ir>
clearly by means of a vector diagram. Fig. 44 shows the vector diagram S
step-down auto-transformer. Fig. 45 shows that of a step-up auto-trr

Fig. 44.- -Step-down. Fig. 45.— Step-up.

Figs, 44 and 45 —Vector diagrams of voltage relations in step-down
i

step-up auto-transformers.

former. as follows: OA is the primary counter e m.f. C*

The construction is
equal to OAmultiplied by the ratio of transformation. The impedanrr
BE, in the case of the step-down auto-transformer (Fig. 44) is eci
(1-m) times the short-circuit impedance voltage of the auto-tran-'
considered as a transformer with the primary short-circuited, the son
of the transformer being that portion of the winding which forms
tli

ondary of the auto-transformer, the primary being the remaining P'

'm' being the ratio of transformation. In the vector diagram
for tli'

up auto-transformer (Fig. 45) the impedance drop B.B is equal to fh^'

circuit impedance of the secondary with the primary wnding
slu

cuited, the secondary being that of the auto-transformer considereU

440
 TRANSFORMERS ScC. 6-187

tasformer. OE is the secondary e.m.f. at 100 per cent, power-

In each case
f'or the e.m.f. across the remaining portion of the winding. The
and OG is
t ng'.e HGK equal to BEF.
is The vector diagrams, Fig. 44 and Fig. 45,
B \v the regulation for a load of 100 per cent,
power-factor; the loci for any
111 of any power-factor may be obtained by following the construction
swn in Fig. 6, described under "General Theory," Par. 23.
87. The cost of an auto-tranaformer designed to deliver a given
nount of power P, depends upon the ratio of transformation. The actual
tJ' at which energy is transformed electromagnctically in the auto-trans-
E^ner, is the- true criterion of its cost; this rating may be conveniently
nrred to as the equivalent transformer rating, though it should be
tt in mind that in the auto-transformer the insulation stresses may be
dirent from those that occur in the transformer. If m
be the ratio of the
It-tension e.m.f. to the high-tension e.m.f. of the auto-transformer at no
i('l, the equivalent transformer rating will be (1 —m)P, whereP is the auto-
tiisformer rating. If to=J, the transformer rating of the auto-trans-
tcaer is one-half its auto-transformer rating. If be very m
small, the two
rings approach equality; if m
be larger, the transformer rating is very small
t< pared with the auto-transformer rating. The cost of the auto-trans-
Icier may thus be expressed in terms of a two-winding transformer with
C(ain conditions of insulation stress to be considered. Since auto-
ti .^formers are most generally used on low-voltage circuits, the effect of

t) difference in insulation stress is usually negligible.

}8. Induction starters are auto-transformers connected for opera-

ti on polyphase circuits, to reduce the voltage applied to an induction
to or at starting. Usually a number of starting-points are'' provided, so
11 the same design may be used for different starting conditions.

INSTRUMENT TRANSFORMERS
9. Voltage (shunt- type) transformers are used for many classes
Ol7ork, such as operating relays for voltage regulation and protection,
Oj ating recording instruments, power-factor meters, and switchboard
inuments, including voltmeters and wattmeters. For accurate work a
pi ntial transformer should carry the load of one instrument only, and
Blild be compensated for this load. ^
0. In the design of voltage (shunt- type) transformers it is im-
P'ant to keep the weight of iron and the effective impedance as low as
pdble; therefore the insulating material used must be highly efficient as an
in ator, and the coils must be so subdivided, wound, and insulated as to
oc py the minimum amount of space. The induction must be fairly low, so
as avoid distortion of wave form due to the exciting current.
)

1. Compensation for the effect of the load current and the ez-
ci ig current may be calculated from the equivalent circuit as discussed
in ar. 19, under "General Theory." No definite rules can be laid; the
b« guide is a comparison between calculated values and test results.
2. Voltage transformers are manufactured to operate on all
TOiges, up to 100,000 volts. For very high voltages the design of a
re ble transformer of low cost becomes exceedingly difficult; the cost of
th crminals alone is a very large item.
3. Current (series type) transformers. It has been shown that in
su- transformers the effect of wave-form distortion of the secondary cur-
re on the accuracy of measurements is so small as to be undetectable, even
wi the most accurate instruments available. It follows that in considering
an "larticular load the wave form of the secondary current may be assumed
ine-wave and the equivalent sine-wave value of the exciting current
taken. It will be found convenient in practical work to consider the
- unity, and the primary current reversed in time phase so as to be
n phase with, instead of being nearly in opposition to, the secondary
it being of course understood that the phase of one of them must
rsed in a transformer. Then, referring to Fig. 4 under "General
(Par. 19 to Par, 22), we find that the induced voltage in the sec-
'Mrcuit under load of impedance Zo = Ro-[-j<x>Lo is

I2[R2 + flo +yI (o,[L2 - M] + «Lo (72)

j ]

441
Sec. 6-194 TRANSFORMERS
The mean induction in the core will depend on this e.m.f. and may be foul
by means of Eq. 4. Let the angle of lag of the exciting current behind 'li

induced e.m.f. be a and let its value considered with reference to the secoi'
ary winding helm; then if the angle of lead of the induced e.m.f. over,
be 9, determined by the formula,
„ &) (Li — M) -\- wLo
tan9=
.

i; r^i^ r
R2 + R0 ^
*^'

we shall have

I^='I^[yjl+[^)W^.o.ie-a,y^ (

where and a are already defined, and the value of 81 is found from the form-

-f^ sin {e — a)
li
tan 01 —
1 + ," cos (g - a)
The quantity under the radical in Eq. 74 is the factor by which the ratio
turns miist be multiplied in order to get the ratio of transformation, and
is the lay of the primary current over the secondary current.

194. The important factors in the design of series (current) tran

formers are the load impedance and the effective secondary impedance I

these together determine the mean induction in the iron for a given seconda
current. These factors being fixed the excellence of the design will depe.
on the quality of the iron and the care taken in building which should
such as to make /m as small as possible. Care should be taken in t
mechanical design to avoid eddy currents in the end frames, and in t
electrical design that in the endeavor to make the induction low by usii
large number of turns this purpose is not defeated by the large increa>
secondary reactance produced thereby.
195. The eSect of these factors and'of different qualities of irci
may be studied by means of curves of ratio and phase displacement, such •

that shown in Fig. 46 which was made by a method similar to those recoi
mended by Crawford and Sharp, Aguew and others (see Sec. 3).

102
 TRANSFORMERS SeC. 6-197

V new design has been developed for high voltages which is less costly.
t consists of a core which is wound with the secondary winding, while the
)rimary winding is wound through a condenser lead which passes through
he opening of the core.
197. Correction factors for power measurements. Errors introduced
n measurements made with the use of series (.current) and shunt (potential)
ransformers are usually negligible, if the power-factor of the load measured
1high. On low power-factors the results will be inaccurate to an appreciable
egree and the calibration curves of the transformers should be used in
rder to make the necessary corrections. If the power-factor of the
lad be cos a and the angle of lead of the secondary current of the series
3urrent) transformer be di arid the angle of lead of the secondary e.m.f.
f the shunt (potential) transformer be 62, and if pi and pi are the corrections

) be applied to their name-plate or nominal ratios as indicated on the

orrection curve (Fig. 46), and further if £2 and 7j are the observed values of
18 secondary e.m.f. of the shunt (potential) transformer and the secondary
.irrent of the series (current) transformer, respectively, then

/ fl I -1 \ wattmeter reading .

he correct value for the power measured will then be obtained by multiply-
;gthe observed reading by the factor

+ ^ lpiP2
multiplied by (product of nominal ratios)
Lcos (ot — fli i

'
198. Standard current (series) transformers are designed to give a
irrent of 5 amp. in the secondary winding with full-load current in the
•imary winding, and a load of 25 volt-amp. They are made for use on
'cuits from 2,200 volts up to 20,000 volts, air-cooled, and for primary cur-
•nts of 5, 10, 15, 20, 30, 40, 50, 60, 75, 80, 100, 120, 200, 300 and 400 amp.
ransformers designed to slip over a stud or cable which constitutes a
le-turn winding, are made for primary currents from 600 amp. up to 3,000
lip. Series (current) transfofmers for higher voltages than 20,(K)0 volts
( usually oil-insulated.
instrument transformers should have their secondary
199. All
Endings grounded, because a high potential may be induced in the
^ondary winding depending on the mean potential of the primary winding
'

ground and the ratio between the electrostatic capacity of the secondary
nding to ground, and the electrostatic between primary and secondary
ndings. In addition to this in the case of current transformers precaution
)uld be taken to see that the secondary winding is short-circuited before
instrument is removed, otherwise an excessive e.m.f. will be induced in
2 secondary winding due to the line current now becoming the magnetiz-
i; current of the transformer. This is tiue of all series (current) transform-
,_but the e.m.f. becomes particularly high in transformers designed for
'

iigh degree of accuracy, and in bus-bar type transformers for 1,000 amp.
i above.
TRANSFORMERS FOR MISCELLANEOUS USES
too. Track transformers for operating signals are small transformers
iiilar in design to those used for sign lighting, hereafter described. The
f ondaries of the transformer are connected across the two rails of a track
'ile the primaries are supplied from 110 volt feeders which are in turn
(jiplied by small step-down tran.sformer8 similar to standard lighting trans-
fjmers from 60 cycles or 25 cycles 2,200- or 6,600-volt transmission lines.
A
line-drop compensator is a device for obtaining with a volt-
^01.
1 located in the generating or substation the voltage at the end of a
ter
li or at some predetermined point, and consists essentially of a reactance
,
« a resistance in series, which may be varied by means of taps.
I current A
I portional to the line current is circulated through them by means of a
8 es-type (current) transformer, and the secondary of a shunt-type (po-
ttial) transformer is connected to the proper point of one of them by
I iris
of a dial; the voltmeter or potential relay is connected between the
r tuning
terminal of the shunt-type transformer, and the proper point
o he other element of the compensation, by means of a dial. With a proper
<; ise of current transformer and with proper connections and adjustment
443
Sec. 6-202 TRANSFORMERS
of the dials the voltmeter or potential relay will indicate the voltage at th
desired point of the feeder or line for any load.
202. Theory of line-drop compensators. Refer to Fig. 6 (uni!
"General Theory"). The voltage at the station is represented bv t
secondary open-circuit voltage, and the voltage at the end of the line
centre of distribution is represented by the secondary full-load voltage; t

reactance drop and the ohmic drop of the compensator are represented !

the secondary short-circuit reactance drop and resistance drop, respectivel\

203. In order to obtain the highest accuracy with line-drop com
pensators, it is necessary that the voltmeter operate on a small rurren
compared with that passing through the compensator. Compensate-
for use with potential regulators, should be designed for larger currents th
those for use with indicating instruments.
204. Compensating transformers for neutralizing inductive dif
turbances in telephone and telegraph lines. Where telephone
telegraph circuits parallel an alternating-current traction system, hi^:
voltages may be induced in them due to electromagnetic inductioi
from the railway system. To overcome this trouble, a number of extr;
pairs of wires are placed among the other telephone wires so that thei
mutual inductance to the railway circuits is the same as those of the regula
telegraph or telephone wires. These extra wires are grounded at variou
points, and connected to the jjrimary windings of a special transformer
so that the e.m.fs. induced in them magnetize the transformer in thi
same direction. The telephone or telegraph wires are then connected t(
secondary coils of this transformer, so that the induced e.m.f. of thi
transformer opposes and neutralizes the induced e.m.f. due to the railwr
system. Since the two wires of any pair encircle the core in the same dirr
tion, the secondary windings are practically non-inductive, as far as t:
telephone currents are concerned. The transformers are usually of the cori
type construction and differ from ordinary transformers only in the largi
number of secondary coils and the manner in which they are wound so as ti
obtain freedom from cross talk. *
205. Insulating transformers for telephone lines are designed t(
protect both the telephone and the user from high voltages, due either t(
induction or accidental contact with a high-tension line. This device con
siats of a shunt transformer provided with a condenser across the primari
terminals, the purpose of the condenser being to supply the greater portioi
of the magnetizing current of the transformer under normal operation. Tb
secondary terminals are connected to the telephone in the usual way. Sucl
transformers are usually built to stand a 25,000-volt test, for 1 min.
between the windings, and between windings and case. A lightning arresto
and special fuses are generally provided for the primary circuit. Tl
secondary may be grounded if desired, or an insulated stool provided for tl
user to stand upon.
206. Extra-high-voltage testing transformers. Test voltages a
high as 375,000 volts above ground potential are becoming common, such i

test voltage requires a testing transformer equivalent in insulation strengtl

to one designed for 750,000 volts with the middle-point grounded. In t!
testing of insulators an artificial ground is commonly used for the higli'
voltages. This method of testing is economical in the respect that it requir.
a transformer insulated for only one-half the potential necessary when t(-
specifications require that one terminal be grounded; but it is open to doui
whether tests made in this manner are as exacting as those made with oi
side of the circuit grounded. Testing transformers may now be obtaim
suitable for intermittent testing up to 600,000 volts with one termin
grounded, and up to 750,000 volts with the middle-point grounded. (>:
testing transformer in present service has been tested up to 720,000 volt
effective (by spark-gap measurement), with one end grounded; another li >

been tested momentarily up to 900,000 volts, effective (by spark gap), will
the middle-point grounded. The voltage impressed on the primary i
raised either by cutting out resistance as in the potentiometer method o
controll or by employing a dial and a separate regulator transformer.
207. Bell-ringing transformers. The bell-ringing transformer, con
nected to a 110-volt, CO-cycle, lighting circuit, produces at its secondar:

*See article in Electric Journal for October, 1911, by Shaw.

444
III:
 TRANSFORMERS Sec. 6-208

irminals a voltage suitable for operating door-bells, buzzers, annunciators,

dniature incandescent lamps, or for any purpose for which dry or wet-cell
itteries are used. The transformer has the advantage over batteries that
requires no attention after it has been installed, and there is no further ex-
jnditure, since its life is probably indefinitely long; and, furthermore, the
inoyance of having bells out of order due to battery failures is done awaj
ith. The amount of energy consumed at no load is very small, being
30Ut 1 watt. Voltages of 16 or 24 volts are obtained.
[208. Transformer equipments for thawing: water pipes by electrlc-
i^y. These equipments consist of a transformer having high reactance, or
: transformer and an external reactance combined. When in operation,
e high-tension leads are connected to the main-line feeders. The sec-
idary leads may be connected to any convenient points in the piping sys-
m, so that the frozen portion is included in the circuit. The transformers
'g generally air cooled and portable.
,209. Sign-lighting transformers. The standard practice in lighting
ictric signs is to use 10-volt tungsten lamps of about 4 c-p., which have a
itt consumption per candle-power of only a little over one-fourth that of
rbon-filament lamps of the same candle-power, and to operate these lamps
multiple, using a step-down transformer by which the pressure of the
0-volt or 220-volt supply circuit is reduced to a suitable value. These
insformers are designed for use on 60 cycles, at voltages of 240, 220, or
volts, or at 120, 110, or 100 volts, and will deliver their full rated load
either 10 or 20 volts. The ratings and eflficiencies of these transformers
L>as follows, in Par. 210.
210. Table of Ratings, Efficiencies and Weights of Sign-lighting
Transformers

Rating in
 :

Sec. 6-213 TRANSFORMERS

rises under certain .specified conditions must meet the guaranteed va

Par. 219 to 223.
(e) Insulation tests. These comprise the overpotential test which '

made for the purpose of exposing any defect or injury in the insulati
between turns, between layers, and between coils; the disruptive test i

determining whether the insulation between the primary and the seconda
windings and between these two windings and ground is sufficiently stroi
Par. 224 to 227.
(f) Tests on instrument transformers; calibration.

213. Shop tests. In the case of large power transformers these te

are sometimes omitted, but in their stead each coil is very carefully inspect
during the course of winding and insulating. The tests to determine a
defects in winding are made by placing each coil on a core which is furnish
with a removable yoke, and inducing in each turn of the coil a specified e.n
A test to determine whether the insulation is intact after the coils i

assembled and the iron built in, is made by subjecting the insulation betwc
the primary and the secondary windings, and between each of these windii
and ground, to a test of several thousand volts. The transformer is th
ready for the testing department.
214. Tests to determine whether the transformer is correc
wound and assembled. The first test to make is the ratio test. T
determines whether the transformer has been wound correctly and the le:
and tap brought out in the right places. The methods used in making t

test will depend upon the transformer to be tested. Large power tr:.
formers are tested for ratio by having a fraction of the normal volt
impressed on a winding while the voltage between taps is measured by mt'
of a voltmeter, and the ratio of the tap voltage to the total is thus obtain
The ratio of the primary voltage to the secondary voltage is obtained i

the same manner. Small transformers for lighting and small power ser^
may be tested by balancing against a standard of known ratio. The sa'
method applies to shunt-type (potential) transformers for instruments.
216. Polarity test. In power transformers this test follows the n i

test, and is made by connecting two adjacent primary and second

Source of Enex^

8.C.PIug

TT«P8f.
CT
K.M.b.
Voltmetor PCl
^ ^

t=5 Small Ditt, Transf,

Beslstanoe
Box
Onlj to 1m used when tbt

Ltn Irou Lo98

VoUmeter
L.T, VolUge of the Inmsf.
under test u bejuod the. range
of the Iron Losa meter

Fio. 47. — Connection for making iron-loss test.

leads together and noting whether the secondary e.m.f. is thereby ai

to the primary e.m.f., or subtracted from it. In the case of small ti s-

formers, the ratios of which are tested by comparison with a standard le

polarity is given at once by reference to that of the standard. Thus le

»•
apparatus for testing may be so arranged that if the polarity of the ti
446
 —
TRANSFORMERS Sec. 6-216

rmer to be tested is wrong, a red pilot lamp becomes energized. This

ethod of determining polarity is characteristic of all balance methods
.plied to alternating-current work, such as, for instance, the shunt-resist-
ire method of testing the ratio and the phase displacement of series-type
urrent) transformers.
216. Measurements of losses comprise those for core-loss, and those
r copper-loss and impedance volts. The core-loss consists of both hys-
•resis and eddy-current losses in the iron. Since the " fiux-linkages " are
e time integral of the induced e.m.f., and since all commercial e.m.f.
ive-forms contain the odd harmonics only, the maximum value of B will
determined by the average value of E. And therefore the hysteresis
ss will depend, not on the root-mean-square value of E, but on its average
ilue. The eddy-current loss, on the other hand, will depend on the root-
^ean-square value of E. Hence the core-loss, to be mea.sured accurately,
be obtained on a circuit having an e.m.f. wave, whose average
ust either
,ilue and root-mean-square value have a specified ratio (the standard wave
'.
and the standard ratio cf root-mean-square to average
sine-wave
ilue is 1.11), or else compensation must be made for any deviation from
lis ratio by some device which indicates how much to raise or lower the
)ltage to obtain the correct loss. It is essential in the former case that
le wave form at the terminals of the transformer, after correction has
, ',;en made for wave distortion due to voltage, regulating devices, etc., shall
* such that this ratio is equal to 1.11.
! The second method may be
\ .led with the aid of an "iron-loss voltmeter" (Sec. 3). Fig. 47 shows
le connections used for measuring iron-loss. When the iron-loss voltmeter
jUsed it should be connected in circuit with the root-mean-square voltmeter:
)th readings should be noted and correction made for the shunt loss of the
Wattmeter from the readings of the root-mean-square voltmeter. Strictly
leaking, the loss should be taken with both voltmeters in circuit and correc-
ons made for their losses also. The iron-loss voltmeter is provided with a
ale by which its loss may be read directly.
'
217. In measuriner the core-loss care should be taken that when a
Drtion, only, of the winding of the transformer is used it is so situated that
'
Sonne of Energy

T-O-^ r^^i
/WWWV1
rS"51a=n|c^

;
Fia. 48. — Connections for making copper-loss and impedance-drop test.
le magnetic leakage is practically the same as under normal open-circuit
mditions. In general it is better to sacrifice a little in convenience and use
le whole winding, than run the chance of error by using
a portion of the
inding. The value of impressed voltage used when the measurement is
ade on the secondary side should be the rated voltage plus the secondary
i drop. The equivalent sine-vrave exciting current is obtained by
447
 )

Sec. 6-218 TRANSFORMERS

the ammeter reading, and the true-watts component is obtained by dlTirr
the observed core-loss by the value of rated secondary voltage plus a
secondary IR drop. i

218. Copper-loss and impedance volts. This measurement is n e

by short-circuiting one winding (properly it should be the primary wind;)
and circulating rated full-load current in the other, observing the losn
watts and the impressed voltage. The connections for the test shoul e
made as shown in Fig. 48. The current should be adjusted with the i>.
meter and the wattmeter shunt winding disconnected. The wattmr
may then be read first, followed by the voltmeter. If the exciting curt
of the transformer is high, a correction, obtained from Eq. 11, Par. I,

miust be added to the copper-loss measured as above. The copper-loss 8( >-

tained will be the true copper-loss of the transformer and includes theec-
current loss in the conductors. By dividing the copper-loss by the rated >
put, the effective IR drop, expressed as a fraction of the rated voltage, wi e
obtained. Divide the observed voltage by the rated voltage, and the eff
impedance-drop, expressed as a fractionof the rated voltage, willbeobt
the effective reactance drop, expressed as a fraction of the rated voltagi
then be obtained by taking the square root of the difference of the squ s
of these two quantities. Efficiencies and regulation may then be comp d
from these results by the usual formulas, which are given under "Gen.l
Theory," Par. 24 to Par. 26.
219. Tests for efficiency of cooling include the measurement of tein(i-
ture rise above the cooling medium at various loads. Resistance ^lea.'^
ments are also included, because they are necessary to determine the i ri.'

temperature of the copper.

220. Resistance measurements may be made with a Wheatston .r

a Kelvin bridge of the proper range. The conditions for mea.'iuri-

cold resistance should be carefully prepared, so that the apparatus
resistance is under determination will be at the temperature of tlu
rounding air. If the temperature of the room fluctuates, it is recommei d
that an idle unit be employed, of the same design as those on test, it
resistance of the winding of the idle transformer may then be used i
basis from which to measure the temperature, by increase of resistance olu
loaded transformer.
221. Methods of loading. There are various methods of artificj
loading transformers. The best method, where two or more tranaforrt

Tooirurmen on Telt
Fig. 49. —-Method of artificially loading a transformer(opposition metl
are obtainable, the opposition method.
is The simplest arrangemeso
tliis method is illustrated in Fig. 49. Two transformers are connecte»
if for multiple operation; then one of the connections of one set of windit
i

448
 TRANSFORMERS SeC. 6-222

'ned full-load current is circulated in the circuit from an external

and
energy.
roe of Either pair of windings ia then excited from a suitable
proper voltage and frequency.
roe at It is preferable that the time-phase
Hions of the exciting e.m.f., and the current-circulating e.m.f.,
should be
•able of variation, so that the conditions of load may be varied to suit
erent requirements.
22. Measurements of temperature. After steady conditions have
n reached, as indicated by thermometers placed at various points in
; windings, preparations should bemade for taking the hot resistance.
S prompt measurement, the instruments should be set before-hand
insure
.the expected values, so that a quick adjustment may be made.
23. In making the heat test both wattmeters and
ammeters
y be used. The wattmeters may be arranged to read the total core-
i
the total copper-loss, and the
,
power input or output. The power-factor
he load may be obtained and adjusted.
!24. Insulation tests include overpotential tests for the purpose
of
ijrmining whether the insulation between turns and coils is intact; and
Eruptive tests to determine the condition of insulation between primary
r secondary windings and between these windings and ground. Some-
es, also, the insulation resistance between primary and secondary
iidings is measured.
,26. Overpotential test. For large transformers an overpotential
: double the rated low-tension voltage is usually applied for 5 min.
; he low-tension terminals. It is desirable when making this test on high-
, ;age transformers to disconnect the high-voltage winding so as to reduce
. voltage. In small transformers an overpotential of five times rated
. .age at 500 cycles may be used. The overpotential test should be made
i le the transformer is hot.

;26. Disruptive test. In making this test on power transformers the

-tension winding is connected to the iron and to ground, and the primary
r ding is connected to one end of a testing transformer, the other end of
t ch is grounded. A sphere spark-gap should always be used, with tests
i ve 50,000 volts, for measuring the voltage, as a rise in voltage is likely to
:ur in the testing transformer. The usual test is from two to two and
:-half times hne voltage. The Standards Committee of the A. I. E. E.
i'. definite recommendations in regard to the tests to employ, and it is
3 ternary to follow them. Small transformers for operation on 2,200-volt
: uits should receive a test of 10,000 volts for 1 min.

27. Tests on instrument transformers. Instrument transformers,

hey are to be used for precise measurements, must have a caUbration
eve made for the conditions of load under which they will be operated.
!se calibration curves give the ratio and the phase displacement for
'

c erent current-values. For methods of obtaining calibration curves on

i rument transformers, see Sec. 3.
28. Instruments used for testing should be carefully chosen.
1'ause of series (current) transformers and shunt (potential) transformers
E-uld be avoided unless they have been calibrated for the particular instru-
f'ats to be used. In testing with high-voltage transformers at pressures
f've 50,000 volts, a sphere spark-gap should always be used, both for meas-
lag the maximum of the applied voltage and also for the protection of both
t testing transformer and the apparatus to be tested. The sphere gap
( be relied on as an accurate method of measuring the maximum value of
t applied voltage.
*

INSTALLATION, CAEE AND OPERATION

29. General. Atransformer is usually very rugged and is capable of
\li3tanding a great deal of abuse; nevertheless, it will be found to respond
tgood treatment by exhibiting longer life and higher operating efficiency.
Farnsworth, S. W. and Fortescue, C. L. G. "Sphere Spark Gap;"
ins.A. I. E. E., Vol. XXXII, pt. 1, p. 733.
phubb, L. W. and Fortescue, C. L. G. " Calibration of the Sphere-gap,"
lin«. A. I. E. E., Vol. XXXII, pt. 1, p. 739. Discussion by Peck, p. 812.

449
 )

Sec. 6-230 TRAySFORMERfi

230. Shipping and unpacking. Before leaving the factory, tra

formers are carefully packed. They are now generally shipped in tl'
tanks with oil, and are ready for operation as soon as they arrive; bu-
always a wise precaution, particularly with high-voltage transform.
draw off from the bottom of the tank some of the oil and give it tht
disruptive test. If the dielectric strength is not high enough the oil
be dehydrated (Par. 239). This may be done without removin.
transformer from the tank, by drawing the oil from the bottom of tin
through the dehydrating outfit and returning it at the top; this should
continued until repeated tests show the oil to be in good condition. If :

transformer has been shipped in a packing case, and is one of a high-volt t

type, it should be dried out before installation, unless it is hermetic:'

sealed in an air-tight metal casing. The safest and best method that \
be used to dry out a transformer is to force dry air at a temperature oft
deg. cent, through the windings. Grid resistances may be used for heats'
the air, and it may be forced tlirough the windings by a blower.
231. Precautions in making connections. When installed ready
operation the transformers should be carefully inspected to see that they
all connected properly, both internally and externally; that all switcl;
apparatus is in good working order; and if new banks are to run in multj
with previously installed banks, it should be noted that they are conned
at the proper operating taps, and so as to have the same polarity as the or
banks. If the new transformers are of the same manufacture as the ,

the polarity will be the same as that of the old, if the banks are simil:/
connected. If they are of different manufacture from the old, the pola;
when similarly connected may be such as to make parallel operation imi-
sible. It is therefore a wise precaution to check up the relative polariti
the old and the new banks before connecting together. This may be d^
by connecting the new bank on the high-tension side and connecting onil
the low-tension terminals to the common bus bar; then, with a voltmel
and if necessary with the aid of a shunt (potential) transformer, aiem
the voltage between the other two terminals and the respective busses i|
which they are to connect (a bank of lamps may be used instead of a ^!*
meter, with 110- or 220-volt connections) and observe the following ru !

(a) If the polarities are alike the voltmeter will read zero, in each ci,
(b) If the polarities are reversed the voltmeter will read, in each c-,
double the secondary voltage. The remedy is to reverse the connectiorl
the low-tension leads of each transformer in the new bank. (In three-p t
transformers it may be found more convenient to reverse the connc •
"

of the high-tension coils.)

(c) In three-phase transformers the following cases may b^
in addition to the above. Having two similarly located low-tensi
minals, of the old and new banks, connected together, the high-t
terminals of each bank being similarly connected to the same soi.
e.m.f., measure the voltage between corresponding free low-tension ten
(c-1) If one voltmeter reads the secondary voltage correctl.\
the other reads double this value, the external polarity of the twi
formers is the same, but the terminals are in different order. The rei
to interchange the internal low-tension connections to the terminal
new transformers, so that the lead connected to the terminal for wlii
voltmeter reads double voltage will take the place of the lead connc
the terminal tied to the corresponding terminal of the old transi
Equivalent external transposition may be made instead.
(c-2) If one voltmeter reads zero and the other reads 1.73 t

the secondary voltage, then we have a case of reversed external i)i

and transposition of terminals, combined. The remedy in the case

delta connection is to disconnect the ends of the two coils from the tcr
showing high voltage and connect the other ends of these two coils '

terminal; the ends previously removed should then be connected to ts

remaining terminals, so that a coil that was originally connected to any
these two terminals will now be connected to the other one. An equi
change of connections must be made in the case of a star connection
232. Multiple connections. Transformers having like primar\
secondary connections may he run in multiple with one another, but '
'

formers having unlike primary and secondary connections cannot be i

<

to run in multiple with the former except by the use of auxiliary d. -

450
 TRANSFORMERS SeC. 6-233

as auto-transformers. It is of great importanee, therefore, when buying

fiformers for multiple operation with
previously installed banks, that
onnections of the latter are given.
3Where independent energy sources supply each bank of trana-
.
lers relativepolarity is of no consequence, nor is it of any impor-
whether the primaries and the secondaries are both delta-connected,
>

!ie delta-connected and the

other star-connected.

A Causes of insulation failures. First, inadequate insulation

* Kth at the point
of failure. Second, imperfect mechanical supporting
ibracing of coils, so that when subjected to the short-circuits
that occur
Jr operation, the coils are deflected or buckled, thereby tearing or weak-
otherwise would be quite adequate. Third,
t' the insulation, which
3
'design in the matter of cooling, such that while showing a
normal
•..erature by thermometer or by rise of
resistance, the windings have
jons that are blanketed or far removed from the cooling medium; in
words, have "hot spots."
- Such a condition will, in the course of time,
u a weakening of the mechanical strength of the fibrous materials of which
!

it'asulation is composed, so that with the least jar the

insulation is broken
1 vn internal short-circuit results. Fourth, imperfect operation of appara-
i n the line, such as circuit-breakers,
electrolytic lightning arresters, etc.
ijL, improper operating conditions, such as overloading, or multiple opera-
c without a proper division of load. Sixth, lack of care in regard to condi-
c of oil, dirt, moisture, etc. Seventh, direct stroke of lightning. Assum-
i; hat the transformer has been carefully designed in every feature, only
uast four causes need receive consideration.
i5. Line disturbances. The operation of circuit-breakers, charging
'.;ctrolytic arresters, breaking down of line insulators, and short-circuits
ihe line, all create disturbances which produce more or less stress on
uransformer insulation; but transformers are insulated to withstand the
^ses due to the above causes as they arise under normal working con-
i'tas. When, however, circuit-breakers fail to operate properly, these
lies may be unusually severe. It is therefore important to see that all
H ctive devices are in perfect working order. With certain connections,
" T" '-connection, the charging of elec-
X as the Scott connection and the
ftic lightning arresters may cause unusually severe stresses. The
q.vior of the transformers under such conditions should be carefully
ftrved and if any unusual conditions are present they should be looked
It

6. Improper operating conditions are very often the source of trans-

);er failures;particularly due to the fact that lack of care in other matters
c- hand in hand with carelessness in operation. Conditions sometimes
r- under which it is imperative that a transformer be overloaded for a
3';derable length of time. After such an overload, the transformer at
Jfirst opportunity should be examined to see that the ducts have not be-
3i! clogged by any deposits from the oil. Transformers should not be
pated for any great length of time on a system, one line of which has
eme grounded; the factor of safety in such operation is only one-half
fiiat under normal operating conditions.

:7. Grounded secondaries. Troubles may be caused when supplying

D-?y for Ughting from high-voltage polyphase circuits, due to the relative
I'ro.static capacity of the high-tension and low-tension circuits, to each
tr and to earth. This condition may cause high insulation stresses in
h low-tension circuit, and may shock anyone touching the low-tension
iiiit sufficiently to cause death. The only remedy for this condition is
around the secondary circuit, preferably at the neutral point. (See
J onal Electrical Code, and also Sec. 12 and 13.)

8. Care of transformer oil. Lack of attention to such details as

b periodic inspection of transformers, and testing of the oil, is responsible
i>nost transformer failures. The oil in a high-voltage transformer should
K sted once a month and if its strength is below par it should be dehydrated
I. 239). It must be remembered that the oil furnishes one-half the
Qiation strength of the transformer.

(9. The best method for dehydrating oil is by the use of the filter-
>*3 type of dehydrator. In this type the oil is pumped through several

451
Sec. 6-240 TRANSFORMERS
thicknesses of blotting paper. When using this apparatus it shoulci
seen that the paper is carefully dried, and it is better to soak it, first ofj
in clean oil that is perfectly dry. Fig. 50 shows this form of oil dehydrt'
When the oil is in very bad condition, the paper should be changed from li
to time, as often as found necessary. Oil in first-class condition should bii
down at not less than 40,000 volts, with a gap of 0.15 in. between
spheres.

Fia. 50. — Filter press type of oil dehydrator.

240. Regulation of quantity of cooling medium. When

cooled transformers are subjected to heavy overloads the water rate
be increased correspondingly. Any oil-immersed transformer will
stand a heavy load, for a short period very much better than an air
transformer. Allowance should therefore be made in operation for tl
ing characteristics of the transformers, and where artificial means ar
for cooling, the cooling may be improved under abnormal load con
by using more of the cooling medium.
241. The oil-piping layout of transformers when installed sh<
arranged so that the oil in any unit may be filtered without disturli
others; there ate several obvious methods of accomplishing this. Wl
scheme be used, care should be taken that all the air is removed fn
oil in the transformer tanks; this may be done by creating a vacuum '

the cover during the process of pumping.*

242. A transformer when burned out or defective should imme<ii
be replaced by a spare unit if one is available. A careful examin
should then be made of the windings; if nothing is disclosed, the tran.sii
should be returned to its tank and measurements made of its open-c
losses. If there are any short-circuited turns or layers, the open-i-
losses will be abnormally high. The location of the trouble can gei.
be traced by the blackening due to smoke, and by feeling the coil.",
first removing the exciting voltage, for the point of highest tenipor:
If either of these methods fail, measurement may be taken of the reli-
ef primary and secondary windings; a short-circuit will be indicate'
lower resistance than normal. In many cases, however, a short
which cripples the transformer may involve only a few turns in a larv
number, so that the continuous-current resistance measurement lu..
be sensitive enough to detect it.
243. Formation of scale in cooling coils. A water-cooled transf '

may progressively increase in temperature and appear to be di

to no apparent cause. In such a case the cause of the trouble '

be traced to the water supply, which will be found to contain fc^

in solution, such as lime and carbonates; these impurities, when the w:
comes heated in passing through the tubes, are precipitated in the i

• Electrical World, Feb., 1913, p. 360.

452
 REGULATORS Sec. 6-244

r, which, in addition to being a bad conductor of heat, chokes the flow of

sr.
Criterion for replacing inefllcient transformers with units of
4.
tier eflSciency. A transformer should be replaced by another of higher
f jncywhen the difference in cost of operating the two is greater than the
f est' on the additional capital that would be invested in the change.
I
ions will dififer in regard to the proper method of computing the cost of
3 iting a transformer. The author's opinion is that the energy consumed
mlosses should constitute a fixed charge to the consumer depending
When it is found by changing to a more
p his maximum demand.
that
ii>rn line of transformers the fixed charge, after making prpper allowances
interest and depreciation on both the old and the new, is less than the
i:er fixed charge the change should be made.

REGULATORS
POTENTIAL EEGULATOES
6.General principles. The principle of operation of all potential
) changing the mutual inductance between the pri-
ators consists in
i,' and the secondary windings of a transformer or auto-transformer,
,1 r by mechanical means or by changing the ratio of the two windings.

6. The variable-ratio type of regulator is simply a transformer

r ided with means for changing the secondary e.m.f., either by cutting out
cons of the winding, or by opposing or adding the e.m.f. of auxiliary
i ings of the transformer provided for this purpose. These auxiliary
i ings are pro\-ided with taps, so that their voltage may be increased or
e :ased, step by step. The secondary winding proper has only a few
I the voltages of which are "bucked" or "boosted" by the auxiliary
9 according to the position of the regulator drum. In this way a
II range of regulation may be provided with a comparatively simple
j)ment. Auto-transformers are some-
113 used instead of the auxiliary wind-

if They have some advantage over the

liiary winding scheme because finer
tu are obtainable thereby.
'7. The single-phase induction
elator depends upon mechanical
1! IS to produce this change in mutual
1 stance (Par. 246) It consists usually
.

f stationary primary wound in a slotted

e and a secondary wound on a drum-
bed core which is rotatable with re-
p to the primary. The secondary
,

.'j. is always practically in time phase

d, or in time phase opposition to, the
.i in the primary circuit.
.

iS. The simplest conception of an

Diction regulator is a transformer with
eible mutual inductance, and it may
h'fore be represented by the circuit
Fig. 51.—Horizontal cross-sec-
tion"or'singre-phase' induction
b-n m
Fig. 4 (Par. 19). When
be- M regulator.
0;s zero, the secondary inductance is L2,
f h is very high: to overcome this defect another independent winding,
hr-circuited on itself, is wound on the primary core in electrical space-
lUrature with the primary winding. A
current is induced in this ter-
li' winding, depending upon the electrical space-phase difference between

t d the secondary winding, which reduces the self-inductance of the latter.

Definitions of currents in a potential regulator. The secondary

9.
the line current, and the primary load current is that current
!t.;nt is
»:h counterbalances the magnetizing or demagnetizing effect of the
»idary current.
. 0. The variation of secondary e.m.f. with change in angular posi-
;ii for a certain typo of single-phase potential regulator is shown in Fig.
W A vertical cross-section is shown in Fig. 52.

453
Sec 6-251 REGULATORS

261. The polyphase regrulator in every essential detail, is a polyph

induction motor, the polyphase coil-wound rotor of which can be locked,
any position desired. Thcpri
Q windings are connected aero
supply lines, precisely lik
primary windings of a pol>
induction motor; howcvci
secondary phase-windings
D induction regulator, ii
of being closed upon them-
as is true of the secondary
ings of an induction motor,
separately insulated and .-.

rateiy connected in series wit'

delivery circuits from the
lator. When polyphase <

are impressed upon the pi

windings, the e.m.f. genera
each secondary coil is of the
frequency as the primary
and its value is entirely in
dent of the mechanical y^
of the movable member; tin
phase position of their <•

however, varies directly wi

electrical space position
movable member. (Cc
with the single-phase in<l
regulator; see Par. 247.)
resultant delivered e.m.f.
 REGULATORS SeC. 6-253

I nore primary phase-windings, and the reactance of the secondary is re-

l3d to that due to the magnetic leakage between the stationary and the
fable members.
Feeder voltage regulators, of either the step-by-step type or the
;)3.
I type, may be operated by a motor, which in turn may be controlled
ictioii
),i voltage relay arranged to start the motor in positive or negative direc-
i according as the voltage is low or high. A polyphase induction motor is
ijilly employed, except when polyphase energy is not available; in this
!( a single-phase series motor may be used. The motor is stopped, when
i relay opens, by means of a magnetically operated brake. The relay may
)ii3ed in connection with a line-drop compensator (Par. 201), so that the
7] age at the centre of distribution may be automatically kept constant at
II desired value.
54. Pole-type feeder voltage regulators. Small feeder voltage regu-
f rs arranged for mounting on poles have been brought out by one firm
jinanufacturers. In many lighting systems, consumers may be supplied
*a one common feeder in such a way that there is no definite centre of
liribution; thus consumers on short branch feeders may receive per-
ely satisfactory service, whereas others served from long branches may
eive poor service due to the larger drop in such branches. It is claimed
!• a saving may be effected by installing one of these pole-type, automatic,

q er voltage regulators instead of increasing the cross-section of the branch

cars. The regulator proper consists of a shuttle-shaped rotor on which
;E primary is wound in one coil; the rotor also carries the tertiary short-
liuited winding. The secondary is a single, form-wound, undistributed
*ding, fitting in two slots in the stationary core.
:he regulator is operated by a single-phase induction motor provided with
I irting clutch, and is controlled by a voltage relay which may be adjusted

Ciny voltage from 10 per cent, above to 10 per cent, below normal. The
ly may also be used in connection with a line-drop compensator, which
\ to be installed outside of the regulator. The regulator and mechanism
I suspended in a cast-iron tank, and the lower part, containing the regu-
i and coils, is filled with oil.
r core
Vector diagram of e.m.fs. in polyphase regulator. Referring
>6.
;t OA represent the e.m.f of a certain primary phase both in value
ig. 54, let .

I! time-phase position. Let OE (or OD) represent the e.m.f. of the cor-
•e ending secondary phase-winding in
ti positive (or maximum neg-
maximum y^ "^^ ^
iie) boost position. Let (or OD) OE /^ /V^~^
//
li iltaneously represent the mechan- / \~^ --^..^^^
(in electrical space degrees) """^-^^^
fc position

51he moving member when

the second- ir
/

^ ^r
^
\
^»- —
i| e.m.f. is in time-phase with (or time- '-> iJ A
? 16 opposition to) the primary e.m.f. Fio. 54.
[liny mechanical position of the mov-
—
Vector diagram of poly-
phase inductor regulator.
E member, such as OD, the secondary
i. f. has a value equal to OE (or OD) and its tlmephase position is cor-
ral y represented by the line OL provided that the "revolving field"
wh is the resultant of the fluxes set up by the separate primary phases is
Kitant in magnitude. In Fig. 54 the primary e.m.f. is OA and the seo-
5-;iry e.m.f. is Ob, the resultant e.m.f. is AB.

CURRENT REGULATORS
General principles. This apparatus generally consists of an ad-
'•6.
K'able reactance, which may comprise a winding on an open magnetic
51 -lit. The coil is counterbalanced, so that with a change in the load re-
*' nee the coil will so adjust itself with respect to the core that there will
OHO change in the value of the current. If a large reactance be placed in
K'.s with a lesser non-inductive resistance, and a constant e.m.f. be im-
[J.sed, the current will vary but slightly with this resistance "all in" or
out" of circuit. The actual ratio of the currents with resistance " all in"
jl

&' "all out" will be equal to the value of vl —

(power-factor) 2, the power-
fB;>r being the value with resistance all in. It is evident that if the operat-
lEpower-factor be made low enoxigh, a series system of incandescent lamps
Di be operated
at constant current, from a constant-potential source, with
^'' little
variation in the series reactance.

455
 . 1

Sec. 6-257 reactors

267. Limitations. The constant-current regulator has a limit)
application combined with a vapor convertor for supplying light for moti(
picture machines, but for general lighting it cannot advantageously take t;
place of the constant-current transformer, since it requires an additioi
transformer for insulation purposes (see National Electrical Code)
268. Types and characteristics. The usual type manufactured
air-cooled and of the form described in Par. 256. An automatic consta:
current regulator may also be made by connecting in opposition two c(
which surround a closed magnetic circuit, using their leakage reactance
the regulating reactance. The two coils are pivoted so as to approach ec
other at the middle of the core. In action they will repel each other wit'
force nearly proportional to the current, for any position; with proper count
weight, therefore, the current will automatically be kept constant.
269. A motor-controlled potential regulator may be used as
constant-cvirrent regulator by controlling it from a constant-curr
relay; it is usually, however, too sluggish in operation to give perfect sa
faction.

REACTORS
260. Oeneral types. Reactors, choke coils, or reactances for pov
purposes may be divided into two classes, viz., those in which iron is ui
and those in which no magnetic material whatever is used. The first 1
consists of a coil encircling a circuit of iron which is usually broken byi
air-gap or a series of air-gaps. The second type is simply a carefully <•
structed, circular coil of rectangular cross-section, of suitable proport i

for cooling, and well supported mechanically.

261. Iron core reactances. The fundamental equations and gen 1

design are the same as for constant-potential transformers. The air-)

should be subdivided so as to avoid concentrated leakage, which causes er
currents in the conductors (which are difficult to eliminate) and also mak t

difficult to calculate the reactance accurately. The relative amou:

copper and iron will be determined largely by the condition for min
cost, but where the conductors are very large, it is advisable to increa-
area of the core and reduce the number of turns in order to keep down e
eddy-current losses in the conductors. In winding with multiple conduct
every care should be taken to see that the reactance of each conductor d
its resistance is the same; this may be accomplished by properly distribn
the "start" and "finish" leads of the conductors.
If the length of the air-gap is /, the required inductance L, the current/*
number of turns n, the effective area of the air gaps must be obtainc
'
'

it will depend on their number and distribution. The value of (B ma,\

be calculated from this area by Eq. 4, Par. 6.
Thus the value of I will be
, 4.51n/ ,. ,
/ On.)
ffi-

where (& is the induction in lines per sq. in.

262. The current densities and the flux densities will be aboutti
same as for transformers. The methods of insulating the coils are very fi'
lar and need no special treatment here, as they are covered under the heiaj
of "Insulation," Par. 41 to Par. 47.
263. Cooling may be effected by any of the various methods appli to
transformers. The problem is the same in every particular and is tred
under that heading, Par. 61 to Par. 70.
264. Applications. Iron reactors for power purposes are i

used in connection with compound-wound rotary converters to obtaiL

pounding or overcompounding of the voltage at the continuous-ci ''
terminals. Iron reactors are also used to shunt the series coils of comjn
wound continuous-current machines, in which case they are knov ••
inductive shunts. They may be used for innumerable purposes, su' m
compensating for the leading current in cable testing; for coniiienf n«
long telephone circuits (Pupin coils); shunting series incandescent I'l*
(economy coils) to prevent an open circuit as the result of a lamp fi r«.
etc.

466
 REACTORS Sec.6-265

ii. Air reactors for precise measurements are made of a single layer
enameled wire, carefully wound on a marble cylinder that has been
e
i as nearly perfect as possible; such reactors are used as absolute stand-
[ Power-limiting reactors are described in Par. 266 and 267. The re-
•ace circuit-breaker makes use of an air reactance to limit the current
,e initial break so that a circuit may be opened in two stages; the first
1 being the introduction of the
tanee, and the second stage being
ii'omplete opening of the circuit.
jeactors have also been put into
rj:e for supplying lagging current
mpensate for the leading current
I'to the distributed capacity of
E mission lines; and are inserted in
r; with transmission lines (choke
»'), for protection against lighting
f rbance. Their office in the last
f nee is to choke back any line surge
1, may arise and prevent it from
j ing the station apparatus.

:i. Power-limiting reactors are

) usually made with no magnetic
trial, although the first reactors
i! for this purpose and installed in
rJos Cob station of the York, New
i Haven & Hartford Railroad Co.
e of the iron-core type with dis-
ited windings.
7. Methods of winding power-
Iting reactors. The methods of
ling adopted by the various manu-
i rers do not differ materially.
'h one firm winds with long cylin-
rl layers, using wooden cleats as
r'"ator3; another firm uses flat dis-
>.l-8haped layers or sections, each
>'uctor of which fits into a groove
rircelain cleats; the cleats when Fig. 55. —
Power-limiting reactor.
1 ped together insulate and separate

1 ndividual layers. A third firm uses methods similar to the second, but
)'leats employs moulded heat-resisting material as a substitute for porce-
i? See Fig. 55.
3. Cooling of power-limiting reactors is effected by natural circula-
iC or air blast. The arrangements of winding are particularly well adapted
3 ooUng by the last method.
269. Mechanical .stresses in the windings,
while severe, are not of such a nature as to produce
OOOOQOOO any trouble. Thus the radial stresses tend to
oooooooo
OOOo noon
elongate the conductors, while at the same time
they produce a compressive action on ine coil sec-
tion. The axial stresses are compressive and tend
to crush the conductors into less space. These
forces are difficult to calculate with any degree of
accuracy, but experience has shown that with the
methods of winding which have been described, and
with reasonable care in installing, reactors will be
amply strong enough to withstand any stress that
J. 56.— Cross-sec-
may arise in service.
_

i<jof reactance coil. 270. Formulas for self -inductance ; Rosa's

formula. This is accurate for any shape of coil.
. i
.
For practical work the correction for the form of
B^onductor is negligible and may be omitted; the formula then becomes

mSm L=L.-AiL (78)

11
 :

Sec. 6-271 REACTORS

To obtain the value of L, the formula below may be used (Eq. 79)
2 54
L. = anmx^, (henrys) ^

Where Q isa function of 2a/b, the values of which for different values of i

ratio are given in the table below, in Par. 271. The correction term ii.
given by the formula
AiL = 4xa(^) (A. + B.) X ~ (henrys)

Where A, and Bt are given in the 'tables below (Par. 272 and Par. 273
functions of c/a.

271. Values of the Constant Q in Eq. 79

2 a/6

\
 RECTIFIERS Sec. 6-274

RECTIFIERS
VAPOR TYPE KECTIFIEES
in structure.
Ji The merciUT-vapor rectifier is exceedingly simplethe air and al
[ sinele-phase type consists of a chamber from which
(ien gases have been exhausted, and in which
there is a mercury pool
aected to a terminal which passes through the
chamber; projecting
I the upper part of chamber are two terminals
I on or graphite which are commonly called the
vies (but which in actual service are alter-
anode and cathode), the mercury pool being
i''ly
aed the cathode. The general arrangement
_^
,.

shown in Fig. 57. In addition to the above, ^

; emay be a supplementary anode which g»__|
i> be a separate rod or, in glass-bulb rectifiers, = a 1
\ jrtion of the mercury pool
•.
ainder by a slight space. This supplement_ary ^ g —
separated from the J g -~. .
|
1 de is used for starting
or exciting the rectifier; « -r- .S
n n used fors tarting only, a tilting
mechanism
f)rovided which enables the two edges of the
ncury pool to be brought together, closing an
i iliary circuit, and thus causing a
spark or arc
;'orm where the edges recede. Once the recti-
i starts, it will continue to operate if the
proper
Dunt of inductance is included in the circuit.
^ere the supplementary anode is used for con-
t,ious excitation, it is connected to a
source
J lirect current. Where the mercury pool is di-
vjdinto three small pools, the two outer pcols Fig. 5 7.— Single-phase
D.' be used as anodes with the centre pool as Mercury-vapor rectifier.
c lode, and a continuous arc may
be supplied for , • . •

3; aining purposes by means of a small au>ihary transforming device or

a D-transf ormer.

76. Characteristics. From the viewpoint of the electrical engineer

t mercury-vapor rectifier may be
considered as an electrical valve, which
pnits current to flow only from a positive terminal to the
pool of mercury,
lis, as long as the terminal has a certain definite potential above that
ahe mercury pool, current will pass, but the moment that this potential
b jmes lower than this critical value, the current commences to
decrease.

76. The theory of operation. An ionizing agent is required to start

t. electron stream issuing from the cathode.
The liberated electrons pro-
c,l at high velocity toward the anode iomzing
molecules of gas on tbeir
C-' rse thereby producing positively charged bodies and i ncreasing the stream
dilectrons moving toward the anode. The positive charges are drawn
t ard the cathode where they become neutralized again
or negatively
c^rged; in so doing they further increase the ionization at the cathode,
and
pduceinits neighborhood a highintensity or potential gradient which as-
8 in accelerating the electrons emitted at the surface of the
:i
cathode. 1 he
rural or negatively charged molecule is forced back toward the
anode,
b becomes ionized again by the stream of electrons issuing from the cathode.
T,- negatively charged molecules apparently rarely move
far enough away
In the cathode, before becoming ionized by collision, and positively
crged,8o as to come under the influence of the electric field of the inactive
etrode. There is, therefore, no leakage or an extremely small one between
t' active and inactive anode.

^77. The thermionic or hot cathode rectifier consists of a tungsten

ade and a hot filament cathode, which is heated by a separate circuit;
V.h are contained in a highly evacuated bulb. The theory of operation
iis follows: The hot cathode emits electrons at a rate corresponding
to the
f\- of current required, until the limit set by the Richardson curve is
r.:;hed; from this point on the rate of emission of electrons
remains con-
^tit for a given temperature of the cathode. Any further increase merely
rSioes the spaced charge in the bulb, increasing the difference of potential
Vween anode and cathode, and thereby increasing the yelocrty ot the
CTtrons. The kinetic energy so imparted is dissipated in ttre form ot
459
 );,.

Sec. 6-278 RECTIFIERS

heat at the anode due to its bombardment and in radiation in the for
of X-rays. Recent improvements make use of an inert gas argon whit
affords the means for producing more electrons by collision, so that a doul
action takes place similar to that in the vapor convertor, and the limitati,
due to the Richardson effect is no longer present.
278. Auxiliary apparatus. The vapor convertor requires a trai
former or auto-transformer with a tap at the middle point so that be
half waves of the alternati
current supplied are utilize
this is necessary in order
W»i« of
imprewed e.liu£»
give the necessary sustaini
effect, which must be furtl'
enhanced by a choke coil
series with the direct-curr<
Current vftre circuit or its equivalent, inc^
Id first
{wflitive electrode porated in the design of tl
transformer; otherwise 1i.

rectifier would become de^

nized and go out. The 1^

posltlTe electrode cathode (argon filled) ci

vertor does not require
Ware of
taining and it is not nccr
rectified ourrent to utilize every half wave
single anode may therefore
used and the whole arran'
Fig. 58. —Typical wave form of single-phase ment Ls simpler and chea;
rectifiers. than that for the vapor
vertor.
279. Tjrpical waveforms obtained in a low-voltage self-sustained >

convertor are shown in Fig. 68.

280. The three-phase rectifier, shown in Fig. 59, is unlike the sing,
phase rectifier in the respect that it requires no inductance to sustain i

direct-current wave. This will be better understood by referring to 1'

60, where a, 6, c, are the consecutive positive voltage waves of a three-ph
system. The secondary current will flow first from the anode connected';
phase a, to the cathode, and thence through the direct-current circuit b
to the neutral point of the three-phase syst.
This will continue until the point h in the w >

a is reached the current will then be transfer

;

to the anode connected to the phase 6; the c

rent will continue to flow from this wave u I
the point k is reached, when it will again
transferred, to the wave c; it will continuo
flow from c until the point e is reached, whet
will once more be transferred to the wav'
completing the cycle. The dotted line represc
the cathode potential with reference to tha f
a h

Fio. 5 9. —
T h r e e-phase
mercury-vapor rectifier.
the neutral point of the three-phase system; the latter is the positive te *>
nal of the direct-current system supplied by the rectifier, its potential bt
represented in Fig. 60 by the line \ox). I

281. With the advent of high-efficiency (nitrogen-filled) inci*

descent lighting and tbo use of carbon flame, alternating-current la <
460
 RECTIFIERS Sec. e-282

street lighting, the demand for vapor converter

-illiant
equipments for
-current constant-current lighting (metallic flame,
magnetite arc
Vapor converters are still being manufactured and
^. has ceased.
:'ied for existing installations.

V. Small low-voltage vapor converters were manufactured for

B charging outfits for charging
batteries for electric vehicles, but
of such
= emand for such equipments has become very small, owners
i'ines preferring to keep them at garages where the charging is done with
1 30 to 50 amp. equipments.
ii. Small charging equipments for starting batteries. The 10-
j,re vapor converter equipment is replaced by the thermionic (argon tilled)
<'?rtors rated as follows:
2 ampere 15 volts max.
6 ampere!
'.'.'.'.'.'.'.
15-30 and 75 volts max.
ii.Vapor converter equipments for moving pictures (30 to 50
rres) are being displaced by incandescent nitrogen-filled lamps run at
E
efficiency with a guaranteed life of 100 hours.
J). Vapor converter equipments for charging telephone batteries
ratings of 10, 30 and 50 amperes, are still being supplied, but
it is

iible that the smaller thermionic outfits will take their place,
on account
e fact that the latter do not require sustaining and
therefore may be
Kted the whole 24 hours -^vithout attendance.
;3. Vapor converters for power service. Development of the iron
• type of vapor converter w^s discontinued during the war but
there are
-lects that it will be taken up again. Such an equipment was used
i"S8fully in America for operating a railway car at 5,000 volts direct-
ij.nt in an experimental installation at Grass Lake,
Michigan.
ELECTROLYTIC EECTIFIBES*
^. Theory of operation. It has been found that when a plate of
^.inum and a plate of lead or carbon are immersed in certain solutions, an
Alternating Current
electric current can be made to (
pass in one direction, but not in
Supply Mains a reverse direction._
In other
words, this combination will act
as an electric valve and is the
basis upon which the electrolytic

I rectifier and electrolytic lightning

arresters are designed. The more
complex the acid radical employed
in the solution of the electrolyte,
the more complete will be the valve
action with a given voltage, or, in
other words, the higher will be the
voltage which may be satisfactorily
rectified. In view of this fact, re-
cent developments have been made
in the use of ammonium phosphate
or sodium borate dissolved in
water, as the basis of the elec-
trolyte.
The electrolytic rectifier, there-
fore,consists essentially of two
aluminum plates and a lead plate
immersed in a solution of ammo-
nium phosphate and connected to
some transforming device, as shown
in Fig. 61. Such an arrangement
Electrolyte Ammonium will allow the current to pass from
--Phosphate
raoBptxate the lead plate but never from the
TN- ^ ^- aluminum plates, with the result
r.6i. Diagram ofc electrolytic
^ ^ -^„*;fi<»,-
rectifier.
current flowing between
^^^^ ^^^
tl terminals marked A and B will be unidirectional, but pulsating.
See Sec. 19.

461
 ;

Sec. 6-288 RECTIFIERS

288. Oeneral characteristics. Such a rectifier ia comparatively cbV

simple to construct, requires no sustaining circuits, and to this ext<"'-
satisfactory for handling very small loads where the service is intern
289. The efficiency of the rectifier is relatively low, seldom en
60 per cent, and frequently averaging much less. The efficiency iin ;

with decrease in the amount of current to be rectified.

290. Heating. Since the efficiency is low, the heat loss in the n .

is comparatively large, which results in rapid deterioration of the

The degree of rectification, as the temperature rises, is much less co;
In other words, the leakage of current becomes excessive as the curr'
creases, unless cooling means are provided.
291. Treatment of plates. A further objection to the electr <

rectifier is the necessity for

occasionally "treating" the plates to for
necessary insulating and rectifying films.
292. General applications. As a result of the low efficiency, th
deterioration, and the rapid heating of the electrolytic rectifier, it is
used for ordinary loads. Its present field appears to be limited to
equipments and experimental purposes where a cheap rectifying di
required for light intermittent service.
293. Artificially cooled electrodes. Recent improvements hav
made in electrolytic rectifiers which permit operation at higher -

densities. One of these consists in cooling the aluminum cathode by a

of water. The effect is such that a current ten times as large can be per
with the cooled cell as with the same cell uncooled. An excellent rec
effectwith a cooled cell may be obtained with frequencies as high as !

to 10,000 cycles per second.*

MECHANICAL RECTIFIERS
294. The vibrating type of alternating-current rectifier is a siii
efficient and inexpensive piece of apparatus adapted particularly to the c
|
ing of three-cell vehicle batteries. However this type is being replacii^
the thermionic converter, which overcomes the difficulties with the ni
anical type due to sparking contacts. i"

296. Oeneral characteristics of vibrating type of rectifier, ij

essentially an electrically operated vibrating switch which reverses the«

nection of the alternating-current line to the battery in synchronism witti
alternations of the current, this reversing action being accomplished fli
moment when the current flow is zero. There is therefore very little spai^
at the contacts and the current delivered is unidirectional and pulsiil
296. The principle on which the vibrating rectifier operates «
follows: a small transformer serves to reduce the alternating-current n
voltage to a suitable value; two alternating-current magnets are coi"''
across one-half of the low-voltage winding and are so arranged as to •

at any instant poles of like polarity before those of a steel n)agnet \

excited from the battery. Hence during one-half cycle of the alt.
current, one of the poles of the pivoted magnet will be attracted and ll
repelled, and the opposite action will take place during the other hai
The pivoted magnet is connected to one terminal of the battery and tl
terminal of the latter is connected to the middle point of the low-
winding of the transformer. Two platinum contacts carried on the ]

magnet are thereby brought alternately in contact with two other v

connected to the low-voltage terminals ot the transformer. It is of
portance which terminals of the battery are connected to the bindii
of the apparatus, since the winding of the pivoted magnet autoni:
determines the proper polarity of the binding posts.
297. Sparking. A properly designed vibrating rectifier should oi i^

without sparking, otherwise tlie life of contacts will be short. To -

sparkless operation, contact should be broken at the instant the

falls to zero and should be made again at the moment the instan'
value of the alternating voltage wave is equal to the e.m.f. of the
battery. If contact is broken before the current reaches zero and mii'
some time after the alternating e.m.f. has reached the proper value, th
* See Elek. Aug. 21, 1913. Phya.
Zeit., Zeit., June 15, 1913.

462
 RECTIFIERS Sec. 6-298

1 input to the battery will not be obtained; on the other hand, if the
d nt reverses before contact is broken, part of the battery charge will be
siated in the circuit. ._

hen the wave-form ot the alternating-current supply differs from a sine-

g it may be necessary to change the adjustment slightly to prevent
*.ing. This may be accomplished by means of a variable resistance in
r with the alternating-current magnets, which permits the time-phase
tf the magnetizing current behind the secondary e.m.f. to be adjusted
1' sparkless operation is obtained.

ii. Ratings and efficiency. The efficiency is usually about 55 per cent-
ofToercial types are made for operation on 60, 50, 40, or 25 cycles, at 110
)] They are designed to charge 3 cells of storage battery and deliver
crent of from 8 to 8.5 amp.
Jl. A commutator tjrpe rectifier is being manufactured by one
1 any for charging small batteries.
Jl. Other forms of mechanical rectifiers. Mechanical synchronous
irctors are used for rectifying alternating-current waves so that direct-
lint galvanometers may be employed for precise and delicate measure-
Bi on alternating-current circuits. Since it is essential in such cases to
\ie the contacts as quickly as possible, so that as much as possible of the
tiiating waves shall be rectified, these devices are costly and require a
e deal of care in their design. Some high-voltage contact rectifiers
also been devised for laboratory work.
I'j

I
BIBLIOGRAPHY
Transformers.
S..
^Fleming, J. A. —
" The Alternating Current Transformer." The
E'trician" Publishing Co. London.
—
iKAPP, GisBERT. " Transformers for Single and Multiphase Circuits."
Itaker and Co.
—
SSteinmetz, C. p. " Alternating-current Phenomena." McGraw-
(
iliook Company Inc. New York, 1900. —
45TEINMETZ, C. P. "Transient Phenomena." McGraw-Hill Book
New York, 1909.
3 lany Inc.
—
£Baum, F. G. "The Alternating-Current Transformer." McGraw-
Company Inc. New
ij'.ook
f;.rATLOR, —"Transformer
York, 1903.
William Practice." McGraw-Hill Book
T.
New York, 1913.
7^Rn88EL, Alexander. — Alternating-currents."
Jiianylnc.
Cambridge Univer-
"

AND Bragstad, O. — " Theory and Calculation

li'ress
r.jK CouR, I. L. S. of
le-ic Currents." Longmans and Co. New York.
ff Protection of the Internal Insulation of a Static Transformer against
'

If frequency Strains." Trans. A. I. E. E., Vol XXVI, Part 2, p. 1169.

1 Reed, E. G.— " Transformers." Proc. N. E. L. A., 1909, Vol. I,
I
Reynders, a. B.— " Type of Insulation for High-
Condenser
ly

1
n Terminals."
Chubb, Jj.
W. —Trans. A.
"Method
E. E., Vol. XXVIII, Part 1, p. 209.
I.
of Testing Transformer Core Loses giving
n vave Results on Commercial Circuits." Trans. A. I. E. E., Vol.
>;III, Part 1, p. 417.
1 FoPTEScuE, C. L.
—
"The Calibration, of Current Transformers by
es of Mutual Inductances." Trans. A. I. E. E., Vol. XXXIV, Part 2,
'Ip. 1599.
1 —
Robinson, L. T. "Electrical Measurements on Circuits Requiring
ufnt and Potential Transformers." Trans. A. I. E. E., Vol. XXVIII,
"-', p.
,lp
1005.
Frank, J. J.
— "Observations of Harmonics in Current and in Voltage
a Shapes of Transformers." Trans. A. I. E. E., Vol. XXIX, No. 7, p.
i5
.

i ToBEY, H. W.— "Dielectric Strength of Oil." Trans. A. I. E.E., Vol.

No.
G. AND SiLSBEE, F. B. — "The Testing
A-., 7, p. 1171.
li Agnew, P. Instrument Trans- of
XXXI, Part
^- — P-
^''"**- ^- ^- 1635.
^•' '^o^- 2, p.
"iVm
T, J?**^^> "The Use
S. Reactance in Transformers."
of TraTis.
V-.E., Vol. XXXI, Part 2, p. 2015.

463
ll
 Sec. 6-302 rectifiers

19. Papers on Transformer Subjects by Various Authors. Trans

A. I. E. E., Vol. XXXII,
Part 1, pp. 191 to 708.
20. FoRTESCUE, C. L. —
G. -"The Application of a Theorem of Electrostatir!
to Insulation Problems." Trans. A. I. E. E., Vol. XXXII, Part 1, p 907.
21. Blume, Louis F.
—
"Influence of Transformer Connection on Opera
tion."
22. FoRTEBCuE, C. L. G.
—
Trans. A. I. E. E., Vol. XXXIII, p. 735.
"Method of Symmetrical Coordinates .\pplirc
to the Solution of Polyphase Networks." Trans. A. I. E. E., Vol. XXXVll
p. 1027.
23. FoRTESCUE, C. L. G.
—
"A Study of Some Three-phase Systems
Trans. A. I. E. E., Vol. XXXIII, p. 753.
24. FORTESCUE, C. L. G.
—
"Effect of Electrostatic Stresses and Grouni
Connecions on Transformer Insulation." The Electric Journal, Vol. VIII
p. 266.
25. Agnew, p. G. and Silsbee, F. B.
—
"Accuracy of the Formulas forth
Ratio Regulation and Phase Angle of Transformers." Scientific Papers of th
Bureau of Standards, No. 211.
26. Rosa, E. B. and Loyd, Morton G.
—
"The Determination of the Rati'
of Transformation and of the Phase Relations in Transformers." Scientifi
Papers of the Bureau of Standards, No. 116.
27. Lloyd, M. G. and Agnew, P. G.
—
"The Regulation of Potenti:
Transformers and the Magnetizing Current." Scientific Papers of the Burea
of Standards, No. 129.
28. Agnew, P G. and Fitch, T. T.
—
"The Determination of the Constant
of Instrument Transformers." Scientific Papers of the Bureau of Standards
No. 130.
29. McConahey, W. M.
—
"Parallel Operation." Elec. Journal, Vol. li[
p. 613. J
30. FORTESCUE, C.L. G. "Theory" and Mateer, J. E. "Manufacture."
"The Condenser Terminal." Elec. Journal, Vol. X, August, 1914.
31. Rosa, Edward B. and Grover, T. W.
—
"Formulseand Tables fortb
Calculation of Mutual and Self-induction." Bulletin of the Bureau (

Standards, Jan., 1912, No. 1.

32. Steinmetz, C. P.
—
"Mechanical Forces in Magnetic Fields." Trm
A. I. E. E. (1911), Vol. p. 367. XXX,
33. McCoNAHBY, W. M. — Determination of Polarity of Transformers, fi
Parallel Operation."
34. Weed, J. M.
— Elec. Journal, July, 1912, pp. 613-621.
"Magnetic Leakage in Transformers." Gen.
Review, No.
— 1912, pp. 756-759. Transformers."
Dec,15, I'M
> Lyon, W. V. "Parallel Operation
35.
—
Feb., 1914, pp. 315-317.
Peters,
36. F. "Harmonics
J.
Warn
of

Transformer Magnetizing Currents

in
Elec.

E. E. (1918), Vol. XXXIV.

M. — "Abnormal Voltages
Trans. A. I. 2157. Pt. II, p.
J
Weed,
37. J. Transformers." Trad in
XXXIV,
A. E. E. (1915),
I.
—
Vol.
Curtis, L. F. "Regulation
38.
2157. Pt. II. p.
V-connected Transformers."
of «t|
,1

Dennison, B. C. — "Minimum Cost Method

World, Aug., 1917, pp. 302-303.
'
,i
J
39. Transformer Design of
ElO:.
40.
—
World, Nov., 1917, pp. 855-S59.
Woodward, W. R. "Characteristics Current Transformei* of .

Journal, Feb., 1918, pp. 48-50.

Open Circuit."
Peters,
41. F.
— "Tertiary
J.
Elec.
Winding Transformers."* Journ
in Elec.
Nov.. 1919. pp. 477-480. — . ,. , „,
Montsinger, V. M. "Cooling
42. Transformer Windmgs
of after bhi
down." Gen. Elec. Review, Dec, 1919. pp. 1056-1065.
302. Rectifiers.
——"Theory Operation Mercury
43. Jackson, R. P. of
„
of
.^
Rectifiers.
44. Brachett, Q. A."Mercury Arc Journal, Rectifiers." Elec. Vol. I

Jackson, R. P. — "The Mercury

45. Journal, Rectifier." Elec. Vol. VI,
397 —
46 Moss, E. W. "Electric Valves." Journal Institute Ed of Elec.
Vol. XXXIX.
47.
..,.,•,/-
NoDON. — "Electric Valves." Trans. International
,
Electrical C<
gress. 1904, Vol. II.

464
 SECTION 7

!a.TERNATING-CURRENT GENERATORS
AND MOTORS
BY
COMFORT A. ADAMS
ffUtOT of Electrical Engineering, Harvard University; Fellow American In-
stitute of Electrical Engineers

AND
HENRY M. HOBART
Consulting Engirteer, General Electric Co., Fellow American Institute of
Electrical Engineers

CONTENTS
(Numbers refer to Paragraphs)
SYNCHRONOUS MACHINES
'aectH _
1 Elementary Outline of the De-
.

'nature Winding 16 sign of Synchronous Machines 92

i.vI.F. Generation 23 Insulation 108
'b Magnetic Circuit 35 Losses and Efficiency 115
i
aracteristics of Synchronous Ventilation 129
alternators 43 Mechanical Construction 140
ichronous Motors 67 The Testing of Alternating-our-
ithods of Synchronizing 84 rent Generators 148
litJlel Operation of Alternators 87
INDUCTION MACHINES
iieral Theory of the Polyphase The Induction Generator 222
Jiduotion Motor 155 The Design of Induction Ma-
uction Motor Characteristics 179 chines 243
Current
(gnetizing 192 The Single-phase Induction
kage Reactance 193 Motor 260
isle Diagram 199 Speed Control of Induction
ises and Efficiency 210 Motors 271
mdard Polyphase Induction
[otors 215
ALTEBNATINQ-CUBEENT COMMUTATOR MOTORS, 286
YSTEMS OF SPEED CONTROL REQUIRING AUXILIARY
COMMUTATINQ MACHINES, 314
PHASE MODIFIERS, 318
MOTOR GENERATORS, 332
FREQUENCY CHANGERS, 346

BIBLIOGRAPHY, 370

80 465
 <

SECTION 7

ALTERNATING-CURRENT GENERATORS AND MOTOJ

BY
COMFORT A. ADAMS
Professor of Electrical Engineering, Harvard University, Fellow Amerit.
Institute of Electrical Engineers

AND
HENBY M.HOBART
Consulting Engineer, General Electric Company, Fellow American Insixt
of Electrical Engineers

SYNCHRONOUS MACHINES
GENERAL
1. Definition. A synchronous generator (or motor) usually consistft:
a system of alternately north and south magnetic poles, comprising i|
field, which moves with respect to a system of suitably connected cM
ductors in which the alternating e.m.f. is induced. These conductors ;!
gather with their mounting are called the armature. See Fig. 1. ''>'\

magnetic poles of the field are usually excited with direct-current supp'lj
by a separate generator called an exciter. See Par. 9. ij

Fig.
and
1. —A portion of the armature Fia. 2.- -A graph of a cycle iil

field of a synchronous machine. e.m.f.

2. The "cycle." In the ordinary heteropolar alternator, the eJ

induced in each armature conductor reverses with the passage of each ]|

i.e., for a peripheral movement equal to one pole pitch (the peripheral diM
between tSie centres of adjacent poles). The set of values comprised w
a double reversal, or corresponding to a movement equal to twice tb*^
pitch, repeats itself indefinitely, and is called a cycle of values, or dml
cycle. See Fig. 2. The graph of those values plotted against time in
tangular coordinates, is referred to as the e.m.f. wave of the machii
question.
3. Frequency. The time required for the execution of a cycle ia
the period of the alternating e.m.f., and the number of cycles per a
is calledthe frequency. Frequency, /, is expressed by the relation:/"
rev. per second, whore 2p is tlie number of polos. Modern comllM
frequencies in the United States are 60 and 25 cycles per sec.
4. Electrical and magnetic degrrees. It is customary to refer to »
as 360 electrical degrees (see Fig. 2), or one electrical revolution, and
circumferential distance from the centre of one pole to that of th^ft

466

1
 A. C. GENERATORS AND MOTORS Sec. 7-5

I
same polarity, as 360 magnetic degrees. Thus two active armature
e of the
t ductors displaced from each other by /3 magnetic degrees will experience
t.fs. differing in phase by P electrical degrees. Two active conductors
1 magnetic degrees apart would naturally be connected in series to form
£)op or coil, since their two e.m.fs. will then be always in the same direc-
ti around the circuit of the loop (see coils I and II, Fig. 3).

The two-phase (quarter-phase) alternator. Referring to Fig. 3,

.

(;^s I and II are displaced from each other by 90 magnetic degrees. The

C^K?
Fig. 3. —
Part of the arma- Fig. 4.— Graph of the elec-
tromotive forces in a quar-
ture and field of a quarter-
(
phase alternator. ter-phase alternator, plotted
against time.

B.fs. induced in these two coils therefore differ in phase by 90 deg. If all
Xs in the same phase as I, are connected in series, and all those
i the same phase as II in another series, the two circuits being
t irate and distinct electrically, the machine is called a two-phase
r^hine. The circuits themselves are referred to as the two phases
1 phase windings of the machine. Sometimes this type of machine
i ailed a quarter-phase machine, since its two
I f?. differ in phase by 90 deg. or one-quarter
I le. The electromotive force in coil I is zero
vn that in coil II is a maximum, and vice
* a. If the value of the electromotive force from
a sine function of the relative
•ant to instant is
ular position of r.he armature coils and revoly-
•
field, the curves of the electromotive forces in
jsl and II, may be plotted as indicated in Fig.
;n which the ordinates represent the instan- Fig. 5.-^Part of the
sous values of the electromotive force, and the armature and field of a
iLoissas represent time. The four terminals of three-phase alternator.
two windings of a two-phase alternator are
'

irally brought out to the terminal board. The load may be fed by three
';8, one the common return for the other two, or four wires may be
iloyed as two independent, circuits.
. The three-phase alternator. Ifthree sets of overlapping coils dis-
:ed by 60 magnetic degrees (Fig. 5) be connected to three separate cir-

/ II III

fi
10. 0. — Graph of the
es in the three armature circuits of
electromotive —
Fig. 7. Graph of terminal pres-
sures in the three phases of a three-
airee-phase alternator. phase alternator.
c s, their e.m.fs. will differ in phase by 60 deg. (see Fig. 6). reversing By
t t.-nninal connections of phase II. we reverse the phase of its e.m.f. with
to the load and obtain the three voltages shown in Fig. 7. These vol-
'

iTer in phase by 120 deg. The difference between the three e.m.fs.
6 and those of Fig. 7 is obviously external to the machine in which they
-'

a generated, which is called a three-phase alternator. In many three-phase

467
 -1

Sec. 7-7 A. C. GENERATORS AND MOTORS

alternators the phases are internally connected, with only three tennin
brought out. There are two principal methods of making these connectio;'
K and A (see Figs.8and9). Let£ and / represent respectively, volts a
amperes per armature phase; and Ei and /jthe line volts and amper
Then, in the Y armature, .Ei = .B V'S, and 7j = J; and in the A armatu
El — E ,a,nd Ii^y/z I. Therefore the power in each case will be 3jB/co,)
= v 3 Eili cos B, where 9 is the common phase difference between the y\
tage and current of each phase, balanced load assumed.

Figs. 8 and 9. — Internal and external and currents in three-phase

e.m.fs.
ternators with Y and A connections.
7. Mote on phase classification. There is a slight inconsistency!
the usual classification of alternators and systems. In the ordinary thi
phase alternator (Fig. 5) there are, in each 360 magnetic degrees of circi'-
ference, six coil groups or belts of conductors. In these groups j

being generated six different e.m.fs. differing in phase progressi\'

by 60 deg. or one-sixth of a cycle. If the six terminals of i

three phases be connected to three equal loads, the six currents in the:
leads, when counted positive in the same direction along the line, will di'
in phase progressively by 60 deg. If, however, the three phases be conned
in Y or A, with three leads connected to the load, the three currents, courl
positive in the same direction along the line, will differ in phase by 120 (.
or one-third of a cycle. To be consistent these two systems should be ref -

to as "six-phase" and "three-phase" respectively, although the alter

is the same. Moreover when a closed-coil armature is used for altera
e.m.f. generation, as in the case of a synchronous converter, it is i

"three phase" when it has three 120-deg. taps and three phase-bel
120-deg. span, and six phase when it has six 60-deg. taps and six phase
each of 60-deg. span. Thus, to be consistent, the ordinary three-;
alternator should be called a six-phase alternator, although mostly
to supply three-phase circuits.
8. Single-phase generators* are occasionally required for railway-
also for certain electrochemical and electrothermal processes,
single-phase generators are simply Y-connected three-phase gener
with one of the three legs left idle. When a generator is opr
single-jihase, it is important that the pole shoes should be fitted
a heavy amortisseur or squirrel cage winding to damp out the effects (

pulsating armature reaction (Par. 44). Furthermore it is important

all parts of the magnetic circuit shall be well laminated in order that i
tions in the resultant m.m.f. may not occasion excessive iron losses.
Occasionally single-phase generators are supplied with distinctly sii
phase windings as shown diagrammatically in Figs. 10 and 11. ThewinC!!
in these two figures differ from one another in the extent to which the i*
ductors are distributed over the surface of the stator. The complete --
tribution employed in Fig. 11 is wasteful. The proportions of Fi;
are more nearly correct. (See Par. 28, Par. 81, and Fig. 32.) A f
phase generator for a given kv-a. output and a given power factor, vi
and speed, is inherently more heavy and expensive than the equivalent
phase generator by fully 65 per cent. Even then,if the speed is very hi:

•Waters, W. L. " Modern Development in Single-phase General

Trans. American Institute of Electrical Engineers. Vol. XXVII, lin
1069 and from 1086 to 1097.
Hobart, H. M. "The Relative Costs and Operating Efficiencies of 1 :•

phase and Single-phase Generators and Transmitting Systems." T »•

American Institute of Electrical Engineers, Vol. XXXI, 1912, p. 115.

468
 GENERATORS AND MOTORS Sec. 7-9

he case of a steam turbme-driven generator, the

temperature rise will be
iter and ita efficiency will be lower
than in the case of the polyphase ma-
le Very few manufacturers of dynamo-electric machinery have reahzed
difficulties attending the design and construction
of single-phase genera-
! and many faultily designed machines have been built. Singular as it
now general failure to pay heed to these unsucceosful
V seem, there is even a
ilts. Even for cases where polyphase machines are required to carry dif!eT-
loads and power-factors on the various phases, the heating may be decid-
/ excessive unless such machines are designed with due regard to the
jating m.m.f. which will be present under these conditions of load.

B. 10 AND 11. -Single-phase alternators with distinctly single-phase

windings.

Excitation: Separate excitation is almost always employed in modern

,

rohronous generators. The exciter is usually either mounted on an exten-

ij of the main generator shaft or driven by a motor from the generator
!>' This is, however, objectionable in that a given percentage variation
ilie speed of the generator will occasion a greater percentage variation
II ts voltage. Thus if, for instance, the speed varies 1 per cent., the speed
» he exciter will vary 1 per cent, and the voltage of the exciter by a
httle
B e than 1 per cent. this causes a little more than 2 per cent, variation
;

iihe voltage of the main generator. It is, therefore, desirable that ex-
Birs be driven by independent prime movers whenever it is
possible.
Vious methods have been devised for rendering alternators self-exciting
b except for comparatively small machines, these are never used.
). Relative motion: revolving armature and revolving field. The
t< )lving-armature type of alternator is now rarely employed even in very
Bill sizes. Revolving-field alternators fall into two classes: (a) those with
e;idrical rotors provided with windings embedded in slots in the surface;
({ hose with salient-pole rotors. The former are now almost universally
ul for extra high-speed generators driven from steam turbines, owing to
stnger mechanical construction, better balance, less noise and lower air
(r ion (which last may represent a loss as great as the aggregate of all the
0' rs). For water-wheel generators and for generators driven by recipro-
jti ig engines the salient-pole construction is usually the most
appropriate,
•lough, for other than very low speeds, a good argument can usually be
Siented for the cylindrical type of rotor.
I .. Vertical and horizontal types. Until 1911 a considerable propor-
l^t of the steam turbine-driven alternators were of the vertical type. The
•liequent large increase of speeds of steam turbo-alternators (in many cases
|«)le) involving greater lengths, smaller diameters, and greater vibra-
Bul difficulties, has made more desirable the horizontal type with its
pfrently better provision for strength of frame and accessibility of parts.
T vertical type is generally used for low-speed water-wheel generators.
A notable instance of the vertical type may be mentioned the 30 Keokuk
g< raters, each 9,000 kv-a., 25 cycles and 58 r.p.m. with 52 poles. The
r-—.-^.] diameter of the rotor is 25 ft. and it weighs 116 tons. The entire
weighs some 275 tons.
Engine type. (Direct-connected to reciprocating engines.) In this
.

t.N sufficient momentum must be provided in the rotating element to en-

81 the required degree of uniformity in the angular velocity. Three ar-
ra ements to accomplish this end are: (a) a separate fly-wheel; (b) the
fl; .heel as an integral part of an internal rotor, Fig. 12; (c) the fly-wheel
a^ 1 integral part of an overhung rotor. Fig. 13.
.\merica the fly-wheel effect is expressed in terms of the WR^ where the
" ht of the rotor in pounds is denoted by W, and the radius to the centre
ot /ration, in feet, is denoted by i?. In countries employing the metric

469
 .

Sec. 7-13 GENERATORS AND MOTORS

system, the fly-wheel effect is expressed in terms of the GD', where D is tlj
diameter at the centre of gyration in meters, and O is the weight of the rot(l
in kilograms. The greater the weight of the required S',
wheel, the more liberal must be the design of the bearing'
13. Water-wheel type alternators have speeds ran,-;
ing widely in accordance with the head of water und'
which the prime movers operate. The Keokuk 9,00i
kv-a. generator (Par. 11) has a rotative speed of 58 re

Fig. 12. — Fly-wheel

rotor for alternator.
Fig. 13. -Umbrella type of revolving-field
alternator.

per min., and the 5,000-kv-a. (Niagara) generator (Fig. 13) 250 rev. per mi
Even for the same head,'{water-wheels are built for any speed within qui
a wide range. m
On the whole, the water-wheel will be lower price and mc.
efficient when constructed for a moderately low speed. On the other hat.
the weight and cost of the generator will decrease with increasing rat
speed, up to fairly high speeds. At all but very low heads, therefore, t
tendency is toward fairly high speeds. For 10,000 to 20,000 kv-a. wat.
wheel sets, speeds of some 300 to 600 rev. per min. are now often enipli
In event of accident to governors or head-gates, the runaway speed wil
roach double the normal speed; see paper in Vol. XXXI of Trans. A. I. 1

E
y D. W. Mead entitled "The Runaway Speed of Water-wheels an.
Effect on Connected Rotary Machinery," and a paper by F. Nagler, eiit
"A New Type of Hydraulic Turbine Runner," at p. 921 of "A/cr/i.;
Engineerinn " for December, 1919. Water-wheel driven generators
'

been built up to capacities of 22,000 kv-a. in the horizontal-shaft type

are being built up to 45,000 kv-a. in the vertical-shaft type.
14. Typical vertical type water-wheel generators
Ex- Total
Rating Stjeed ternal weiglr
No. of in dia.
Location poles
in
kv-a. r.p.m. in 2000-1!
feet toil

Cedar Rapids (Quebec) 136 10,000 556 30.5

Whitney (North Caro-
lina) 28 18,000 154 19.5 h
Niagara Falls 20 32,500 150 21.5 3U..

Ebro (Spain) 16 14,000 375 14.5 120

Spain 10 18,750 600 14.5 125

470
 GENERATORS AND MOTORS SeC. 7-15

8. Steam turbine-driven types.

* Extra high-speed generators are
rv almost invariably constructed with the cylindrical type of rotor carry-
i the field winding embedded in slots distributed over its surface. Owing
tithe great stresses associated with high peripheral speeds, the entire
r )r (including the extensions constituting the shaft) is often made from a
sjle piece of steel. In the largest machines, peripheral speeds of the order
c!5,000 ft. per min. (127 meters per sec.) are employed. Bipolar 25-cycle
d igns are now under construction for rated loads of 40,000 kv-a. at a speed
c ,500 rev. per min. Bipolar 60-cycle designs for a speed of 3,600 rev. per
El., have been built in sizes up to 9,375 kv-a.
t is characteristic of extra high-speed alternators of great capacity that
B-e they are so exceedingly small for their output they can only be main-
tied at appropriately low temperatures when in operation, by circulating
t?ugh them enormous quantities of air. For this purpose, and also in
c er to ensure reasonable absence of noise in their neighborhood, such
f erators are of the completely enclosed type with definite inlets and
cletsfor the circulating air. These subjects are discussed in Par. 129 to 139.

ARMATURE WINDING
6. Considerations tweeting the choice of armature winding for
E alternator, (a) Efficient e.m.f. generation, i. e., without considerable dif-
f generation in series-connected conductors.
'ntial This indicates coils
^:>se pitch or span is about 180 deg. The pitch is on other accounts
sietimes as low as 0.66 or even 0.50. (b) Wave shape. In most cases an
Eiroximate sine-wave is desired, w lich ordinarily means a distributed
\ ding (several slots per pole per phase). Itisnotnecessary tohave a whole
rnber of slots per pole per phase. In fact a fractional number is some-
t es desirable, e.g., a machine with li slots per pole per phase will have
agood a wave shape, other things being equal, as a machine with five
ss per pole per phase. Wave shape also usually indicates a fractional-
r;h winding (Par. 20), i.e., coils with a pitch less than 180 deg. (c)
I m the standpoint of heat dissipation, as well as of wave shape, the winding
Buld be distributed rather than concentrated; this also reduces the leakage
riJtance sUghtly. On the other hand, much distribution means more insula-
I I space andless slot space for copper, particularly in high-voltage machines.

( From the standpoint of first cost it is important that the coils shall
t wound and insulated before being placed in the machines, also that they
»11 be of one shape father than of many shapes. This involves the neces-
B'of open slots, although magnetic wedges are sometimes inserted after
t winding is in place, in order to secure the advantages of closed or partly
c .ed slots.

Classifications of armature windings: (a) coil-end classification

7.
( one range, two range, three range or barrel); (b) according
ral or lap;
t number of layers (one or two); (c) according to the pitch of the coils;
he
( open slots (usually with form wound coils) or closed slots; (e) according
t-.he number of slots per pole per phase; (f) according to the number of
tuits in each phase; (g) according to the number of phases; (h) in three-
ise windings, F or A connection.
)iagrammatic illustrations of three-phase windings are shown in Fig. 14
V ch explains itself. All of these illustrations are for single-layer wind-

Kloss, M. "Selection of Turbo-Alternators, " /owrn.. Inst. Elec. Enters..

\. XLII, p. 156.
toney, G. and Law, A. H.
, "High-speed Electrical Machinery," Journ.
I:. E., Vol. XLI, p. 286.
Valker, Miles. "Design of Turbo Field Magnets for Alternating-cur-
rt Generators," Journ. I. E. E., Vol. XLV, p. 319.
imith, S. P. "Non-salient Pole Turbo-alternators," Journ. I. E. E.,
^ XLVII, p. 562.
.

anime, B. G. "High-speed Turbo-alternators," Trans. A. I. E. E..

13, Vol. XXXII, p. 1.
it'ld, K. B. "Some Difficulties of Design of High-speed Generators,"
I rn. Engrs. (1916), Vol. 54, p. 65.
Inst. Elec.
hepherd, J. "Failures of Turbo-generators and Suggestions for Im-
1 vements," read before the Institution of Elec. Engrs. in January, 1920.

471
 Sec. 7-18 GENERATORS AND MOTORS
Ings, such that they can be wound with one coil-side per slot. It will I
observed also that, in effect, they are all full-pitch windings, i.e., that tl
two groups of active conductors belonging to any given phase and lyir
under adjacent poles are always 180 deg. apart, as groups, although son
individual coils of the spiral windings have a pitch less than 180 deg.

Fia. 14. — Three-jihase windings.

18. Athree-phase spiral winding with three slots per pole per pha
is shown in Fig. 15, and a two-phase spiral winding with six slots per pole i

phase in Fig. 16. For obvious reasons these are sometimes called cha
windings. They are also two-range windings, i.e., the coils extend oi
ward in two ranges, or rows. Fig. 5 shows part of a three-range windin
19. Two-layer lap winding. A more common type than any of I

windings mentioned in Par. 18, is the two-layer lap winding, shown in F

17. This type has the advantage not only of a single shape of coil, but a
that the coil pitch may be any whole number of slots, without disturbing 1

symmetry of the winding. ,

Fig. 15. —Three-phase, spiral, two- Fia. 16. — Quarter-phase,

range winding.
spiral, I

range winding.

20. Fractional-pitch winding. When the coil pitch is less than 180 d
the winding is called a fractional-pitch winding. Fractional-pitch wi
ings are much used not only because of their effect on the wave shape U
25 et seq.), but also because of the saving in coil-end copper and in ovcil
length of machine. The gain is particularly noticeable on two-pole raach '

where fractional pitch is practically universal. It is also possible will:

type of winding to have a fractional number of slots per pole, which
to eliminate tooth harmonics from the e.m.f. wave. The end connci
of the two-layer lap winding stand out in a single range, but because
appearance and continuity it is often called a barrel winding. Fi
and 18 show samples of three-phase, two-layer lap windings with full
and 50 per cent, pitch respectively. The between-coil connections and
terminals, are shown for only one phase. AH things considered, the
layer lap winding is the most flexible and generally useful type. In
high-voltage machines, the necessity for insulation between the two 1

is an objection, particularly with fractional pitch, when there is a relai

large potential difference between the two coil-sides in a slot.

472
 A. C. GENERATORS AND MOTORS See. 7-20

1234 5 67 89 10 11 12

[.'17. —Three-phase two-layer lap winding with full pitch (i.e., coil

pitch — =» 1.00), Two poles. Six slots per pole.

10 11 12

F IS. —Three-phase two-layer lap winding with five- tenths pitch (i.e.

coil pitch Tr= .50], Two poles. Six slots per pole.

19. —Three-phase single-layer lap winding with five-tenths pitch (i.e.

coil pitch ^= .50V Two poles. Six slots per pole.

?nlr-,^r-,^r-,'^^^^6^''„8 9 10 11 12 13 14 16 16 17 18

20. —Three-phase single-layer lap winding with five-ninths pitch (i..

5
I coil pitch — = .556 \j Two
, poles. Nine slots per pole.

473
 Sec. 7-21 GENERATORS AND MOTORS

21. Fractional pitch single-layer lap winding. It is also possible t

have fractional-pitch coils with a one-layer lap winding, but here the nunibi
of combinations is quite limited, see Figs. 19 and 20. Inter-ooil connectioi
are shown for only one phase. Fractional-pitch one-layer polyphai
windings have the serious fault that in a certain portion of the slots, tl
phases alternate with one another, causing a very unfavorable distributic
of the m.m.f. of armature reaction. Thus with three phases A, B, and i

four slots per pole per phase, and 75 per cent, pitch, the distribution of tl
phases in successive slots is as follows: ACAABABBCBCCACAABABB, et
When each slot contains conductors of only one phase, the m.m.f. distrib
tion is very unfavorable, but with a two-layer winding with four slots p
pole per phase, and the same coil pitch, we obtain the following arrangemen
i AAAABBBBCCCCAAX .„
t CCC AAAABBBBCC C !
'"^''•

This arrangement provides a nearly sinusoidal distribution of the m.m.l.

22. Multi-circuit windings. Another classification of windings is a
cording to the number of similar circuits in each phase; e.g., a two-circ:\
220-volt alternator could be changed to a single circuit 440-volt machine 1

series-connecting the two parallel circuits. In three-phase alternators thf

is still another distinction, namely, between Y and A connection of the thi
phases.
E.M.F. QENERATION
23. Electromagnetic induction. The law of electromagnetically
duced e.m.f. may be stated in two ways: (a) whenever a conductor cut:
magnetic flux, an e.m.f. is induced which is proportional to the rate of cuttii
i.e., to the flux cut per sec; (b) whenever the flux linked with a loop
coil of wire, changes for any reason, an e.m.f. is induced in the loop or c
proportional to the rate of change of the flux and to the number of turns in i

coil. For all ordinary cases, statements (a) and (b) are exactly equivale
but for alternator electromotive forces, (a) will ordinarily be more convenie
24. E.m.f. formulsB. Let I = gross length of armature core, incl
V = peripheral velocity in ft. per sec. CBi = maximum gap density (m
wells per sq. in.) of equivalent sine-wave, e" = root-mean-square vr
per active conductor.
in. of N
= series-connected active conductors
E = volts per phase. kbi\
|

phase (twice the number of turns per phase).

kp are the differential factors, Par. 28 and 29.
Then

) :---t)(BilO =8.5d(Bi10
V2
(volts)

and
= kbkpe"Nl = 8.5kbkpt<S,\NnO
E (volts)
Another very common variety of the e.m.f. formula is obtained as folic:
let flux per pole in maxwells; then the average e.m.f. per active c
* =
-8
ductor is 2/*10 and neglecting differential action, the average e.in
,

-»
phase is To obtain the root-mean-square volts and
2f^NlO.
same time to take account of the differential action, involves the form
(/t/ = ratio of root-mean-square to average volts), and the diffi
factors, giving for the induced volts _,
E = 2k fkhkpf-^N 10
The three k'a are usually combined in a single term which has an K i

value of 1.05 for full-pitch windings.

2S. E.m.f. wave shape. * Assuming constant speed, the e.m.f. i

by a single active armature conductor, or by a group of series-conneo

ductors making up a coil side and lying in a single slot, is proport
each instant to the density of the magnetic flux through which it is '

and when plotted in rectangular coordjnates will have the same shapra
"field form," i.e., the curve showing the peripheral distribution m
entering the armature from the field poles (see Par. 32 and 33 ). ThiJ
be referred to as the elementary or slot e.m.f. It is an alt ernating e
• See also S. P. Smith and R. S. H. Boulding, 'The Shape of the
' Pm
Wave in Electrical Machinery," Journal Inst. Elec. Engrs., Vol. 53 (H
p. 205.

474
A. C. GENERATORS AND MOTORS SeC. 7-25

N
I 1

Fig. 21.
\~J
—Elementary field form.

475
Sec. 7-26 A. C. GENERATORS AND MOTORS
but visually not sinusoidal, see Fig. 21. The no-load wave-shape of
machine is then obtained by adding together the e.m.fs. of the Be:,
connected coil sides. This is very tedious as it involves the point-by-p
addition of several dephased non-sinusoidal waves. An approximatio
some kind is usually employed. The most satisfactory method of hand
this problem is as follows: Analyze the field form or slot e.m.f. into its
damental and harmonics; compound or add vectorialyin their proper p!
relation, the fundamentals of the several series-connected conductors or
sides, to obtain the fundamental of the resultant e.m.f.; and compound s
larly the harmonics of each order to obtain the resultant harmonic of ,

order. To this end the armature conductors are grouped as follows.

26. Similars. Any number of conductors or coil sides, 180 magi;
degrees apart (generally called similars), connected in series, alternu
right and left across the face of the armature, will yield an e.m.f. wa^
the same shape as that of the field form or slot e.m.f., the result b;
simply the product of the e.m.f. of a single conductor or coil-side, by;
number in series. • !

27. Phase-belt. In nearly all alternators the conductors of a single p i

are not confined to one slot per pole, but are distributed in several si
The group of conductors belonging to one phase and corresponding toi
pole, will be referred to as a phase belt. When the number of slots per I

per phase is a whole number, all the phase belts of a given phase are simi i

and the phase e.m.f. will have the same shape as that of a single belt. In;
layer winding the group of conductors for one pole and phase may be )•
conveniently separated into the top-of-slot belt and the bottom-of-slot i

particularly in the case of fractional pitch windings where these two I

are displaced circumferentially. See Fig. 78 and 79, pages 499 and 500
28. Belt differential factor. In general the resultant or vector su:
the e.m.fs. of the several coil-sides in a given belt will be less than i

numericalsum, owing to their phase differences. The ratio of the vectoii

to the numerical sum will be called the differential factor, which is al j
equal to or less than one. In the case of differential action within a si (

phase belt, the differential factor will be called the belt differential t&i
kb. Remembering that a fundamental phase difference of /S deg. mea i
nth harmonic phase difference of n/3 deg., it is easy to see that a fundam l

phase difference which affords a relatively large differential factor fo]

fundamental, may give a very small differential factor for one or nice
the harmonics. Thus, in a three-phase alternator with two slots per jt
per pole, or six slots per pole, the phase difference between two adjacent^
IS 30 deg. for the fundamental, 5X30 deg. - 150 deg. for the fifth harit
etc. The belt differential factors will then be <:6i = cos 15 deg. =0.966,
cos 75 deg. =0.259, kht = —0.259, etc. Thus the 6th and 7th harmoDK
greatly reduced without appreciably reducing the fundamental. E
ential factors for the fundamental and for the various odd* harm
up to the 27th, for 60-deg. and OO-deg. belts and for various numbers of
per pole are given in Table I, Par. 81. Differential factors for a 12C
belt may be obtained by multiplying those of the 60-deg. belt (same
by the 66 J per cent, pitch differential factors, Fig. 22.
29. Pitch differential factor. When the coil pitch differs from thi >
pitch, the e.m.fs. developed in the two sides of a single coil, or in th «
series-connected belts of a phase-group of coils, will differ in phase a 1

angle ff, which is the angle (in magnetic degrees) by which the coi
differs from the pole pitch. This introduces another differential

(--2) for the fundamental and cos -^- for the mth harmonic, wl
be called the pitch differential factor. Its values are plotted in i

SO. Phase differential ftictor. The addition of the two e.m.f.'^.

phases of an alternator, involves differential action of exactly t!;
kind as that between the two series-connected belts of a fraction
winding (Par. 29). In a three-phase F-connected machine, the an;
deg.. which is equivalent to a § pitch; and the phase differential fa
thefundamentalandforalltheoddharmonicsnotamultipleof three, .

while for the harmonics which are multiples of 3, it is zero (see Fie

I* Even harmonica are not present in any appreciable degree in tli'

waves of commercial alternators.

476
 .4. C. GENERATORS AND MOTORS Sec. 7-31

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I

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OOOOCO'HOOSCOOOOiO'HMOO
OStOi-Hi-iMOO'-^OO'-^OO'-^ oeO'-iT-i.-i^oooOi-;'-;'-;'-;
ddddddddddo ooo dddddddddddddo'
+++I I !+++! I 1++ ++ ++ 1++ ++
I I I I I

tDINCOroOst-tOOSlO N t" N "? O M!0owo>t-e<ie<ib-o»«otoo

oso>-i'-<c^oO'-;opr-ioO'-<
00 05'«)"'-iOOOO'-i'*050
O)C0'-l"-'.-lrtl-lr^l-<rH^.-^C<3O>
dddddddddddddd
+++1 I !+++! 1 I++ ++ 1++ I++I I 1 I ++

0>®>-i'-i<N'-iOi-<0 0'-;0»->iN
000>'^M'-"^C<l'*OiOOOO
dddddddddddddd
+++I I I+++I I 1++ ++ 1++ II ++
I I I 1 1

lONOtSrocOOlOIMiOiOC^OC!
lOTtiO'^-^OOOOOTf'l'O'* 0'-<OiO'^^»00^00'-<0>0
dddddddddddddd dddddddddddddd
+++ +++ ++ I I 1 1 I I
++ ++ ++++ 1 I I I
I
I

OOOWOOMOOCOtOOONOON
C50(Ni-iC*l'-i'-iC^^N50 05C5
O—I'-iaOOO'-i'-iOO'-l'-iOOOO'-l

dddddddddddddd
+++I I I+++1 I 1 I I ++ II ++ II ++ I 1 I I

Ot^OON-Mt^OOt^OOt^OCt^M

oooooooooooooo dddddddddddddd
+++I I I ++ ++++ ++++ I I I I

Tjlc<5«l->}<-*M(W*-^«MTCT)iro
cOO>OiOOOCDOiOiOO^OO
ddddoooooooooo
+++ 1 I I I I I +++++ ++I M 1++++I 1 I 1

oooooooooooooo
oooooooooooooo

II n II n II II u II n ii ii ii ii ii n II n II II II II II II II II II II II

477
Sec. 7-31 A. C. GENERATORS AXD MOTORS

Sl.2
 A. C. GENERATORS AND MOTORS Sec. 7-32

neld form of salient-pole alternators. Neglecting the fringing

IX atthe pole corners and assuming a uniform air-gap under all parts of
pole,the field form will be rectangular (see Fig. 23)
. The fundamental
wave of this field form has a maximum value: 5i = 1.27cosir/2(l-A:)Be
ip. Values of ai for various values of k are
k in Fig. 23. Fringing at the pole face edges
increase ai and chamfering the pole face will
»;ase oi slightly, (Ba being the actual gap den-
ial the centre of the pole face.
?. 24 gives the harmonics (up to the 19th)
ese rectangular field forms, plotted against A,
rms of the fundamental. The fringing will in
< cases eliminate the higher of these harmonics,
J considerably change the magnitude of the
ir ones, usually reducing them. Thus Fig. 24
< only a rough idea of the upper limits of the
T harmonics in the case of a uniform air-gap.
le pole face is shaped, these values may be
i farther reduced. Three actual and quite dif- FlQ. 27.- — Observed field
i t field forms are shown in Figs. 25, 26 and form.
J nd their harmonic analyses given below:

^1 :
3rd 5th
 Sec. 7-33 A. C. GENERATORS AND MOTORS
over each belt, the magnetic potential differences (ampere-turna) acrosa
air gap, and therefore the field form, is shown in Fig. 29.
A simple manner in which to obtain the equivalent sine-wave of sue
field form is as follows: Any such distributed field winding may be (

sidered as made up of pairs of conductors, the two in each pair being 180 (

apart. Consider the m.m.f. of a

single pair. The field form of the
pair if acting alone will be a rec-
tangle, Fig._ 30, of which the fun-
damental sine-wave has a maxi-

SegreM Belt Span

FiG. 30. —
Field form of single 18ft- Fio. 31. — Belt differential factoi
m.m.f. of distributed field windi
deg. loop, with its fundamental.
(Na> = No. of slots per belt.)

mum val
6th, i, el
m.m.f. a
the wind
small anc
winding
sary to (

'10

y
 A. C. GENERATORS AND MOTORS Sec. 7-34

(lots per belt, plotted against the belt span in degrees. Fig. 32 gives
I- belt differential factor of the harmonics for the case of a large number
I lots per belt.
Nik = the ampere- turns per belt, or per pole, and if Ki = ratio of gap
I'wre-turns to the total (including ampere-turns in the iron part of the cir-
n, the ampere-turns consumed in the single gap at the crest of the wave of
r ;netic p.d. across the gap is

2
Nil, = - kb/kpKiNib (amp-turns) (4)
IT

fre hf from Fig. 31 and kp from Fig. 22.

is
S be the air gap (inches) and Ki the contraction factor due to slot open-
t (Par. 40), the crest value of the equivalent sine-wave of gap flux den-
i is

(Bi = 3.2 KiNig -T- 5 = 2.03 khfkpKiKiNih (5)

i thus possible to produce a substantially sinusoidal distribution of mag-
I'O potential difference across the gap, and therefore of flux density in the
[i when the gap is uniform. If the teeth are highly saturated the field
ci will be flattened somewhat as compared with' the m.m.f. curve.
l. Tooth kinks. The field forms of Figs. 21, 25, 26, 27 and 29, are
Uvn as if there were no slot openings. Strictly speaking, they are there-
c the equivalent smooth-core field forms, but are usually referred to
i )ly as the field form. The presence of slot openings introduces flux
nations, and kinks in the slot e.m.f. If there are 12 slots per pair of poles,
,1'e will result an eleventh and a thirteenth harmonic; if 24 slots, a 23rd and

!;i harmonic, etc.

machines with a few large slots these tooth kinks sometimes dominate
'i

;1 wave shape. They may be largely eliminated by the choice of a frac-

tal number of slots per pole, so that the kinks will occur in different direc-
a's in different parts of the winding at the same instant. Sometimes
;1 end is accomplished by the addition of one dead slot. The extra slot
8 len called a hunting slot. An uneven spacing of the poles accomplishes
;1 lame end in the same manner. In machines with a large number of slots
3' 3ole, small slot openings and a relatively long air gap, the presence of
;c h kinks is not noticeable.

THE MAQNETIC CIRCUIT

'. Calculation of no-load saturation curve. The saturation curve,
hrinre of terminal voltage at no-load, plotted against field ampere-turns, can

150.000

75 100,000

^50,000
Sec. 7-36 A. C. GENERATORS AND MOTORS

Pole Co
 A.C. GENERATORS AND MOTORS Sec. 7-37

tween the pole core and the cores of the adjacent poles, and that (*;,) which
leaks between the pole shoe and the shoes on the adjacent poles. Below
are given formulae for calculating $;, the total leakage flux from one pole,
for rectangular (Fig. 34a), straight-sided with semicircular ends (Fig. 34b),
and circular pole cores (Fig. 34c); and for rectangular (Fig. 34d), and straight-
sided with semicircular ended pole shoes (Fig. .34e). FormulEe are given for
both non-stepped (that is parallel-sided) field coils, and for stepped or tapering
field coils. The notation is obvious from Fig. 35. NI = the ampere-turns
I
on one pole consumed in the gap, teeth and armature. The constants
•fci, ki, f\, and /z are given in Figs. 36 and 37.

37. Core leakage flux.

Rectangular (Fig. for non-stepped

\ coils.
34a)
{ *jc= {NI/l.b9)h[(2lc/nc) -fA.i]/2 for stepped coils.
Straight-sided with [^le={NI/\.o9^h[{2lc/nc)-\-hi]fi for non-stepped
semicircular ends j coils.
(Fig. 34b) { *(c= {NI/\.59)h{{2lc/nc) +fo]/2 for stepped coils.

Circular (Fig. 34c) / *;c= (iV//1.59)Afe/i for non-stepped coils.

1 *!c= (iV//1.59)/ife/2 for stepped coils.
38. Shoe leakage flux.
Rectangular (Fig. 34d) *i. = 1.255A'/«-f«)[(2i./n,)-fA,-i]
, Straight-sided with *i, = 1.255iV7«-f 3)[(2i./n») +A:s]
f semicircular ends
(Fig. 34e)
I

I If *i= ^ic + iu and *is the useful flux per pole, the leakage coefficient is
(*-F *;)/* = »'. If NI corresponds to * at no-load, v is the no-load leakage
coefficient va', if at full-load, v is the full-load leakage coefficient, as explained
in Par. 41.
39. Flux densities in the iron, and required ampere-turns. Divid-
ing *e by the cross-section of the pole-core, the flux density is obtained.
The necessary ampere-turns to drive the flux through the pole are deter-
mined by finding from
some such curve as that a
in Fig. 33, the ampere-
turns per in. necessary for
this density, and multiply-
ing by the length of the
pole core. Similarly the
ampere-turns for the yoke
may be determined, remem-
bering that only one-half
the yoke path is charged
to one pole, and that the
flux in the yoke is (*c/2).
The tooth density varies
from the tip to the root
of the tooth. A roughly
equivalent density is that
at a point one-third of 5
U loo lio 120 13U no 150 160 170 ISO 190 200
the distance from the nar-
Cucorr.cted Density-Kiloliut-s
j per
» Sq.In.
i u.
row to the wide end of
the tooth. If we let kt3 Fig. 38.
represent the width of the tooth density,
—
Curves for obtaining the corrected
tooth at this point, divided
by the tooth pitch, and if qn is the net iron length of the armature divided
by the gross core length, the equivalent density to be used in computing
ampere-turns for the teeth is that found by dividing the actual maximum
density ((Bj) in the gap by ktiqu, and correcting by the curves in Fig. 38,
which take account of the fact that all the flux does not enter the armature
through the teeth, but that some of it passes through the slots.
The density i^ the armature core varies from the centre of the pole to
the point midway between the poles, but a good approximation
is obtained
oy finding the density midway between the poles (*/2 divided
by the net
ron cross-section of the armature core) and estimating an
equivalent
Sec. 7-40 A. C. GENERATORS AND MOTORS
length of path for this density. A considerable error in this item is evidently
a very small part of the whole number of ampere-turns per pole.
For a non-salient pole machine the ampere-turns for the rotor can best bt
determined by finding the density midway between the poles, as for the
armature core, and approximating to an equivalent length of path for this
density. The rotor teeth may be treated exactly as the armature teeth.
A curve of terminal volts plotted against the necessary ampere-turns foi
the iron part of the magnetic circuit is called an iron saturation curve.
40. Ampere-turns for air-gap. If the armature were smooth-cored with
no air-ducts, the cross-section of the air-gap would be the area of the pole
face plus an allowance for fringing of the flux at the edges, and the actua
density would be that determined by dividing the total flux per pole by this
cross-section. This will be called the mean pole-face density. Since the fiuj
'

is crowded into the teeth as it enters the armature, the density which must
be used in computing the necessary ampere-turns is somewhat higher thai
the mean pole-face density.
The flux does not all enter the tips of the teeth, but fringes from the sidei
of the teeth, having the effect of increasing the width of the tooth tip (ten)
This equivalent tooth-tip is given by the expression wii-{-2Sc/ where c/ is th<
fringing constant and 5 the length of the air-gap. Values of c/ as a functioi
of wu>/S (the width of slot opening di-
vided by the air-gap length) are shown
.0.0t
in Fig. 39. Ifn is the tooth-pitch,
ao= (io«-f2Jc/)/T(is the fractional part
of the tooth-pitch, which is effective as
1.6

S 1.2
Cf
v
OS

0.4

Fia. 39.
 GENERATORS AND MOTORS Sec. 7-41

per cent, and 130 per cent, of the full-load terminal voltage, we shall obtain
he saturation curve over a sufficient range for all calculations of regulation.
1
41. No-load saturation curve with full-load leakage coefficient.
'his may be determined as follows: In Fig. 41, curve Fo is the no-load
aturation curve of the machine in question, curve Ni(f+y) is the m.m.f.
onsumed in the field core and yoke. Assume that F at full-load = 1.4Xi''i»
t no-load, see Par. 61. Assume also that the field leakage coefficient at
o-load isvo=1.3. Then at
ill-load the leakage will be
icreased by 40 per cent.,
nee it is proportional to the
impere-turns on the poles;
hd the full-load leakage co-
Oacient will bei'/=l+0.3X
.4= 1.42; i.e., the fluxin the
olesand yoke has increased
om 1.3 to 1.42, or 9.2 per
'mt. The corresponding ex-
•a m.m.f. necessary will de-
snd upon the shape of the
irve iVt (/+!/). and ia desig-
ited iVi.inFig. 41. Adding
lese extra ampere-turns to
le no-load saturation curve,
e obtain a point (P) on a
irve of no-load volts plotted Amp.Turna-^t
jSainstampere-turns for full- Fig. 41.- -No-load
saturation curve with full-
!ad leakage, or a no-load _
load leakage, vf.
'.turation curve with full-
'ad leakage. It is obvious
;iat a change in either phase or magnitude of the armature current will
'lange the ratio (,F/Fo), and thus the corresponding saturation curve, i.e.,
.ere corresponds such a load-leakage saturation curve for each load and
i)wer-factor, see Par. 61 et seq.
I. Table of average Sux densities in magnetic circuit of alternators
Flux density (lines per sq. in.)
Frequency
(cycles per sec.)
Ordinary steel Silicon steel

Armature 25 60,000 to 70,000 70,000 to 80,000

*
core 60 50,000 to 60,000 60,000 to 70,000
Armature 25 100,000 to 120,000
teeth 60 90,000 to 110,000
Pole core 95,000 to 110,000 lines per sq. in. for wrought-iron or steel
poles.
Cast steel 90,000 to 100,000 Hnes per sq. in.
Yoke*
Cast iron 30,000 to 35,000 lines per sq. in.

CHARACTERISTICS OF SYNCHRONOUS ALTERNATORS

'43. Regulation. The ratio of the difference between no-load and full-
id terminal voltage to the latter is called the regulation, constant speed
d full-load excitation assumed. Unless otherwise specified, unity power
3tor is assumed. The rise in voltage when the load is thrown off, or the
op when the load is applied, is chargeable to three causes: (a) armature
.action; (b) armature resistance;t (c) armature leakage reactance. See
^o Doherty, R. E. and Shirley, O. E., 'Reactance of Synchronous Machines
'

d Its Applications," Trans. A. I. E. E., Vol. XXXVII (1918), Part II,

,1209; and Still, Alfred, "The Inherent Regulation of Synchronous Alter-
.tmg-current Generators," Jour. I. E. E., V ol. 53 (1915), p. 587.
• The yoke density
of a slow-speed machine is frequently lower than
'^5,above, as the yoke is made large in order to obtain fly-wheel effect.
T The
resistance here employed should be larger (say 20 per cent.) than
e ohmic resistance, to take account of the core losses
due to the local or
kkage flux, and eddy currents in armature conductors.

485
 1

Sec. 7-44 GENERATORS AND MOTORS

44. Arinature reaction. The magnetic p.d. across the gap due to the
armature m.m.f. may be considered as made up of two parts: (a) A sinu-
eoidally distributed p.d. stationary with respect to the field poles; and (b)
pulsating kinks due to the distribution of the armature current in belts and
to its localization in slots, (b) is larger, the smaller the number of phases.
Neglecting (b), the maximum or crest value of this equivalent sinusoidallj
distributed m.m.f. is
-4i = 0.45 kbkpAr (amp-turns) (6"

where A = r.m.s. ampere conductors per in. of armature periphery

T = the pole pitch in inches; ki, = the belt differential factor, see tabulatec
values in Par. 31 ; and kp = the pitch differential factor, see Fig. 22.
If the field m.m.f. were also sinusoidally distributed along the air-gap, i
would bean easy matter to compound or add vectorially these two m.m.fs.
in order to obtain their resultant. This is nearly enough the case for alter
nators with distributed field windings. In the case of salient-pole machines
the m.m.f. across the gap at no-load is practically constant at all points of th
pole face, but in order to simplify their treatment, the equivalent sinusoids
m.m.f. distributions will be considered. This method results in considerabi
errors in some cases. The crest value of this equivalent sinusoidal distr:
bution is
Fi = aiFg (amp-turns) (7

where ai (Par. 32 and 33, Fig. 30) is about 1.27 a.ndFg is the constant mat
netic potential difference (in ampere-turns) between armature core and po'
core. With narrow or chamfered pole faces, oi will be slightly less. Fq — Kil
where F is the total field ampere-turns per pole and Ki a constant varying!
different machines and with different fluxes. A
rough average value of i
is 0.8, although in extreme cases it differs considerably from this value.
Eq. (6) holds for any number of phases; but for the case of the singh-pha
alternator, the alternating armature m.m.f. must be replaced by two ha!
value revolving m.m.fs., one forward and one backward with respect to t!
armature; or one stationary and the other at double frequency with respe
to the field. Eq. 6 gives only that component which is stationary wi
respect to the field. The other component induces double frequency e.tii.
and currents in the field coil, and reactive e.m.fs. in the armature. (In t
balanced polyphase case the backward revolving components of the sevei
phases cancel or neutralize each other.)
46. Leakage reactance is generally supposed to represent that part
the flux linked only with the armature conductors, but as a matter of U
the only such flux is some of tt
linked with the coil ends, since t

whole effect of the armature m.n

in the vicinity of the air-gap is mer
to distort the main flux. Howev
owing to the localization of the c
rent in slots surrounded by magne
material which moves with the »
currents, and owing to the group
of the slots in phase belts wl
move relatively to the field, t!
are local flux pulsations which
best treated as if separate from
main flux, although as a matter of f

they are only pulsating distortion

the latter. Armature leakage n
tance of an alternator is about as d
I .__i_- cult to define as to compute,
t— most practical purposes the f oilov
—
!

Fig. 42. Slot section. method will give satisfactory resi

46. Slot leakage is the cross-
flux, computed as if independent of the main flux. Referring to Fijr
the "inch permeance," or the flux linkage per amp-inch of slot, is
f/2 2</3
V). = 3.2 a'- (maxwt'llii^
Wfo/
and the corresponding or slot reactance per phase is

x,=-2irfkfilNNc, <p, 10-« (ohms)

4^
 — —
A. C. GENERATORS AND MOTORS Sec. 7-47

•here core length and

Na is the number of conductors per slot, I the gross convenient
^
the seriea-connected conductors per phase. The most form
1which to express reactance is as the ratio of the reactance volts to the induced
Ms. In this case it is

Qz, = 0.7i<ps Tt ~
kb
-IfT
»(Bi
= 4.44 -i7
N,p
;- 7S-
kb. (Bi
UU)

here T( is the tooth pitch in inches, A the root-mean-square ampere-

)nductors per in. of periphery, and iV.p the number of slots per pole.
; 47. Tooth-tip leakage. This includes the flux that links with the slot
ijnductors from tip to tip of tooth, sometimes ^^
V way of the interpolar air space, and
some-
mes across the air gap to pole face and back
!ain. The effect of the presence of the pole
oe is usually neglected in making this calcu-
tion, since not only is the air gap long in the
ajority of alternators, but even were it not,
le damping effect of the pole-face eddy cur-
;nts would tremendously increase the appar-
at reluctance of the path through the iron of
e pole face, with the result that it would
)proach the reluctance of air. In computing _
is flux, the integration is carried only to the
„
*''' *-^- Tooth-tioleakaa.
^°^^'^ tipie»Ka«. —
ntre of the tooth (see Fig. 43), since any-
,ing beyond this point would be chargeable to belt leakage The flux link-
e per ampere-inch of slot is

^,, = 3.2 (O.a-f - log, -^) =0.96-1-2.35 logio-^ (11)

d the per cent, tooth-tip reactance or reactance ratio, see Eq. 10, i

^P /A. = 4.44 yii kp

— Qxu O.T^ipttrt (13)
kb Ml N,p kb
48. This covers the belt pulsations mentioned in Par. 44
Belt leakage.
). It is difficult to define or to compute this effect in terms of an equivalent
ikage reactance, but the following method gives fairly satisfactory results.
>mpute the average mutual inductive effect of all the other slots in a given
It upon a given slot, by an extension of the tooth tip integration in circular
ithsto the edge of the belt. This is taken as a measure of the belt leakage.
le equivalent flux linkage per ampere-inch of slot, for a full-pitch wind-
H, is roughly, _ ^..„^
¥'6 = 0.7 (iV.,- 1) (13)
lere A'^^^ = number of slots per belt.
iThen since N .= N Bp'/p', where p' = number of phases, the
'^ ' *^ belt-reactance'
. . Bb '

"10 13

g,,=4.44^*-
<pb A 1\A
A-=3.3(^,-^M „„/l (14)-.
kb(S>i

1 pitch winding only.

full The effect of changing the pitch, on this"
•iment of leakage, is very marked, but not readily computed for the general
le. The pitch factor kp, as used when the slot is the unit, cannot be
•iployed when the belt is the unit. Certain special cases may, however,'
li computed. Take for example the case of a five-sixths pitch in a three-
Ijse winding; the three belts per pole are broken up into six equal belts
\h. a pitch differential action in each belt. For the purposes of this
caputation there are now six phases and qxb will be reduced to considerably'
1,1 than half of its full-pitch value. If A^jp = 6, qxb will be reduced to «ero.'
lV,p = 12, git will be reduced to one-third, and so on. For two-thirds
ph, however, the number of belts is not changed and the pitch factor fcp
^Ues directly.
yet <et =<pB-\-iptt-\-<pb be the total flux linkage per ampere-inch of slot, then
t total leakage reactance volts of the slot-embedded active conductors, in terms of
t induced voltage, is

Li g„ = 4.44^|^|- (1,5)
Nip Kb Oil
corresponding reactance in ohms is
xe = 2t fkpnNNc,V>M-» (ohms) (16)

487
 —

Sec. 7-49 A. C. GENERATORS AND MOTORS

For very hurried computations ^,is sometimes approximated without oom-
putation; it varies from 8 with shallow open slots to 15 with deep nearly
closed slots.
49. Coil-end leakage. This computation is simplified by the fact that
V»/, the flux per ampere-inch of
outside phase-belt-bundle, is nearly a constant
quantity for full-pitch windings. Its values
for all pitches of working range are given in )

Fig. 44.
<p/ The coil-end reactance in ohms is then —
xf='2rUflf^lO-^ (ohms) (17)

where If = the
length of a single coil end, or
the free length corresponding to one active
conductor, N
the active conductors per phase,
and 2p the number of poles.
The coil-end reactance ratio (Par. 46) is

«., = 1.48A.,„,^^A (18)

where k/ {=lf/T) is about 1.5 times the per cent, coil-pitch expressed as ^

a fraction (somewhat larger for very high-voltage machines), and Aj=t/I.

50. Total leakage reactance.

x-'X.+x/ = 2TfN10-»{kpnNc^e+^l,V/) (o^ms) (19)

L ^ /-AAA f" ''" I

1-48 fc/ \
 A. C. GENERATORS AND MOTORS Sec. 7-53

'
Starting with E and /, add Ir and Ix to get Ea; from the saturation
curve with full-load leakage (Figs. 41 and 46) take R add — A to get F, which
;

is the required excitation. From the saturation curve corresponding to

]
no-load leakage, take Ep; the regulation is then {Ep—E)/E. There are
many variations of the above method, some of which are contained in Par.
86 to 58.
The rise of voltage when the load is thrown off is partly due to the release of
the impedance voltage Iz, and partly due to the release of that part of the
field m.m.f. employed in balancing the armature m.m.f., A. The first of
these changes (i.e., from E to Ea) is dependent wholly upon the magnitude
of r and x and the power-factor of the load, r and x being assumed constant.
But the change from Ea to Ep is due not only to the magnitude and phase
of A but also to the degree of saturation of the magnetic circuit, i.e., to the
mean slope of the saturation curve between Ep and Ea.
63. Saturation factor. The degree of saturation maybe expressed in
terms of the saturation factor, which is defined as the ratio of a small per-
centage increase in excitation to the corresponding percentage increase in
the flux or induced voltage. The mean saturation factor between Ea
and £j? is o5/a5 (Fig. 46). Designating this by k,t,'Ep''EaF/k.tR. The
jaturation factor should be taken from the saturation curve for no load
eakage; but for other purposes, use the satu-
ration curve for full load leakage. (See Par.
11).

,
64. Short-circuit diagram and leakage
reactance. The short-circuit diagram is
,
?iven in Fig. 47. From this the leakage react-
ince may be computed as follows: From F
mbtract A (computed from Eq. 6) to obtain ft;
ook up corresponding Ea on saturation curve;
:= Ea/I and z = \/z' — r». In most cases it is
lufficiently accurate to subtract A from F nu-
nerically, since they are nearly in phase, and
.0 assume a; = r. x may be obtained in a
limilar manner from the zero power-factor
saturation curve. Par. 56.

FlQ. -Defining saturation

factor.
Fig. 47.
gram
— Short-circuit dia-
for alternator.

In both of these cases however the results are very crude, since a small
in A means a larger error in x.
ipror

66. Load saturation curve for sero power-factor. Referring to Fig.

8, curve the no-load saturation curve with full-load field leakage, and
E<, is
6 is the field ampere-turns corresponding to a given armature current on shorty
ircuit (E = O). From Fig. 51, oh is approxima^ly equal to A', ab
? laid off equal to A, the_jirmature m.m.f. Then oa approximately equals
i (Figs. 47 and 51), and ac is approximately equal to Ix. If any load has
ero power-factor and the same current as that assumed on short-circuit,
X will be approximately in phase with the terminal voltage E, and at right
ngles to I. Thus for any point Eo on the no-load characteristic, the ter-
ainal aero power-factor voltage for the given current will be obtained by
ubtracting Ix vertically, and adding A horiaontaUy, The zero power-
489
 )

Sec. 7-56 A. C. GENERATORS AND MOTORS

factor saturation curve_will then be obtained by drawing lines from B«

equal and parallel to cb, as shown. The fact that Ir is neglected is not
significant, since it is in this case at right angles to E and does not affect
the result appreciably. This curve may also be determined experimentally.
66. Load saturation curves at other power-factors. If the load
saturation curve at other power-factors could be obtained, it is obvious that
the regulation and excitation for any power-factor and terminal voltage could
be obtained directly therefrom. A semi-empirical method of obtaining these
curves, recommended in the latest edition of the Standardization Rules of the
A. I. E. E. is given in Sec. 24.
87. E.m.f. method. This method practically assumes a field flux
wholly dependent on the field m.m.f., as given by the saturation curve, and
that all the drop is due to an internal impedance which is commonly called
the synchronous impedance, 2«, of which the synchronous reactance
is x». Fig. 49 shows saturation and short-circuit characteristics with the
derived synchronous impedance curve, the ordinates of the latter being the
ratios of corresponding ordinates of the other two.
88. The m.m.f. method. This method is best understood by refer-
ence to Fig. 50, where the general diagram is dotted in. Starting
with E and 7, add Ir to E
to get E', which is assumed
to be the total induced
e.m.f., corresponding to R'
as taken from the satura-
Q tion curve. From R' sub-
tract the m.m.f. A' taken
from the short-circuit char-
acteristic xorresponding to
the particular current in

V2 10 20 24
Eieitlug Currrat ( Amp.

Fig. 48. —
No-load saturation curve and zero- Fia. 49. — Alternator char-
power-faotor load saturation curve. acteristic curves.

question. A' is the F of Figs. 47 and 51 and includes with the armature
m'.m:f. A, an additional m.m.f. AA' (Fig 50), which is practically equiva-
lent to R of Fig. 47, and which is the appro-ximate m.m.f. equivalent of Jj-
Under short-circuit conditions, E' = It and the diagram reduces to Fip. 51
whence it is obvious that the field ampere-turns at short-circuit practicallj
corresponds with what we have called A'.
69. Excitation characteristics. Curves showing the relation of exci-
tation (for constant terminal voltage) to the load current, at various power-
factors, are shown in Fig. 52 for a 1,600 kv-a. slow-speed alternator wit!
close regulation, and in Fig. 53 for a 6,250 kv-a. turbo-alternator with pooi
regulation. These were computed by the m.m.f. method.
60. Relation of regulation to per cent, armature strength anc
length of air gap. A study of Figs. 45 and 50 will show that for a givei
current and power-factor, the regulation depends upon the following ratio.'
A
IrlE^^(lT\ Ix/E.'-Q.iaKe Eq. 20); -,--q
R
m
 —
.4. C. GENERATORS AND MOTORS Sec. 7-60

J saturation factor, kst; and that except for their relation to the satu-
[a given gj will have exactly the same effect as the same numerical

\Q. 50. M.m.f. diagram (full lines) and general diagram (dotted lines).

20 40 CO 801001201*0160180
i of Full Load Armature Curreut

Fig. 52. —
Excitation characteristic curves
for a 1600-kv-a. slow-speed alternator with
relatively long air gap.
280
Sec. 7-60 A. C. GENERATORS AND MOTORS
Of these four ratios, qr varies from less than 0.005, in large turbo-alteri
nators, to 0.02 or more in small slow-speed machines; Ox from 0.04 to O.h
or more; g from 1.00 to 0.35; and k$/ from 1.5 to 2.0. These last two aretW
dominant factors in regulation. i

Since (approximately) R = 0.313(S,iS/(KiKdKi) (see Par. 38 and 40), «

a = (A/R) = aA3kikpKiKdKiAT)/((&iS) (2l|

or taking average values for the K's,

fl .=0.9(Ar)/((Bi«) (22

100

80

60

40

20

1
5 10
 A. C. GENERATORS AND MOTORS Sec. 7-61

64 and 55 are plotted from Eqs. 24 and 25. For email low-speed
ji.

I where ^r and Qx are larger than here assumed, the curves will
chines
j' higher at their lower ends,
a little
hus good regulation means large R' and long air gap, longer in
portion to A and t, i.e., very long for large high-speed machines
i h as turbo-alternators. In fact, to obtain a regulation of even 10
1 cent, in large turbo-alternators would necessitate a tremendous air
it and more field copper than there is room for.

lOU
Sec. 7-63 A. C. GENERATORS AND MOTORS
be about 3 times full-load current. At no-load excitation the short-circuil
current will be 2.7 times full-load current. For an alternator with 20 pei
cent, regulation and a saturation factor of 1.6, the short-circuit current wil
be 1.56 for full-load excitation and 1.18 with no-load excitation.
63. Sudden short-circuits. Since on short-circuit, most of the fielc
m.m.f. is consumed in balancing the armature m.m.f., the net m.m.f. and th(
flux are greatly reduced. If the short-circuit is applied suddenly, the sudder
decrease in flux induces a large e.m.f. and current in the exciting winding
which tries to keep the flux from changing, and as the electromagneti(
inertia and the time constant of the combined circuits are large, an appreci-
able time elapses before the field is destroyed. Meanwhile the opposing
m.m.fs. of armature and field rise until nearly all the field flux is shiintec
across between field and armature. To do this requires a m.m.f. as man;
times greater than that at full-load, as the full-load field flux is greater thai
the total full-load leakage flux (field and armature). Thus if = 1.12 ai'

full-load zero p.f., and Qi=0.10 (salient pole slow-speed machine), the r.m.s
armature amperes will rise temporarily to nearly 5 times its full-load value
and owing to the fact that one of the phase currents will be boosted up abovi
its zero axis, because of the position of that phase at the instant of short
circuit, the maximum instantaneous current in one phase may be nearl;
double the maximum value of the above r.m.s. current.
In non-salient pole turbo-alternators v may be as low as 1.04, Qx as lov
as 0.04, the r.m.s. current nearly 12 times full load, and theinstantaneou
maximum more than 20 times normal. This means mechanical stresses oi
coil ends more than 400 times normal, which shows the imperative necessit;
of providing great strength in the design of the end connections and th
means for their support.
64. Current-limitingr reactances. As the total leakage (v— l-|-g.)
should not be less than 0.15, external reactances are very often supplied t'
protect against sudden short-circuit^. See Par. 140.
65. Rating of alternators. As the armature current, irrespective o
power-factor, determines the armature copper loss, it is customary to rat
alternators in kv-a. rather than in kw. In fact at low power-factors, ao'
therefore at smaller values of delivered power, but with a given current an'
terminal voltage; the flux, core-loss, field current and field copper loss are a
larger than at unity power-factor. Therefore the safe output is less for
given temperature rise. It is thus necessary to specify the lowest powei
factor at which an alternator is expected to operate, "in order that enoug
excitation may be provided, and the corresponding field copper loss diss
pated without excessive temperature rise. The maximum safe voltage ral
ing is that which can be maintained at rated current and power-f actr
with the excitation voltage available, and without exceeding approve
temperature limits for the field windings.
66. Automatic voltage regulators, external to alternator. Tb
most successful of these is the Tirrill regulator or some modification thereo
In principle it is merely a voltage-operated relay which closes a low resistanc
by-pass around the shunt-field rheostat of the exciter when the voltage
too low, and opens it when the voltage is too high. This relay vibrati
continuously, so that the exciter-field current does not change at each contai
by any considerable amount, but assumes a pulsating intermediate vali
depending on the percentage of time the by-pass is closed. With propi
adjustment this regulator will maintain the voltage as nearly constant i
is ordinarily desired in commercial power plants.

SYNCHRONOUS MOTORS
67. Structure. The synchronous motor is simply a synchronous gei
erator with its function reversed. In structure it usually consisLs of
synchronous generator with the addition of pole-face windings to_ provid
suitable starting characteristics. If an auxiliary motor is provided fi
starting, there is no need for the pole-face windings for starting purpose:
although it is still desirable for counteracting "hunting." (See Tar. %
to 79.)
68. Diagrammatic representation. Owing to its simplicity the e.fti

method of diagrammatic representation will be employed here, in spite t

444
 GENERATORS AND MOTORS Sec. 7-69

i A single-phase machine or a single phase of a

considerable inaccuracy.
, machine will be considered for the sake of simplicity. Single-
>lyphase
synchronous motors are, however, practically never actually employed.
lase
69. Theory of operation. Consider a synchronous machine driven
such speed and at such excitation that its e.m.f. (.E2), in frequency and
lagnitude, is exactly the same as that (Ei) of the supply circuit, of which
h g f d

I'lr
f<-
— EicoB Oi >|

Fig. 56.- -E.M.P. vector diagram of synchronous motor.

le voltage and frequency may be assumed constant. Assume also the
fhase of the machine voltage in exact opposition to that of the supply
c'tage. As these two exactly neutralize, there will be no current when
fie machine is connected to the supply circuit. Imagine now the
power removed.
riving The machine will begin to slow down; but
soon as the retardation begins, Ei falls back (clockwise), yielding a
i

f^sultant E, and a current I = E/z, (Fig. 56), where z, is the synchronous

inpedance of t"he motor. As r. is almost wholly synchronous reactance
:;he resistance being frequently not more than 5 per cent, of Xi), the cur-
|!nt will lag almost 90 deg. behind E, and, for small values of <p, will
e nearly in phase with Ei and in opposition to Ei. Thus the power Pi
'elivered by th e supply circuit is E\l cos di (proportional to the area of the
ictangle obdg), the power P2 transformed into mec hanic al formin the motor,
i Eil cos 02 (proportional to the area of rectangle abdf) and their difference
\~P-2 = I^r is the ar matu re copper loss in the motor (proportional to the
rea of the rectangle oafo). Other losses are neglected.
The power (Pi) transformed is a function of <p, the coupling angle; it is
_
P2 —
= E-fi cos ( -^~^cos(9-v) (watts) (26)

The
significance of the negative sign is that the electrical power is negative,
e., received instead of delivered. In Fig. 57, —
P2 is plotted against <p-,
•hence it appears that as the motor lags (not in speed but in phase) behind
the supply e.m.f., theoutputincreasea
to a maximum, then decreases, be-
D
comes negative and returns to zero.
As soon as <p has opened out to a point
such that P2 is sufficient to carry the
load,it will hang at that point asif the
motor were driven by an elastic coup-
ling. If the load increases, <p will in-
crease accordingly, until the maximum
point is passed, when the motor will
break down. During a little more
than a half ofeach slip cycle (see Fig.
67), the motor is acting as a genera-
tor, since — Pi is positive, and is in
series short-circuit with the line. So
much of the kinetic energy of momen-
tum is lost during this half of the
slip cycle that a synchronous motor
does not readily pull back into step
after once breaking, even if the me-
.
chanicalload beimmediatelyremoved.
fr visualizing these relationships and their causes the Blondel
diagram is
y far the simplest device.

495
Sec. 7-70 GENERATORS AND MOTORS

Blondel diagram. Referring to Fig. 58, the isosceles triangle QAC

70.
is constructed on the base Ei with base angles, 9 = tan~'(i./r). It cat
easily be shown that with constantimpressed voltage Si, and constant load'
Pi, the locus of the point B, as the excitat ion and Ei vary, ia a circle witl
centre at C and with radius y/jEl/2)^^^^^r -i- coa 6. If Pi = 0, the radiui
is (Si 4- 2 cos e)= CA
and the circle passes
through O and A. As
Pi increases, the radiw
decreases until it be-
comes zero, which cor-
responds to the maxi-
mum possible output
with the given motoi
atthegiven impressed
e.rn.f. But this theo-
retical limit is never
reached practically,
because of the very
large value of Et re-
quired to reach up to
the high-power circles
of small radii. This
will be better appreci-
ated by reference to
the diagram of Fig. 59,
Bad. of Power Circle - f^-|^' - P^ r where the proportions
\ are more normal and
FiQ. 58. —Blondel diagram for synchronous motor. the point C
the page.
is far off

For varying load and constant excitation, B moves along a circle about
A, clockwise for increasing and counter-clockwise for decreasing loads.
The maximum load for any given excitation occurs when B falls on AC;
beyond that B swings
around on to circles of
smaller power, and the
motor breaks down; i.e.,
the decrease of cos 6i more
than balances the increase
in/.
71.Interpretation of
Blondel diagram. In
Fig. 58 the area inside of
the zero-power circle cor-
responds to motor power,
and that outside to gener-
ator po wer the area to the
;

left of AC corresponds to ,

stable operation and that

to the right to unstable
operation; the area within .

the zero- pow er circle and '

between AC and OC corre-

sponds to stable motor
operation with a lagging
current; and that to the Fia. 59. — Portion of Blondel
scale.
diagram drawn to
left of OC to stable motor
operation with leading cur-
rent. The point B is not only the extremity of the Et vector, but may
be used also as the outer end of the current vector, since E is proportional
to /, and angle COB = ffi. Thus when B falls on OC, I is in phase with E\ and
J is a minimum for that particular load. With normal steady load con-
ditions, the angle never approaches the angle 0, i.e., the point B never
<t>

approaches the breakdown point on AC (see Fig. 59) but if either the load
;

406
 GENERATORS AND MOTORS Sec. 7-72

or the frequency of supply pulaatea or changea auddenly, a hunting may be

get up which will carry B
over into the region of unatable operation.
72. Excitation and power-factor curves. The familiar "V" curves of
current vs. excitation or induced e.m.f. may be easily obtained from the
;Blondel diagram. This has been done for a 60-h.p. motor, and the result
is shown in Fig. 60. Power-factor curves similarly obtained, are shown in
Fig. 61.

120

100 aOO 300 400 500 600 700 800

iB-daced E.M.F ~ Et
Fig. 60. — V-curvea for 60-h.p. synchronous motor.

73. Synchronizing power. By this is meant the stiffness of the coup

ng or the change in power absorbed per degree change of the coupling
ngle it increases with the air gap and inversely as g'(=' A'/F).
<t>, See
ar. 60.
74. Hunting of synchronous motors. Owing to the elastic nature
; the electromagnetic motor coupling, any impulse willtend to set up an

100 200 300 400 500 600 700 800

I
Induced E.MJ. « JETs

Fig. 61.- -Power-factor curves for 60-h.p. synchronous motor.

cillation about the position of equilibrium, which will continue until the
ergy by which it was initiated, is absorbed by the extra losses incident
the oscillation. Such oscillation is called hunting, and the absorption of
e energy of oscillation is called damping.
78. Hunting may be instigated either by a temporary disturbance,
ch as a sudden change of load on the motor or of the frequency of supply.
497
 — i

Sec* 7-76 A. c. generators and motors

or by some periodic disturbance (Par. 76) such as the pulsation of impressed
frequency set up by the prime mover. This periodic disturbance may be
one of comparatively high frequency due to the pulsation of the crank efforll
of a reciprocating steam or gas engine during each revolution, or one ol
comparatively low frequency due to the hunting of the governor of the prime
mover.
76. Frequency of hunting. If the period of the impressed disturb-
ance be approximately equal to that of the natural oscillation of the motor
there will obviously be a tendency for the motor to hunt with increasinf
amplitude, which may result in a complete breakdown or pulling out o
step. A periodic pulsation in the load on the motor may also produce th«
same result, although such is much less common. It is thus important te
know what is the natural frequency of oscillation of a synchronous motorj
and upon what factors it depends. i

The natural hunting frequency is approximately i

"
/ ~'

A = 0.422 El V -r
Jz,
— r-
rev. per. min.
(2r
1

where J is the moment of inertia in lb. ft." and p' the number of phases.
The z$ used in Eq. 27 should be the combined impedence of alternator
line and motor. The smaller the motor as compared to line and alternator
the less will be the effect of line and alternator impedence upon the huntinj
period of the motor.
77. Dampers. Forced hunting may be considerably reduced and tern
porary oscillatioms more quickly damped out, by means of field dampers
consisting of : (a) a copper loop around each pole face; (b) a copper bridg
between poles; or, better still, (c) a squirrel-cage set of copper conductor
through the pole face with end rings. These dampers tend to check pulsa
tions of the pole-face flux due to the pulsating armature to. to./., by inducei
currents which absorb the energy of oscillation.
78. Length of air-gap. A short air-gap, other things being equal
results in a large synchronous impedance, a large per cent, armature reactioi
(q^ =A -i- R), a soft electromagnetic coupling, and a longer natural huntin;
period. This is desirable up to a certain point, as it decrf ases the frequenc;
of hunting, improves the self-starting quality, increases the effectivenes
of the damping devices and cheapens the machine; but there is an obviou
limit to the desirable softness of coupling, namely, that beyond which ther
is danger of a motor breakdown. The value of g'( = A'/F) should rarel.
be more than 0.6 when F is taken at full-load and unity power-factoi,
Also, referring to the Blondel e.m.f. diagram, it appears that with a large 31
(short air-gap) there will be a large variation in the power-factor of the moto,
from no-load to full-load under constant excitation, or a frequent adjustmen
of excitation will be demanded in order to maintain a constant power-factoi.
79. Self-starting synchronous motors. The a.c. starting of tli
polyphase synchronous motor is as follows: If the field circuit of such
motor be opened and the armature be supplied with polyphase current;
there will result a fairly uniform field revolving around the periphery of tb
armature. Any energy transmitted across the gap to the field poles throug
the medium of this revolving field must be accompanied by a correspondin
torque. Thus any hysteresis or eddy-current losses in the pole faces, dii« •

the revolving field, represent a torque; or if the pole faces carry dam
coils these will act as the short-circuited secondary of an induction mo;
yielding a torque depending upon their reactance and resistance.
In this way a polyphase synchronous motor will supply a small startin
torque, sufficient to start without load and run nearly up to synchronisnr.
if it is a salient-pole machine it will then fall into step. Following this th
field circuit of the motor may be closed and the motor is ready for the applf
cation of its load. If it is a non-salient pole machine, it will not com
quite into synchronism until the field is excited, after which it wi,
usually pull itself in step. It is sometimes even possible, with a littl
coaxing to start a polyphase motor when the only torque is that supplie.
by the hysteresis and eddy-current losses in laminated pole faces, althoug
this is not a very satisfactory arrangement whore frequent starting is r«,
quired. With damping coils, however, a polyphase s>;nrhronous moK,
will.Btart readily on reduced voltage and without excessive current.

498
 A. C. GENERATORS AND MOTORS SeC. 7-80

,80. Polarity. During acceleration with open-field circuit, the induced

larity in any given pole alternates less and less rapidly as the speed ap-
saches synchronisni. The final polarity of any pole, when the speed
3 reached synchronism, is largely a matter of chance and obviously may
t be the same as produced by the field current as connected. If these
iarities are in opposition, the revolving part will slip back one pole when
! field circuit is closed, the large time constant of the field circuit allowing
s to takeplace without serious shock. It is safer, however, to determine
.ipolarity before closing the field circuit, and reverse the latter if necessary.
II. Starting current. As the chief function of the starting current is
itation, the shorter the gap the less the current required.
The minimum starting current for polyphase synchronous motors is usually
I h as to require only a portion of the line voltage for starting purposes,
3 being obtained by means of inductionstarters. If, for example, a cer-
I
I motor requires in starting, double full-load current at half line voltage,
t line current at starting would be practically equal to the full-load run-
rg current.
a. starting: synchronous motors by external means. Where
starting current is objectionable to the system, external means, such
t

or induction motors, must be employed.

trie, With single-phase synchro-
I s motors, this is obviously necessary.

!hapter VI, of" Design of Polyphase Generators and Motors," by Hobart,

8 forth reasons for employing synchronous motors more frequently.
This
r rence contains descriptions of methods
of building synchronous motors
»,i high starting torques.

i. Effect of differing impressed and induced wave shapes on power-

f ;or. When the impressed and induced e.m.f. waves are of different
sue, the unbalanced e.m.f. harmonics produce wattless harmonic
currents,
» 'h though small compared to the full-load current may
be considerable
« I respect to the no-load fundamental current. Thus the p.f. at no-load
« be less than unity even with the fundamentals of the current
Hfuise.
and e m f
METHODS OF SYNCHBONIZINa
Necessary conditions. Impressed and induced e.m.fs. equal,
1.
0] and of same frequency.
jsite,

.
Synchronizing with lamps. Connect lamps in series between the
>.

;r iming machine and theline. When thelamps are bright (or dark, accord-
in: o whether the machines
are connected in unison or in opposition in the
8J hronizing circuit) and the beats are very slow, showing opposition of
,

piieand approximate synchronism, the line switch maybe

closed and the
in hine will quickly settle down to stable operating conditions.
If a motor,
tt load may then be applied.

the case of a three-phase machine, lamps should be connected in

at
le two phases, and if both sets are not dark at the same time, there is
in !ation that the three phases are
not connected in the proper order and
M two of them should be interchanged. The chief objection to the use
01 mps for synchronizing is that they do not
tell just when the two e.m.fs.
ar n exact opposition, nor whether
the in-coming machine is fast or slow,
ai)ugh with a little experience it is possible to become
quite proficient in
tti use.
Synchroscope. Various electromagnetic instruments called syn-
•

CDQizers, synchronoscopes, synchroscopes, etc., have also been devised for

m ating synchronism. In most of these, the principle of operationis that
01 3 rotary held, synchronism beingi ndicated
in n-roming machine is above or
by a pointer on a dial. When
below synchronism, the pointer revolves
in le direction or the
other respectively, and at a rate proportional to the
811 or beat) frequency. At synchronism the pointer stands still, and in a
po ion on the dial which indicates the
relative phase of the two e.m.fs
le torm of synchronizer is
constructed as follows: The armature consists
<M o coils at right
angles connected in parallel, a non-inductive resistance
ju nes with one and
an inductive resistance in series with the other. The
Bi^jnary held coil is connected to the
supply bus and the armature to the
•a- mmg
machine. The split-phase revolving field produced by the arma-
""{Tents, reacts on the alternating field to produce
a rotation whose speed
ainerence between the frequencies of armature and field cur-
B.1
"" .
wu
When these are equal the armature coil remains stationary.
Sec. 7-87 A. C. GENERATORS AND MOTORS
PABALLEL OPEBATION OT ALTERNATORS
87. Mechanical analog. When two or more alternators are connect
in parallel and driven at the same frequency, they are aa if coupled togetl
by an elastic coupling just as in the case of a synchronous motor connected
a generator. Thus they must run at exactly the same frequency as long
they are coupled.
88. Dlyislon of load. Consider two similar alternators driven by sei
rate prime movers, of which the speed characteristics are shown in Fig. 62,
o and 6. Then if the speed is that represented by the horizontal line ss, \

powers supplied by the two prime movers will be Pa and Pb respective

The division of load will then be wholly dependent upon the speed chari
teristics of the prime movers, i.e., upon the governors.
89. Division of reactive current. The only effect of changing the i

citation on either machine is to change the division of reactive current: e

starting with equal loads and currents, if the excitation of a be increased,
will take more of the lagging reactive current, and b will take less. A
inequality of excitation is equalized by a circulating reactive current whi
transfers the excitation from the overexcited machine to the undereicit
one. The terminal voltage will be determined in any case by the to
excitation of both machines and by the magnitude and p.f. of the load.
When the voltage of a power plant is controlled by a Tirrill regulator, a
ing on the exciter bus from which the fields of all the parallel connected un
are supplied, the per cent, increase in excitation for a given increase of lo
will obviously be the same on all the alternators. But if one alternator ha
close regulation and another poor regulation, and if in the first case they shai
the active and reactive currents in proper proportion, with increased lo
the close regulation machine will be relatively overexcited and will ta
more than its share of the lagging reactive current.
90. Switchboard control of speed of prime movers. In prime movi
with very close speed regu
tion (no-load to full-load),
is obviously necessary tt
the two speeds be very closi
adjusted (Fig. 62), andthii
often difficult by the cut-ai
try method, which in so:
cases requires shutting do
each time to adjust the gi
, ernors. Large units are of I

^P*^ provided with a means

governor adjustment duri
operation. This may be
complished by means of
small motor connect
through worm gearing to '

governor adjustment a
controlled from the swit
Load board.
Fia. 62. — Diagram of division of load be- 91. Oovernor dampi
tween two parallel-connected alternators. to prevent hunting. Si
den changes of load f requen
cause the governor to hunt, i.e., open up too wide, then close too far and
on. This may be easily preventeci by a dash-pot connected to the govern
ELEMENTARY OUTLINE OF THE DESIGN OF STNCHRONOU
MACHINES
92. Specifications. Every electrical machine is built to meet cert
specifications whether proposed by the purchaser, his engineer, or the mai
facturer. In addition to the ouatonnary specifications there is always '

question of first cost which must be reduced to a minimum. Many of tb:

specifications, requirements, or standards are thoroughly treated in J

Standardization Rules of the American Institute of Electrical lOngmW;

these are given in Sec. 24. For a synchronous alternator the specificaf"
refer briefly to the following: frequency; number of phases; rev. 1

min.; terminal voltage; rated output in kv-a.; minimum power-factt

500
 A. C. GENERATORS AND MOTORS See. 7-93

ipcrature rise (Sec. 24); efl5cien;y (Sec 24); inherent regulation; per cent,
cage reactance volts; insulation tests (Sec. 24); wave form. These are
I all specified in each case, whereas in some cases much more elaborate
fjifications dealing with the details of mechanical and electrical design are
fplied. With reliable manufacturers, very simple specifications are or-
iirily sufficient, telling chiefly what the machine shall accomplish rather
a how it shall be built. In the case of many modern alternators, regula-
, is not a controlling specification, it being in most cases important to
.

fe a high reactance rather than a low one (Par. 63 and 64). Efficiency
[uch is also not directly a controlling factor in design,. but chiefly as it is
I»sary to keep down the heat developed in the machine. A fraction of
'•r cent, in efficiency is not as important to the user as a safe operating

perature.
List of symbols used.
ii.
i=»Max. value of equivalent fundamental sine- wave of air-gap flux
^ density (lines per sq. in.).
i= Actual max. flux density in air-gap at pole-face (lines per sq. in.).
^= Maximum apparent tooth-density of flux (lines per sq. in.) in teeth.
^= Diameter at air-gap (inches).
!;=Depth of slot (inches).
'= Volts induced per in. of active armature conductor.
Frequency (cycles per sec).
,=
»= Allowable copper watts per sq. in. of armature surface.
[= k.v.a. output.
,= developed in the armature.
k.v.a.
Belt differential factor.
1=
i«»
specific output.
" pitch differential factor.
I=» ratio of pole pitch to gross armature core length.
gross armature core length.
cir. mils per amp.
no. of pairs of poles.
ratio armature to gap amp-turns at full load.

ratio of net iron length of armature to gross length.

ratio of coil pitch to full pitch.
ratio of slot width to tooth pitch.
rev. per min.
- Temp, difference in deg. cent, between armature conductor at centre
and at end.
peripheral velocity, ft. per sec.
wt. of armature copper (lb.) per kv-a. output.
1= peripheral loading; ampere conductors per in. of armature periphery.
output coefficient.
pole pitch (in.).
Output equation. The volt-amperes per sq. in. of peripheral sur-
(Par. 24) are Ae" =-S.50kbknAv^BilO-», and the
total power developed, in
is, Ka = 8.50irkbkpAvBiDllO^^.
Allowing a maximum drop of 5 per
between induced and terminal volts, and taking Bi corresponding to
oad, the kv-a. output is
I
K = 2.54khkpAvBiDllQ-iO='koDl (kv-a.) (28)
ace D = 720r -i- (wR)
l=l.72X10^KR-h(kbkpABiv^) (inches) (29)
i-bikikpAvBilQ-i' is the specific output, or the kv-a. per sq. in. of pro-
Id area of the air-gap cylinder. By substituting for v its value irDR/720,
jo tain
K=l.llkbkpABiDnR10-i"- = ^DnR (kv-a.) (30)
le i = K/(DnR) = l.llkbkpABilQ-i2 is called the output coefficient.
Pffkb = 0.950 and kp = 0.95, this may be written, { = (A/ 1,000) (Bi/ 10<) 10"'.
etimes ko andsometimes f is more convenient as a starting-point for
both being rough measures of the economy of material.
poinary design,
ajor design constants. Bi, v and A are the major design constants,
',
their choice (R being specified) determines the general dimensions D
• of the machine. The larger these constants, the smaller in general
W the product Dl, and, within certain limits, the weight and cost of the
une. The considerations which govern the choice of these constants

501
Sec. 7-05 A. C. GENERATORS AND MOTORS
are so numerous that they cannot all be given their due weight in any dire
method of attack. Some of the more important considerations and hn
tations are as follows: Par. 96 to 107.
Ratio of pole pitch to core length.
k, = t/1 = 3.5kbkpABiv* -i- ( lO'/A'/Z)
Number of poles.
2p = 120///e (3
Pole pitch.
T = 6b// (inches) (3

95. Tooth-denSity limit. In order to avoid excessive eddy-curre

losses in the slot conductors and in the teeth, the flux density Bir at t
narrowest part of the teeth should not exceed (for open slots) the values
Par. 42, although for partly closed slots and stranded conductors 10 to
per cent, higher values are safe. Bg is related to Btr as follows for the rot
or internal element, and parallel-sided slots:
«, =(B,rg.((l - Q«.- 2d./Z)) (a
and for the stator or external element
(Bff = (Birg.j(l-g«,) (5

(Bj is usuallyslightly less than (Bi, (the crest of the fundamental sine-wa
of flux, see Fig. 23, and Par. 32). Also in extreme cases the tooth saturati
flattens the flux distribution curve still more. For laminations 0.014
thick, qu varies from 0.7, in an exceptionally well ducted core, to 0.8, ir
poorly ducted core, and 0.9 in a core without ducts. Thus if (Bir is assuni
at its reasonable upper limit, and qu is known, the relation of (&(, to Qm
fixed.
96. Beatingr limit. At 60 deg. cent, the copper loss under 1 sq-
of armature surface is hc = A/m, the resistance of one circ.
mil. inch of copi
at 60° cent, being just 1 ohm. he obviouslylimited (a) by the heat
is : (i

sipating power (//o) per sq. in. per deg. cent, of temperature rise, (b) by I

allowable temperature rise, r,(c) by the relative amount of coreloss, and

by the relative amount of coil-end surface. Assuming average values of (

(c) and (d), Ha will vary with the nature of the ventilation, the perii
eral velocity, and the amount of heat thrown off by the rotor. For op',
salient-pole machines, a very rough preliminary guide is
;»c = A/m = 0. 4(1+0. 016t)) (watts per sq. in.) (*^

For high-speed turbo-alternators he has little relation to v, owing to 1j

widely differing methods of ventilation, and varies from 0.8 to 1.6.

9T. Temperature gradient in slot conductors. Assume that
the heat developed in the active conductor is conducted longitudinally to ',

coil ends. This is approached in high voltage stators. Then the te

perature difference between centre and end of conductor will be Te'-il
1272)/m2, where I is the gross ^ore length in inches. Or if Tc be limite(
will be limited, thus I = (m^/fl)/ 127. Thus the larger the value of m,
longer may be the armature core without excessive temperature differeiK
The table in Par. 98 gives the temperature differences in deg. cent,
various values of I and m.
98. Temperature differences between centre and end of armatt
conductors
 A. C. GENERATORS AND MOTORS Sec. 7-99

19. Weight of copper vs. A. With Ae(=A/m) limited, mmust increase

hA. Then the total weight of active copper (also of total copper if k»
unchanged) will be proportional to A.
00. Depth of slot. On the same basis the slot depth will be proportional
li!. Slot reactance does not limit A and slot depth, as is sometimes the
te with induction motors (see Par. 251).
01. Armature-reaction limit. If on the score of regulation, e.m.f.
'
ire shape, or stability, it be desired to keep S^(
= ^ -^^) within any given
Ivit, it might become necessary to limit the ratio A/(B, see Eq. 22, Par. 60.
02. Choice of (B and A. From the standpoint of the economy of
ii;erial or of the maximum output coefficient, that value of gro.is
the best
vch results in the maximum product (BiA. But since, for a given depth
clot, A increases as (Bi decreases, the maximum product will occur where
t net width of slot (excluding insulation) is approximately
equal to the
rimum tooth width, i.e., when gnr>0.5. A considerable change in qi.
f:(i the exact value which makes (BiA a maximum, does not seriously
r ice this produ t, so that considerable variations from the best value of
fl.will be found, as there are other considerations
involved.
:. Assume q^c chosen, e.g., to keep down the ratio A (B (Par. 101), or to
n e (BiA a maximum (Par. 102). Assume also <S,tr as chosen (Par. 96);
then
&g given by Eq. 34. ,..'.,.,, , . <. x
limit of A is likely to be set for turbo-
u
Assuming Ac constant, the upper
alternators by the limited space for
copper on the rotor, since this limits
F, and A (and therefore A) must be
smaller than F. A glance at Fig. 63
shows that the cost of copper is not
likely to set the A limit. In fact, an

-t6
Sec. 7-104 A. C. GENERATORS AND MOTORS
The weight of armature copper is a consideration but a relatively un
portant one in high speed machines; in lbs. per kv-a. it may be expres
approximately as follows:

^Ib. per kv-a.)

1,000 VMffl. '"'''' KRf/ (

which has its lowest value with respect to v when

« = 100 -Sl
j^^i^ and^,=-^ (

But for high speeds, this would result in a very long machine of sn
diameter and hard to ventilate; so that larger values of kz are usually e
ployed for high speeds.
In Fig. 63, W
c is plotted against v for a case where the following val
obtain: ii: = 10,000;/ = 25; ii = 1,500; A = 1,200; (Bi = 40,000; 95 = 0.667; k,
0.866; TO = 1,000; from which it is obvious that ki may be increased c
siderably above the value corresponding to minimum copper, without c
siderable increase of cost. As kt varies proportionately with ti', it ii
critical ratio and useful as a guide to the determination of v, up to
mechanical limit. Rarely does ka occur outside of the range 0.6 to 1.4, be
in general larger as the number of poles decreases, although each case m
be considered by itself, and many other factors taken into account.
The major considerations affecting v are those of ventilation and
mechanical design. A high v means a diameter in direct proportion, a c
length inversely as v-, a much larger percentage of exposed coil-end surfc
higher heat dissipating power and better ventilation, but a larger and m
expensive frame and bearings. In large two-pole 60-cycle machines, the i

upper limit of Bis that of mechanical strength. With solid cast-steel rot
V may be carried as high as 420 ft. per sec.
104. Machine proportions. Having approximated (Bi, A and t,
general dimensions of the machine are determined. Only some of the m
important considerations have been possible here, but enough to give a cr
notion of the more obvious factors.
106. Caution. The greatest care should be employed in making use
the values and limits here given for the various constants, as there are m;
other considerations and many details of design not here considered, wh
affect individual cases. Moreover, in commercial lines of machines,
necessity of utilizing one punching or one frame for machines of sevc
ratings, voltages, or speeds, results in kinks in the curves plotted fr-
actual data.
106. The air gap in salient-pole alternators, when regulation is 1

important, may be reduced until the distortion of the flux across the polef!
endangers the wave shape, or until pole-face losses become too large.
'

the first score qj^ (Par. 60) should not exceed 0.60, and on the second accol
the air gap should not be less than one-third of the slot opening in low-, r

one-half in high-speed mechines. In the case of non-salient pole high-sp'l

turbo-alternators, one of the chief considerations governing the length ofi
gap is that of providing a sufficient path for the ventilating air (Par. 1:.
107. tiOect of number of slots. A small number of large slots md
more heating of armature conductors, poorer wave shape, less insula^
and lower cost.
INSULATION
108. Stator-slot insulation. In the design of armature-slot insul.i
for high-voltage turbo-alternators, restrictions of a very serious nature i
encountered. It is a comparatively simple matter to insulate 600^
windings and provide liberal factors of safety, but when dealing with winwl
for 12,000 volts, it becomes necessary to employ very high-grade mstejl
and to observe many important precautions in the manner in which til
materials are applied. For a given material the disruptive strength perl
of thickness grows less as the thickness is increased. In this circumstrl
lies a serious handicap in designing the insulation for rotating appar:l
wound for high pressure. For stationary apparatus which can be imni'' j
in a tank of oil, reliance can be placed on the disruptive strength of the oil 1

504
A. C. GENERATORS AND MOTORS SeC. 7-109

0.3
Sec. 7-113 A. 6. GEA'ERATORS AND MOTORS

citation is low, but the difficulty arises from the high temperature to whi
the insulation is subjected and the high centrifugal forces to which t
conductors are subjected. The facilities for ventilation are necessar
exceedingly poor, and the space for the copper is so restricted that it
necessary to operate the field winding at high current densities. T
result is that portions of the insulation in the slots of high-speed rotors (

usually subjected to temperatures much above 100 deg. cent, and frequeni
temperatures approaching 150 deg. cent, are experienced at the very hotti
spots of therotor insulation in designs of the most difficult ratings. Cf
sequently mica must be the chief ingredient of the insulation, notwithstar
ing that the voltages are very low. The construction must present t
utmost rigidity since the slightest displacement of any insulating mater
will suffice to unbalance the rotor. The case is ably presented by Lami
in a section entitled Rotor Insulation on p. 29 of his paper on "High-spe
Turbo-alternators," in Vol. XXXII (1913) of the Trans. A. I. E. E.
113. Insulation of aJternator leads and connections. Acu
problems are not often encountered in the insulation of the leads and co
nections, since, on the one hand, machines are rarely built for pressuras
excess of 15,000 volts, thus eliminating the questions arising in connect!
with the insulating of extra high-pressure leads; and, on the other hand, t
voltages in large machines are rarely lower than 4,000, so that there do n
arise any questions associated with the handling of very large currents. Tl
latter statement should be conditioned by calling attention to the insta
taneous current flowing on the occasion of sudden short-circuits. Such
current (Par. 63) may for an instant amount to from ten to twenty times t
full-load current of the machine and is associated with the development
enormous mechanical forces. Consequently the problems of leads and ca
nections reduce chiefly to the provision of elaborate mechanical support I

all leads, conductors and cables from the armature windings to the switc
board. The end connections of the stator windings must be elaboratt
supported; many fine machines were wrecked before this was realize
The end connections are sometimes lashed by stout bands of cord to hea'
rings which are supported by stepped brackets constituting extensions of t
frame of the machine. Also see tne following:
Walker, Miles. "Short-circuiting of Large Electric Generators," Jour
1. E. E., 1910. Vol. XLV, p. 295.
Field, A. B. "Operating Characteristics of Large Turbo-generators
Trans. A. I. E. E., 1912, Vol. XXXI, p. 1645.
Lamme, B. G. " High-speed Turbo-alternators," Trans. A. I. E. E., Vc
XXXII, p. 1.
Davis, C. M. "Alternator Short-circuits," Gen, Elec. Rev., 1914, p. 80.'
Diamant, N. S. 'Sudden Short-circuit Phenomena of Alternators
'

Trans. A. I. E. E. (1915), Vol. XXXIV, p. 2043.

114. Sequisite protection against potential stresses caused I
special conditions, gi'ounded phase, switching, etc. If a Y-coDnert<
generator is operated with the common connection grounded without ai
resistance, then if a dead short-circuit to ground occurs on one of the thr
lines, although the circuit-breakers will at once disclose the faulty line, sevf
mechanical stresses will be imposed on the windings of the generator, due
the sudden short-circuit. If on the other hand, the neutral point is connect
to ground through a resistance, the amount of current which can flow wli
a dead ground occurs on one of the lines will be limited by the amount of t
resistance. Let us consider the case of a Y-connected generator with
pressure of 7,000 volts in each leg of the Y, and with a 9-ohm resistance
ground. If a dead ground occurs on one of the lines leading from thegc
erator, then asuming that the resistance of the winding and line and grou:
aggregate 1 ohm, only 7,000/(9-(-l) = 7(X) amp. can flow through t
ground. But this will raise the potential of the neutral point from zero
700X9=6,300 volts, and this combined with the pressure of the other t'
phases, on which no ground has occurred, will increase the pressure betwe
the high-tension ends of these windings and the frame of the machine
about 12,000 volts. Thus while the use of a resistance between neutral a
ground decreases the severity of the mechanical stresses to which the windin
of the generator will be exposed on the occasion of sudden short-circu.
on the line, it increases the severity of the potential stresses on the ins
insulation.

506
 A. C. GENERATORS AND MOTORS SeC. 7-115

The extra stresses imposed upon the main insulation of the machine would
3 still greater were the machine to be operated with its neutral grounded
irough a resistance, and with its terminals tapped into auto-transformers
/ means of which the generator voltage is stepped up (say in the ratio of
: 2) to the line pressure. Consequently when auto-transformers are em-
oyed, the generator must not have its neutral connected to ground through
resistance, but must be dead-ground. If the stepping-up is accomplished
/ means of transformers with distinct primaries and secondaries instead of
ith auto-transformers, then the generator's neutral may be grounded
..rough a resistance. Operation with grounded neutral is to be pre-
rred for systems from which many expensive underground cables are
,pplied, since a ground on some one cable will clear that cable off the line
'r the opening of its local circuit-breakers and without interruption to the

St of the system. But for a system consisting of a single long line with an
iportant distribution system at its distant end, and where, consequently,
ly interruption of the supply would be very serious, there is a widely held
(inion that the generator should be operated with non-grounded neutral,
ice it is maintained that the development of a ground at some one point
the line is then less likely to shut down the system. It will, however,
.'crease, by 73 per cent., the extreme potential stresses across the genera-
•r's main insulation, and this must be recognized in the proportioning of
e generator's insulation.
Switching operations, arcing grounds, lightning-arrester discharges, and
her disturbances are likely to occasion surges in a system. The generator
ndings must be protected against the resulting high-potential stresses,
'metimes such protection is afforded by suitable reactances interposed
tween the line and the generator, and sometimes the last few turns in the
nding are especially insulated so that the steep potential wave front
'all not occasion breakdown between adjacent turns. See also page 164
"Vol. 53 (1915) of Jour. Inst. Elec. Engrs. for a description of the protec-
:a of an alternator by the "Circulating-current System." This is in a
])er by E. B. Wedniore entitled 'Automatic Protective Switch Gear for
'

ternating Current Systems."

LOSSES AND EFFICIENCY

116. Core losses. The data in the following table serves as an approxi-
vte guide to the determination of the no-load core loss in synchronous
Uchines.
There are further core losses called
•au core losses which increase as the Density in Core loss in stator core
,a increases. These are due to the stator core (including teeth)
X distortion in core and teeth, (below slots) (watts per lb.)
tised by the armature m.m.f. lines per sq.
^.16. ESect of rated speed on in. 25 Cycles 60 Cycles
/ises. Returning to a considera-
n of the no-load core losses it is 40,000
'interest to note thattheinherent 50,000
^ture of low-speed and high-speed 60,000 4.9
Migns is such that while the no- 70,000 2.0
'
(1 core loss may constitute a 80,000 2.4
aively small component of the 90,000 2.8
;il loss in low-speed synchronous

chines, it is necessarily a
Ige component in high-speed A B
f'lchronous machines. The Rated No. Armature Ratio
Nc^load
>'erse is the case with the speed of
oorpln*.' copper loss of A
^nature copper which
loss, poles 7t?
(%)
at full-load to B
I'relatively high in low-speed (%)
1. chines, and relatively low in

th-speed machines. In a 83 36 1.93 .93 2.07

rup of 3,000-kv-a. 25-cycle 125 24 2.02 .73 2.77
«'se-regulation designs for 250
'

12 2.17 .57 3.82

. ious speeds, particulars of 375 2.24 .50 4.45
*ich are given by Hobart and 500 2.27 ..50 4.39
^ in "High-speed Dynamo 750 2.30 .47 4.92
trie Machinery" (John

507
Sec. 7-117 A. C. GENERATORS AND MOTORS
Wiley and Sons, N. Y., 19081, the rated speeds And these two losses in pi
cent, of output are given in the table at the bottom of the preceding page.
117. Armature copper losses. In addition to the normal I'R loa
there are eddy current losses due to the flux fringing into the tops of the slot
depending largely upon the tooth density; and also eddy losses due toil
cross slot leakage flux, depending largely upon the slot depth and the si:
of the conductor. Consequently each effective armature conductor is usual
built up of many small component conductors in parallel. Since econon
of space is of the utmost importance in the slots of extra high-speed altern
tors, each of these component conductors is usually of rectangular cros
section. The subject of subdividing conductors to eliminate eddy losses h;
been dealt with by A. B. Field in a classical paper " Eddy Currents in Larg
Slot-wound Conductors," Trans. A. I. E. E., 1905, Vol. XXIV, p. 76
Also see "Eddy Currents in Stator Windings," a paper read by H. V
Taylor before the Inst. Elec. Engrs. in January, 1920, and abstracted
the London "Electrical Review" for January 23, 1920, at p. 102. Also si
" Stromverdrangungsfreie Leiter fiir Wechselstrom," by L. Flcischman
at p. 203 of Archiv fur Elektrotechnik, Vol. VIII (1919).
118. The field copper loss
is usually of moderate amount in salient po
machines, even in cases where the machines have many poles. In no
salient pole machines this
loss is, for designs of all speeds, a fairly considerah
component of the total loss in a machine. For relatively low-speed machin
this is partly due to the relatively large number of field spools among whii
the loss is distributed and each of which must provide a fairly large magnet
motive force. In extra high-speed machines, the considerable amount
field copper loss is, in part, a consequence of the high armature magnet
motive force per pole to be offset at low power-factors. In addition it a
partly be traced to the deep air gap which must be provided in order th
sufficient cooling air may be circulated through the machine. Finally, fie
copper loss in this type of machine is high, because of the limited space
the rotor slots, which renders it necessary to employ somewhat high currei
densities, in spite of the consequent high temperatures. Furthermore,
contrast to the salient pole machine, the field poles link with the flux :

relatively low density, and some of them also link with only a part of the flu

119. Actual windage and bearing-friction losses, for ten lart

turbo-alternators

e
 A. C. GENERATORS AND MOTORS SeC. 7-121

the output. Of this amount, about half represents the power required
drive the fan.
For moderate-speed and slow-speed machines not employing fans for ven-
ation, allowances ranging from 1.0 per cent, in small machines down to 5
r cent, m
large machines are usually made for windage and bearing fric-
.n. A further consideration controlling the magnitude of the allowance
ates to the number of bearings whose friction loss should fairly be charged
the generator as distinguished from the prime mover. Where, for testing
rposes, the synchronous machine can be separated from the prime mover
d driven by a small motor, the windage and bearing-friction loss may be
lermmed by test when the machine is built.
;121. Calculated values of bearing friction for several turbo-
alternators
Bearing friction in horse-power
Rated out- Speed
lo. of poles (rev. per)
put (kv-a). Turbine Middle Bearing at
min.)
bearing bearing collector end
9,400 1,800 7 62 24
6,300 1,800 11 60 14
6,300 1,800 6 41 13
3,100 1,800 4 25 5
2,500 1,800 6 21 6
2,500 1,500 3 20 4
]d present the tendency is to reduce the length of the bearings and
C ain lower losses.

22. Summary of losses. We

have now reviewed the component losses
i).ynchronous machines. These are: (a) no-load core loss; (b) extra core
li, increasmg with load;
(c) full-load copper loss in armature winding- (d)
e y loss at full-load in armature winding; (e) field copper
loss at full-load"
l:. windage and bearing friction loss.
.osses (a), (c), (e) and (f) may
be considered accurately determinable
e or by test or calculation. Losses (b) and (d) are not commercially
ai^rminable; i.e., their determination would require an
elaborate and ex-
P nve investigation each case. m A
reasonable value may be assigned to
tl-5um of losses (b) and (d) (Par. 127), in cases
where they cannot be de-
tt lined from tests It may in general be stated that all the losses except
ic (b) and loss (d) are readily
susceptible to either exact or sufficiently
determination, and hence they may be designated as
ll'^^i"^^^'^
«:mnaD.e de-
losses. It is in commercial transactions futile to attempt
tcjnclusively determine losses (b) and (d).
Consequently it is desirable
ic;rouD these two losses together, and to
designate them as: indeter-
v. «j.
K.able losses or stray losses.

n, '; J^u "fflcieicy; * The true efficiency of a machineis the ratio of the
01 ut to the input. The efficiency should bebased upon the rated output.
power-factor and speed. The
K
toldlY^u losses on which the efficiency
be corrected to 75 deg.. the temperature of reference for
is based
efficiency
de-nunatipns (see Sec 24). The determination of the true efficiency of
a chine involves either an accurate determination
of all the component
an accurate measurement of the output and of the simul-
tSt; ',„ .•

^° °-*^®'' than small machines, both of these methods

S fp 'f.^ii--
impracticable unless resort is made to expensive scien-
Sfi Sirements''^
'° practice, use should be made of two approximate effi-
oie P« '^"tk*'^ designated as follows: (a) the efficiency exclusive
of
01 avlJ=^
ay .k'T!^'"'
losses; (b) the conventional efficiency.
I

*"'*'?;• "?'"sive of stray losses. This is the ratio of

thf'utmi^V^f
the machine to the sum of the output and the determinable
loa Jl k!
separate measurement
^
(kt^f^oKi
^Tunable 1
loss.
^^J^^
This efficiency is necessari
or calculation of each
ly greater than the true

'
Determination of the Efficiency of the Turbo-alternator,"
bv'
«>y .irclay T'l"
ftfi^°and Smith at p. 293 of Vol. 57 (1919) of the Journ. I. E. E.

509
Sec. 7-125 A. C. GENERATORS AND MOTORS
efficiency, but approaches it in machines in which the indeterminable loss
are neghgible.
126. The conventional efficiency differs from the efficiency exclusi'
of stray losses, to the extent to which appropriate values for the indete
minable losses are included in estimating the input. In all matters relatii
to guarantees, the allowances to bo made for the indeterminable losses a
specified in each case. The conventional efficiency is, by definition, le
than the efficiency exclusive of stray losses, except in cases where the co
vention is to take the stray losses equal to zero (see Standardizatii
Rules, Sec. 24). With the application of a reasonable amount of ca
in assigning appropriate values to the indeterminable losses, the difFe
ence between the conventional efficiency and the true efficiency shou
usually be quite unimportant and often negligible.
126. Stray losses. A realization of the extensive nature of the stray loss
has only gradually taken place. It is by no means unusual for the stray loss
to amount to from 25 to 50 per cent, of the no-load core loss. These stray loss
arise from various causes; a notable cause existsin the local variations in t

reluctances of the magnetic circuits around the individual slots and groups
slots with the continually varying relative positions of stator and rot(
Although such losses are not a function of the no-load core loss, neverthele
practical purposes are sometimes fairly served by assuming the stray loss
to be equal to half of the no-load core loss. For example, in a certain machi
with a rated output of 2,000 kw. we may have the following losses: armati;
copper loss, 10,000 watts; field copper loss, 20,000 watts; core loss at no-los
12,000 watts; bearing friction and windage, 15,000 watts.
With this assumption as to the stray loss, the total of all losses at full-lo
amounts to 10,000-|-20,000-|-12,000-f 15,000-1-6,000 = 63,000 watts. T
full-load efficiency wiU then be taken as: 2,000,000/ (2,000,000 -|-63,000)
96.9 per cent.
127. Determination of stray losses. An approximation to the str
losses may be obtained by operating the machine at its normal spe
and with sufficient excitation to circulate rated current. From the pow
required to operate the machine thus, the friction lo.ss and the copper l(

should be subtracted, and the remainder taken as the stray loss at ft

load. Experience indicates that in many cases this is a fair approxiraatii
128. Variation of stray losses with load. The nature of the str
losses is too vague to justify any positive statement as to the laws of
variation with the load. It may in .some instances vary as the square
the load. But with a view to practical liberality it is well to detenu
upon a representative figure for its full-load value and arrive at figu
for its value at other loads by assuming it directly proportional to
load.
VENTILATION
The process of cooling and ventilatincr low-speed and mediu
129.
speed synchronous machines is not one presenting any grave diffii
ties, since such machines are so large as to expose extensive surfaces to
surrounding air. In such machines the field coils are usually arranged on
salient poles of the revolving field. The fan action occasioned by the revi
tion of such a salient-pole field, may be readily supplemented by the |

vision of fan blades suitably disposed on the rotating structure. The

friction is one component of the losses in the rnachine, and serve.'
decrease the machine'6 efficiency, particularly at light loads. Thepo
required to drive the fans of such machines is comparatively small a
the pressure developed by the fans is low. See also "Ventilation as a Fa i

in the Economical Design of Electrical Machinery," by Edgar Knowlto i

General Electric Review.

130. Stator ventilation. Owing to the rapid flow- of heat by con^
from the copper in the slot to the end connections,^ it is not alway
sary to provide vertical ventilating duct."* in the laminated core of :i

machine provided it is arranged to cool the end conncction.-i vijr'

When this principle is employed, it is practicable, in reasonably
machines, to maintain the armature windings at a low temperature v
610
 A. C. GENERATORS AND MOTORS SeC. T-lMl

I )rting to the relatively expensive method of providing vertical ventilating

c ts. In many high-voltage machines the thickness of slot insulation is
e' h that most of thisheat must flow to the coil ends, even with compara-
t ilylong coils, Par. 97-98.
31. Rotor ventilation ejecting diameter. From the standpoint
c otor ventilation, a large diameter and a short core-length are desirable
8 permit of economy in field copper. But the gain, as regards decreased
clay for copper and magnetic iron when a large diameter is employed,
iV involve a very disproportionate increase in the outlay for frame and
f bearing supports and for structural material in general.
Yith vertical-shaft machines it becomes practicable to resort to larger
d neters than with horizontal-shaft machines, since in the latter type a
8 rt machine of large diameter requires a lavish outlay for material in order
t -ender the stator frame sufficiently stiff to ensure absence of sagging.
Ir sagging would unbalance the air gap, which must be of uniform depth
or the entire circumference.
;'he field winding should usually consist of flat copper, wound on its thin
e'e. The heat then readily flows to the outer surface, and is carried away
t the surrounding air.

32. Intense forced cooling^ and ventilation. Extra high-speed

p m turbine-driven generators of large capacity present the most extreme
i :inpes of the necessity for forced cooling and ventilation. The quantity

Air from Room,

Fig. 66. —Ventilation design for a vertical-shaft turbo-alternator.

;j which must be forced through such machines per kv-a. of rated output
ir
ir rder to limit the temperature rise at full-load to permissible values, is
ohe order of from 2 cu. ft. per min. for a 50,000-kv-a. machine to 4.5 cu.
ft)er min. for a 5,000-kv-a. machine, depending on the efficiency of the
ff hine. The precise values vary with the arrangement of the ventilating
pi:ages, and the speed. The customary method of circulating the air con-
* in providing the rotor with fans which force air through appropriate
P-iages. Fig. 66* relates to the ventilating method employed in the design

_
J*'rom an article by E. Knowlton, "Ventilation of Steam Turbine-
'd en jMternators," General Electric Review, Oct., 1912, page 656.

511
Sec. 7-133 A. C. GENERATORS AND MOTORS
of a steam turbine-driven alternator of the vertical type. Mr. B. G. Lamme
haa dealt very fully with this subject in a paper entitled "High-Speed
Turbo-alternators," at p. 1 of Vol. XXXII (1913) of the Trans. A. I. E. E.
Lamme subdivides methods of cooling turbo-alternators by the forced circu-
lation of air into three classes: (a) radial methods, (b) circumferential
methods, and (c) axial methods.
133. In the radial system of ventilation all the air passes out radially
through ventilating ducts in the stator core. In the design of these high-
speed generators the rotor diameter is limited by the peripheral speed. Con-
sequently the design is of relatively greatlength parallel to the shaft. There
is very little space on the rotor even for the windings, owing to the limited
radial dimensions, and itis often necessary to dispense with the circulation ol
air through the interior of the rotor. Even in the most favorable cases
such circulation of air through the rotor is limited to but a small part of th«
air required for the cooling of the stator. The greater part of the supplj
required for the stator is, in the radial system, first passed along the an
gap; the radial depth of the air gap is often made very great expressly out ol
consideration for providing sufficient section for the flow of the required
amount of air.
134. A typical arranKement of the radial system as applied b>
the General Electric Co. in its horizontal steam-turbine alternators ii
shown in Fig. 67. The system is described as follows: the air enteri
the generator at A A; passes through the air gap, windings and air ducti
in the stator core to the annular spaces BBB flows around circumfer
;

entially to the openings CCC in the bottom of the armature frame ant
thence to the outlet duct. In some machines part of the air passei
through the field core. The movement of air is produced by fans oi
the ends of the rotor. In some instances the armature frame is modifiet
so that the air is expelled from the top into the dynamo room. Prope
passages must be provided below the generator for the ingoing and outgo
ing air. As shown in the sketch, air is taken in at both ends of the gener
ator and discharged through an open
ing in the centre of the frame, anc
the passages must be so arranged a
to prevent the outgoing heated ai
from mixing with the incoming coo
air; a simple method of accomplish
ing this 18 also shown. In cer
tain cases other arrangements ma;
better suit local conditions. For ap
proximation the area of the ingoini

Fio. 07.— Radial system of ventilating a Fig. 68.— Circumferential syster

horizontal-shaft high-speed generator. of ventilating turbo-alternators.

or outgoing duct will lange from 5 sq. ft. for a 1,000-kv-a. to 60 sq.
ft

for a 50,000-kv-a. generator. The outgoing air should be earned out

side the building, care being taken that it cannot immediately re-ente
the intake. The ducts should be as short and have as few bends as poBsmi
and these should be made with a large radius. Both ducts should hnv
adjustable dampers so that part of the air may be taken from or expeiiei
012
GENERATORS ASD MOTORS Sec. 7-135
Sec. 7-13S CENERATORS A!VD MOTORJi

of air per niin. These screens occupy a great deal of space, they giailuully
liecoine cloptred with dust, atid constitute a fire risk.
138. Air washing. Decidedly the best method of oleaiiinc the air consists
iu passing it tlirough sprays of water to wash it, instead of straining it
through cloth screens. E. Knowlton and E. H. Freiburghouse deal at
length with this method in the course of an article entitled "Ventilating
Systems for Steam Turbine Alternators," in the Oeneral Electric Kemew
for April and May, 1918. See also a paper by J. Christie, entitled "Air
Filtration, Cooling and Ventilation of Electrical Machinery;" P^lectrica)
Review; June 27, 191.3, page 1088. Mr. Christie states that filter cloths
wear out quickly and are expensive to renew. He states that $400 to $500
per annum for cloth and labor is by no means an outside figure for the
efhcient maintenance of this equipment.
139. The cooling of air incident to water filtering. The humidi-
fication of air in its passage through the water filter occasions a lowering
of its temperature, the amount of which varies with the condition of the air.
If it is utterly dry on entering the humidifier, the air will have experienced a
considerable decrease in temperature by the time it has emerged from the
humidifier and entered the machine which is to be cooled. Asa consequence of
these considerations, it is obvious that the average conditions regarding
humidity and temperature in any locality, affect the amount of advantage
to be derived by air filtering in addition to that of removing the dirt and
the dust. The average reduction in the temperature of the air for the
months of July and August in different parts of the United States is stated
(Knowlton) to vary from 2.-5 deg. cent, at points on the coast to 1 1 deg. cent,
at points in the Middle South West. On certain days during these months
the maximum reduction effected may considerably exceed these average
values.
MECHANICAL CONSTRUCTION
140. Abnormal conditions reqwring large factors of safety. In
providing adequate strength in the design of synchronous machines it is
usually utterly insufficient to take the conditions in the machine when run-
ning at uniform speed at its normal load as the basis which, with usual
factors of safety, will lead to a satisfactory design. On the contrary, it is
the conditions occurring during sudden short circuits (see Par. 63 and 64) and
,

when the machine is carrying sharply fluctuating loads, which determine

the strength required in the various parts. These are impossible of exact
calculation; consequently, in the design of all those parts upon which the
mechanical strength of the whole machine depends, lar^e margins of the
nature of safety factors must be added to the values which would usually
be employed in machine design.
141. Critical speed of shafts. Irrespective of questions of cost, condi-
tions arise with some capacities and speeds where it is impossible to find
room for a shaft of large diameter, and it must have a critical speed below the
operating speed. The peripheral speed at the bearing would otherwise
exceed desirable values; furthermore, there is but limited room for accom-
modating the windings in the radial depth available between the surface of
the rotor (which is itself of small diameter) and the surface of the shaft.
142. Effect of critical speed on rotor design. If the critical speed is
to be well above the normal running speed, it is impracticable to employ
laminated rotor bodies for capacities much above 1,000 kv-a. at a speed of
3,600 rev. per min. or above 5,000 kv-a. at 1,80() rev. per min. or above 7,50()
kv-a. at 1,500 rev. per min. But for designs in which the critical speed is
below the normal speed, it is practicable to employ rotor constructions
with laminated cores up to ratings of 3,000 to 4,000 kv-a. at a speed of 3,600
rev. per min. of some 10,000 to 15,000 kv-a. at a speed of 1,800 rev. per min.,
and of some 20,000 kv-a. at a speed of 1,500 rev. per min. In the construc-
tion of 1,.500 rev. per min., 25-cycle, or 3,600 rev. per min., 60-cycle rotors
solid cores are especially appropriate, since greater mechanical strenath can
be obtained in con.structions in which the slots for the windings are milled out
of a solid steel core. The rotor windings may be retained in the slots by
solid steel or bra.ss wedf^es, since the magnetism is of constant direction in
each part and since the air gap is so deep in these extra high-speed generators
that there is no lo.ss in the rotor surface from pulsating influences from
the alternating m.m.fs. due to the conductors in the stator slots. In some
designs the shaft ends consist of enlarged extensions bolted to the rotor core.
514
 A. C. GENERATORS AND MOTORS SeC. 7-14S

Section B-B-B

\."c-_----.-r_---r
Sec. 7-144 GENERATORS AND MOTORS
that no oil shall be thrown or leak out from the bearings, as it is liable
to occasion harm to the insulation. Even though there may not be any
apparent escape of oil, it may be present as a fine vapor and be thus taker
up by the air in the engine room.
Spring thrust bearings. The spring thrust bearings manufactured by
the General Electric Company are used extensively on hydro-electric gen-
erating units. On horizontal-shaft turbines a double thrust bearing is
provided to take the unbalanced water thrust, and on vertical shaft units a
single thrust bearing supports the entire weight of the rotating parts and
the downward thrust of the water. A spring thrust bearing of typical de-
sign for large vertical shaft generators is shown in Fig. 70,4.
The distinctive feature of the spring supported bearing is that it will
automatically adjust itself while in operation, if there is a loss of alignment
due to the settling of the foundation, or to other causes. On large machines
the finishing of the parts is not as accurate as on small units. With an oil
film of only about three ten-thousandths of an inch in thickness between the
thrust bearing surfaces, it is evident that even with good machining and
erection, very severe conditions may exist for any large thrust bearing with-
out a yielding support.
The bearing consists of a runner of a special grade of cast iron resting on a
thin steel disc with a babbitted surface. This babbitted ring, in turn,
re.st8 on short helical springs and is held in place by dowel pins. The high
base casting shown is used in connection with a deep housing in case it is
desired to instal water cooling coils to remove the heat from the surroundinK
oil bath._ The bearing surface of the runner is finished with extreme accuracy
and is given a high polish. Radial grooves in the rotating bearing surface
produce a rapid circulation of oil across the babbitted surface. The babbitt
surface upon which the runner revolves is given an accurate tool finish in
the factorj', and it is not necessary to give this surface any further finish
such as hand scraping to the runner or to a surface plate, which is generally
done in the case of other types of bearings.
144. Bearing pedestal. It is only in small machines that the bearing
pedestal continues to be a distinct and readily recognizable component.
There is a tendency in modern machines to embody the functions of the
pedestal either in the base or in the end shields.

Fig. 71. — Box-type frame for .5,000-

kw. alternator.
146. Frame. In the case of the frames of low-speed alternators of very
great diameter and small width, the design should be liberally stiffened with
deep ribs. Any weakness in the frame of such a machine is certain to
occasion trouble. In Fig. 71 is shown a liberal, box-type construction
employed by the Westinghouse Co. in the design of a 5,000-kw. alternator.
The internal diameter of this armature is 9.76 meters.
 GENERATORS AND MOTORS Sec. 7-146

146. Representative weights of turbo-alternators

Weight of tur-
Weight of bine including
B " tj Rated Speed, generator base and bear- Weight
3 o 01 output rev. per without ings but ex- of set
J) o ©
(kv-a.) min. base or bear- clusive of (lb.)
ings (lb.) accessories
(lb.)

60 2,500 1,800 34,600 76,000 110,600

60 2,500 3,600 33,000 36,000 69,000
60 5,000 1,800 53,570 93,000 146,570
60 12,500 1,800 133,500 256,000 389,500
60 25,000 1,200 300,000 510,000 810,000
60 50,000 1,200 350,000 S75,000 925,000*
25 2,500 1,500 49,000 73,600 122,600
25 5,000 1,500 96,900 120,500 216,400
25 12,500 1,500 180,300 277,000 457,300
25 25,000 1,500 340,000 452,000 792,000
25 39,000 1,500 305,000 395,000 700,000 *

147. Bi\>liography.
Livingstone, R. ';The Mechanical Design of Electrical Generatore,"
The blectncian Printing & Publishing Co., London, 1914.
Horsnail, W. A. "The Useof Comparative Formula in the Mechanical
Design of l!.lectnc Generators," Engineering, May 11, 1906, page 605.
I
Niethammer, F. "Die Durchbiegung von Dynamogehausen,"' Zeit-
fur Elektrotechmk, June 19, 904, page 367.
ichrift
,
"Notes on Design of Shafts with Special Reference to High-speed Electric
Benerators, The Engineer, Dec. 3, 1909.
Peineke, W. 'Die Konstruktionen Elektrischer Maschinen."
'
Published
jy Friednch Vieweg & Sons, Braunshweig, 1912.
Hobart & Ellis. Chapter XII entitled "Stresses in Rotating Field
Systems, of High-speed Dynamo-electric Machinery," John Wiley &
sons. New York, 1908.
Barclay, F. S. , ''The Mechanical Design and Specification of the Turbo-
ilternator Rotor, Journ. Inst. Elec. Engrs. (1918), Vol, 56, p. 472.

^ IK TESTING OF ALTERNATINQ-CUEEENT OENEBATOBS

ft **?•.
londitions
The heatingtest of large alternators under normal full-load
troublesome and expensive, even when the necessary amount
is
)f power IS and many suggestions, such as those of Mordey and of
available,
:{ehrend,t have been made with a view to reduce the amount
of energy
wasted during the tests. These methods necessitate alterations in the
ionnections of either the armature coils or the magnet coils.
If serious
nechamcal stresses are to be avoided, these methods can only be
vith machines having very large numbers of
employed
poles, and even then the mag-
letic conditions are not accurately the
same as those which exist at normal
uiMoad. Ihe following method, known as the "intermittent short-circuit
nd open-circmt method," or, briefly, the "intermittent
method," involves
10 change whatever in the connections of the
machine, and requires the
xpenditure of only sufficient energy to cover the losses
of the machine, and
et every part of the alternator reaches the
same temperature as it would
^""-'°ad heating test. The method involves a previous
nnLitS ^""^^fl
.nowledge of the separate losses of the machine, but these
are, in any case,
letermined in the ordinary course of a systematic test.

"^/'"''^ j^*' *?'''^ ^''•'^Pt *'i«'se t^o, represent practice prior to

Qi%^" ^'if V^
;^° ^^'Vies represent very recent designs and afford a
n«^'ni. Jl*" .u c
^^® '?P''^ progress in reducing the weight per kv-a. in
,^H?n lu i°° °{
+ T^k " °^ ^^^y ^^'S* capacities.
are described by Mordey, Journ. I. E. E., Vol XXII
QQo ol^^j'^'^i^
"^^ '"^ XLII, Oct. 31 and Nov'
"'"' ^"»'"«'''"' Vol.
4 1903

517
 SfeC. T-1'49 A. C. GENERATONS A\D MOTORS
149. Intermittent nxethod of making a heating test. Suppose a
oertain machine has at full-load: a friction loss of 10 kw.; an armattire copper
loss of 20 kw. and an iron loss of 100 kw.
; In the course of an hour's run at
full-load the loss of energy will be: 10X60 = 600 kw-min. as friction; 20X60
«= 1,200 kw-min. as copper loss in armature; 100X60 = 6,000 kw-min. aa
iron loss.
Let the machine run for 5 min. with the armature short-circuited,
and at such an armature current that the armature copper loss is 60 kw.,
i.e., at a current equal to yS times the normal current. Next let the machine
run for a further 10 min. with open armature circuit, but overexcited,
so as to give an iron loss of 150 kw. This adjustment is made according to
indications of the wattmeter on the driving motor, allowance being made for
other losses, such as losses in the motor itself and friction of the alternator
and the driving mechanism. If this cycle of operations is repeated regularly
throughout the time of the test, it is obvious that 10X60 = 600 kw-min.
will be lost in friction per hr. 60 X 20 = 1,200 kw-min. will be lost in armature
:

copper per hr.; 150X40 = 6,000 kw-min. will be lost in the iron per hr., or,
exactly the same loss in each case as would have occurred under normal
full-load in the same time. There is still the loss in the magnet windings
to be considered. During the short-circuit test this is less, and during the
open-circuit test it is greater than the normal, so that on the average it does
not differ very greatly from the normal. If, however, great exactness in
this respect is required it is obtained as shown in Par. 180.

160. Further refinements of the intermittent method of maldng

a heating test. In the above example one-third of the time of each period
of the test was devoted to the short-circuit test, and two-thirds to the open-
circuit test. These proportions may, however, be changed at will, and by
varying the short-circuit current and the overexcitation correspondingly,
the total energy expended in the armature copper and iron per hr, may be
kept at the right value, while the average exciting energy will have some
value other than before. Except in very extreme cases, e.g., in the case of
alternators which require only a very small change in excitation between
no-load and full-load, and which at the same time have a very low value for
the ratio of short-circuit current at full excitation to normal fijl-load current,
it is always possible so to adjust the two time intervals, that while
keeping the copper loss and the iron loss per hr. at the correct value,
the exciting loss per hr. has practically the 'same value as at normal full-
load. Exactness is, however, unnecessary, as, in any case, a simple calcula-
tion will always enable the temperature rise of a field coil at the correct full-
load'losa to be determined from the temperature rise measured at some
slightly different known number of watts. See Hobart, H. M., "Electrical
Machinery Tests and Specifications Based on Modern Standards," fi'orw.
A. I. E. E., Vol. XXXV (1916), Part II, p. 1278.
161. Pre-heatlng, before a test, with excessive currents. A grest
saving in the time required to test a large generator may be effected by
applying excessive losses for a sufficient time before the commencement of
the periodic test above described, and thus heating the machine up to the
maximum temperature it is likely to reach. The continuation of theinter-
mittent test (Par. 149 and 160) for a very few hours will then, e\'en in
the case of the largest generators, allow the steady final temperature to be
reached.
162. The calculation of the copper losses requires measurements of
the resistance of the windings. When the windings are of sufficiently high
resistance and low current capacity, the resistance is most readily determined
from the pressure in volts required to maintain through the winding a
known current. When the winding is of very low resistance and of large
current-carrying capacity, the best method generally consists in conneotinK
it in series with a conductor of a known resistance of the same order of
magnitude, and comparing by a millivoltmeter the pressure across each of
the resistances when carrying a considerable current. Obviously the value
of the current need not be known.

IBS. The friction and windage losses and the iron losses should be
measured by driving the alternator by a motor of which the eflBciency
is known for all values of the input. The motor should, if practicsble,
 j ;

OENERATOR^ AND MOTOR.'; Sec. 7 154

be directly coupled to the alternator. This will usually be impracti-

cable, hence, in most cases an allowance must be made for the loss in tKe
driving belt. The capacity of this motor should preferably not be much
greater than sufficient to drive the alternator on open circuit with full
excitation of its field circuit. The motor will thus always be operating either
well on toward its full-load, or else at overloads, and its efficiency will be
iiigh and fairly constant. The measurements should not be made until the
ilternator has been run for a sufficiently long time to bring its bearings into
:{ood condition. Then the speed of the small motor should, by shunt control
pr otherwise, be adjusted at such a value as to drive the alternator at its
>ated speed. Suppose that the input to the small motor is then volts E
ind / amp., and that its efficiency at this input is 75 per cent. Then the
nction and wmdage loss of the alternator amounts to 0.75XEXI. The
ield of the alternator should then be
!xcited|at constantly increasing values,
jind readings should be made of the N '

i
'
'

1
'

1 1

/olts and amp. input to the driving

,notor (whose speed must be main- »
-ained constant), and of the terminal S
/oltage of the alternator on open cir- .3
.!uit. This last reading permits of 3
jbtaining data for the saturation curve , »
luring the progress of the core-loss ^^"^
est. If, at that value of the satura-
g
ion corresponding to normal voltage of s
ihe alternator at no-load, the input —
the driving motor is Ei volts, and Ji >
.mp., and its efficiency under these con- m
itions is 80 per cent., then the friction
ijsses and the core loss together amount
o 0.80X£iX/i, and the core loss
mounts to 0.80 £1/1-0.75 £/. The
Sec. 7-156 GENERATORS AND MOTORS
As this cuts across the secondary conductors, currents are induced therein
which, according to Lenz'slaw, are in such direction as to oppose the cause.
That is to say, these secondary currents react on the revolving magnetic
flux in such a way as to drag the secondary conductors and structure along
with the rotating flux.

Fig. 73. FiQ. 74. Fig. 75.

Fioa. 73, 74, 75. — Diagrams of coils and magnetic flux in elementary two-
phase two-pole induction motor.

IBS. Sevolving field. Fie. 73 shows a two-phase, two-pole, laminated-iron

stator with each coil imbedded in a pair of slots. The flux shown corre-
sponds to the instant ti in Fig. 76. Figs. 74 and JS: show the flux corre-
sponding to instants (j and t» inFig. 76. The rotation or progression of the
flux is obvious. Ifin place of the two- pole field of Fig. 73, we substitute a
multipolar field, as many cycles of current variation will be required for one
revolution of the magnetic field, as there are pairs of poles.
167. Synchronous speed and slip. The speed of the revolving field
is calledthe synchronous speed, and
the percentage by which the speed of
the rotor or secondary falls below this
speed is called the slip. If 2p repre-
sents the number of poles, and / the
frequency, the synchronous speed in
rev. per min. is i?o = 60//p.

9i^? '78;^—iCurrent-time curves for

two-phase indicator-motor windings.
Fig. 77. —Four-pole, two-phase
induction motor with one stator
slot per pole per phase.

168. Induction motor similar to direct-current shunt-wound

motor. Synchronous speed in an induction motor corresponds to that speed
of a direct-current shunt-wound motor at which the counter e.m.f. is just
equal to the impressed e.m.f. In fact the mechanical characteristics of the
two motors are practically identical, within their working range. For ex-
ample, starting with the rotor at nearly synchronous speed, assume a load
to be applied at the pulley. Thespeed will drop the rate at which the sec-
;

ondary conductors cut (or »lip backward through) the revolving field, will
520
I
increase;
GENERATORS AND MOTORS Sec. 7-15§

and the induced e.m.f., the current and the torque will increase
until the increase in torque just meets the demand imposed by the load. AH
of this is analogous to the operation of a shunt motor, but there is one im-
portant difference. In the induction motor, as the slip increases, the fre-
quency and therefore the leakage reactance of the secondary increases in
direct proportion. This results in an increasing lag of the secondary current
behind the flux by which its e.m.f. is induced, and means, therefore, a de-
creasing effectiveness of the secondary current in torque production.
159. Stalling torque. Beyond a certain point, the increase of slip and
slip voltage with load, is accompanied by an almost proportional increase of
impedance, so that the secondary current ceases to increase with the slip
at the same time that its torque effectiveness is decreasing. Thus there is a
point or slip beyond which the torque actually decreases, causing the motor
to stop. In a good motor this stalling torque is largely in excess of the
*
torque at its rated load.
160. Primary or stator winding. Fig. 77 shows a two-phase, four-
pole stator with one slot per pole per phase.
161. Distribution of primary winding. On the score of tooth-tip or
sigzag leakage (Par. 196), the concentrated or unicoil windings shown in

Fig. 78.- -Diagram of a four-pole five-sixth pitch winding for the stator
of a three-phase induction motor.

Figs. 73 and 77 are objectionable, and it [becomes even more necessary

than in the case of the synchronous machine, to distribute the winding
among several slots per pole per phase, from two to eight or more, but rarely
less than three.
162. Classification of stator windings. Stator windings correspond ex-
actly with the armature windings of synchronous machines (Par. 16 to 82),

Fig. 79. — Sectional diagrammatic development of the phase belts of the

winding of Fig. 78.

and, as in that case, the two-layer lap winding is usually employed. Figs.
78 and 79 relate to a three-phase, four-pole, two-layer lap winding, with five-
sixths pitch (ten slots in 12) and four slots per pole per phase. The bottom
and top slot belts labelled o comprise the back-connected {down through

'See provisions regarding stalling torque in the A. I. E. E. Standardization

Rules (Sec. 24).

521
Sec. 7-163 GENERATORS AND MOTORS
the paper) conductors of the a phase, those labelled a' the out-ward con-
nected {up from the paper) conductors of the same phase; similarly with the
b and c phases. Several coil ends of the c phase are shown diagrammatically.
Fig. 79 shows a diagrammatic developed end view of the phase belts.
A developed diagram of connections of the winding of Figs. 78 and 79 is
shown in Fig. 80, where the dotted lines indicate the bottom-slot coil sides or
the lower layer.
163. Secondary or rotor windings. These may consist of any sym-
metrical arrangement of short-circuited conductors in which series-connected
conductors do not generate opposing e.m.fs. There are three principal types.
^
(a) Phase wound, like the primary, except that the phases are short-
circuited or brought out through collector nngs for insertion of starting
resistance. The number of phases need not be the same as for the primary.
and is usually 3.
(b) Independently short-circuited loops or coils. The two active
aides of each loop are approximately 180 magnetic deg. apart.

Fig. 80. — Developed winding diagram corresponding to Fig. 78 and Fig. 79.

Squirrel cage, consisting of conducting bars in slots, all connected

(c)
at the ends by conducting rings, called the end rings.
In (b) and (c) there are as many phases as there are slots per pole.
164. Peripheral distribution of current, m.m.f and gap flux. The
.

cylindrical shell comprising the currents on the two sides of the air gap, and
the magnetic flux crossing the gap may be considered as the active region
of any generator or motor, and the analysis of the phenomena in this region
will yield most of the vital characteri.'^tics of the machine. Neglecting the
localization of current in the slots and taking the average amperes per in.
of periphery in each phase belt, the heavy full-line curves of Fig. 81 show the
primary current distribution of a three-phase fnll-pitch winding at the
instant!^ m, n, and o of Pig. 82. The axis of each curve in Fig, 81 T«pre-
sents the air gap, and the sections a, b, Cj etc., the primary phase belts
along one side of the gap. The broken-hno curves of Mg. 81 show the
m.ni.fs. around the flux paths crossing the gap at each point. That is, the
maximum ordinate of the m.m.f. wave at /> or />' is proportional to the ampere-
turns with which the longest flux path pp' (shown dotted) is linked. This
is the sum of the ampere-turns of belts c , a, and 6. Similarly the ordinate
at o or g' represents the ampere-turns of the belt a with which the path
gq' links.
Neglecting the ampere-turns consumed in the iron part of those paths, the
ordinates of the m.m.f. curve may be used to designate the magnetic potential
differences across thegapnt the several points. But since the gap is normally
of constant radial <lepth, the broken-line curves may be used also to repre-
sent the flux-density in the gap, the disturbing effect of the slot openmgs
being neglected. If the concentration of the current in slots be considered,

322
 GENERATORS AND MOTORS Sec. T-ie*?

the m.m.f. curves would be of the step variety with a step for every tooth.
Fig 83 is the same as Fig. 81 except that the coil pitch has been reduced
to five-sixths. In both Figs. 81 and 83, it will be observed that although
the gap-flux-distribution curve changes its shape slightly, it is nearly sinu-
soidal, and that it progresses or rotates uniformly around the gap periphery.
Sine-waves are shown for comparison. The shape of the current distribu-
tion curve changes more than that of the m.m.f. curve, but it progresses or
rotates at the same velocity. The changes of the flux curve, in shape and
magnitude, are graphically analyzed for full-pitch windings on pages 380-
390 of the 2nd edition of Hobart's "Electric Motors." See also pages 120-

FiG. 81. —
Peripheral distribu- .

tion of primary current and \0)

m.m.f. in a three-phase, full-
pitch stator.

'm n o

Fig. 82.—Current-time curves

a three-phase winding.
for —
Fig. 83. Peripheral distribution of
prim.i.ry current and m.m.f. in a three-
phase, five-sixths pitch stator winding.

125 of Hobart's "Design of Polyphase Generator? and Motors," especially

the diagram on page 123.
165. Flux and current distribution for two-phase motors. In
a two-phase motor the belts are broader, the steps in the current and flux-
distribution curves larger and the change of shape from instant to instant
greater. The breaking up of the belts by usng a five-sixths pitch in the
three-phase, or a three-quarters pitch in the quarter-phase motor, reduces
these variations and smooths out the curves.
166. Secondary current and m.m.f. relations. Since the secondary
e.m.f. is induced by cutting the gap flux, the resulting secondary current will

523
 .

Sec. 7-167 GENERATORS AND MOTORS

bear a definite space-phase relation to the gap flux (Fig. 84), and ita m.m.f.
will be sinusoidally distributed around the gap. Also, since the primary (<or
stator) counter e.m.f. is nearly equaltotheimpressed e.m.f. and is induced by
the rotation of the gap flux at synchronous speed, the flux willbe nearly con-
stant in magnitude, for constant impressed e.m.f. Thus the resultant of the
primary and secondary m.m.fs.
will be nearly constant and such
as to produce the constant flux
,-v6
the in-
167. Similarity of
duction motor to the trans-
former. Thus the induction
motor is similar to a trans-
former. In fact, at standstill,
it i 8 a short-circuited poly ph ase
transformer with distributed
windings, and an air gap be-
tween primary and secondary.
Like the transformer, the in-
duction motor may be regarded
as having three fluxes. These
are the main flux, linked with
both primary and secondary;
and the primary and secondary
leakage fluxes, linked only with
the primary and secondary
respectively (Par. 193 t9 198). Fig. 84.^Peripheral distribution of flux and
Owing to the air gap in the currents in polyphase induction motor.
main magnetic circuit, the
quadrature magnetizing current of the i nduction motor i a several times as
large as in a closed magnetic circuit transformer, even though the air gap
is usually reduced to the lowest safe mechanical clearance. Because of
this same air gap and the separation it makes necessary between the pri-
mary and secondary windings, theleakage reactance ia also several times as
large as in the average transformer.
Thus the power-factor of the induction motor is inherently low m
compared with the closed magnetic circuit transformer. Representative
power-factors for motors of various frequencies, speeds, and outputs, are
given in Figs. 119 and 121.
168.Revolving flux and current distribution. Assume that the gap
flux and currents are distributed sinusoidally around the gap periphery at
any instant, and that the rotor conductors are independently snort-circuited.
Referring to Fig. 84, gg is the developed air-gap line; above this line it
the primary or stator, and below it is the secondary or rotor. Flux directed
upward in the figure is thus directed outward from secondary to primary;
this direction will be called positive and will be indicated in the curve by
ordinates measured upward from the gap line. Current directed outward
from the paper will be called positive and will be so indicated in the curves.
The flux and the rotor are assumed to be revolving counter-clockwise
(right to left), the rotor less rapidly than the flux; therefore the rotor revolves
clockwise with respect to the flux (left to right in the figure). Curve /
represents by its ordinates the space variation of flux density, &j, crossing
the gap. This sinusoidal flux distribution will be assumed as the starting
point. Its magnitude is approximately constant and dependent upon the
impressed e.m.f. as in the transformer. See also B,, in Fig. 85.
169. Magnetizing Current i„. In order to supply the corresponding
distribution of magnetic potential difference, there will be required a sinu-
soidal distribution of magnetizing current im, such as shown by curve //,
Fig. 84. See also Im, Fig. 86. The m.m.f. (and therefore the flux) dis-
tribution must be the integral of the magnetizing-current distribution, and
differ in space phase by 90 deg.

170. Secondary or slip e.m.f., e'l. As the rotor conductors slip back-
ward (left to right, Fig. 84) through the flux, each will experience an p.m.f.
proportional (at fixed slip velocity) to the density of the flux at the position
in question. Curve / may therefore be used to designate at proper scale the
024
 A. C. GENERATORS AND MOTORS SeC. 7-171

e.m.fs.,e'j, induced inthe several secondary conductors (plotted according

to the positions of theconductors in whicii the e.m.fs. are induced) at any
given instant. Curve I may also be used to designate the e.m.f. of a single
conductor as it moves through the flux, plotted according to the position of
that conductor with respect to the flux.
171. The secondary current it will have a time lag with respect to ei',
because of the secondary leakaee reactance; its curve will therefore be dis-
placed to the right, curve III, Fig. 84, since each conductor will have moved
with respect to the flux during the lag interval between the occurrence of
corresponding values of e't and is. See also It in Fig. 85.

i
Fio. 85. — Semipictorial induction-motor
representation of vector quantities involved in
operation.

172. Primary current ii. The primary current density at any point
of the periphery and at any instant, must then be such as to neutralize the
m.m.f. of the secondary current and also to supply the magnetizing current
im. It will then be represented by Curve V
which is the sum of im (Curve
II; and —
12 (Curve IV) at that same point and instant. See also 7i in
Fig. 85.
173. Basis for vector diagram of induction motor. It should be
remembered that the curves of Fig. 84 represent primarily space distributions
of the several variables at a given instant, and that these distributions revolve
at synchronous speed around the gap periphery, keeping the same relative
positions or space phases for a given condition of load. These distributions
are shown in semipictorial fashion in Fig. 85, where the vectors Bg, It,
and /i point to the positions at which the maximum positive values of these
quantities occur, at the instant shown.
The time variation of all these quantities with respect to any par'icular point
or conductor on the primary side of the gap, will be sinusoidal at primary
fre-
^ency, and at secondary or slip frequency with respect to any point or con-
ductor on the secondary structure. Tt is only from this point of view and with
th\3 under stan,ding that it is possible to represent consistently primary and
secondary variables on the same vector diagram.

525
 '

Sec. 7-174 .1. C. GENERATORS AND \rOTORS

Thus the vectors of Fig. 85 may be used to represent not only the space
phttaes, but also the time phases of the several variables, when viewed from
or rotating structure, it being obvious that there is no fixed
'

either stationary
phase difference between the primary current in a particular primary con-
ductor, and the secondary current of very different frequency in a particu-
lar tecondary conductor. By extending the vector diagram of Fig. 85 we
obtain the complete space and time vector diagram of the induction motor
in Fig. 86.
174. Analysis of vector diagram. E'l is that part of the impressed
e.m.f. to neutralize the counter e.m.f. induced by the mutual flux *, the
direction of the vector * being that of the plane of the coil when it links
the maximum flux, just as the direction of B, is that of the plane of the coil
when it is cutting the densest gap flux and generating the maximum e.m.f.
/mis the magnetizing current and le+h the core loss energy current, their

Vector diagram for induction motor.

sum being 7o, commonly called the exciting current. Assuming all secondary 5

quantities reduced to primary turns, Ei^^E'i is the e.m.f. that would be

induced in the secondary at standstill. The actual secondary induced e.m.f.'
is E'l, which equals s£s„, where s is the slip. Et, = (1 — s)iEj„, is the e.m.f. that

would be induced in the secondary if revolving in the flux * at its actual

speed, and will be called the speed e.m.f. xt is the secondary leakage react-
ance at primary frequency, and sxi the same at slip frequency. The second-
ary resistance is rj. The secondary current is therefore:
B«»
/2- -r= (amp.) (37)
Vn' + s^zz'
^jO' -f-X!»
(The two e.m.f. triangles corresponding to these equations are shown in
Fig. 86.) /'i is the part of the primary current to neutralize h, and Ji
the total primary current. Tin and iixi are the e.m.fs. consumed by primarj'
resistance and leakage reactance respectively. Ei is the impressed e.m.f.
176. ,The corresponding "equivalent circuit" scheme is given in Fig.
87, which is exactly that of a transformer with a non-inductive load resist-
ance {n/s)(,l — s).
176. Direct-current shunt-motor analogy. It is obvious that the
speed voltage Ei^ consumed by the fictitious load resistance is the
representative of the rotational power transformed, including output and
friction losses, and is exactly analogous to the counter e.m.f. of a direct-
current motor. Similarly, Et^ corresponds to tne impressed e.m.f. and £>'
to the net or resistance consumed e.m.f. of the direct-current motor.

526
 A. C. GEA'BRATORS AND MOTORfi Sec.'^-17t

177. Power analysis. The following analysis of the' power Pi, delivered
to the motor primary, may be readily followed from either Fig. 86 or Fig.
^7. Designating the number of phases by p', the primary power per phase
8

''"
-J = 7i£i co3 9i = /Vi+£'i7icos9i»
'
P
= l\+I,+kE'i+(,E'iri co8«s =£i/t cos St)

= I^ri+I,+hE'i+I^rt+Ei^l2 cos 9j

= j'ri+J.+*£'i+/r,+/Y^')(l-») (watts) (38)

in words, Pi = primary copper loss + core loss + secondary copper los8+

mtput (including friction), andP'2= p'E'iI'i cos 82 = p'Et^It cos di is the power
ransmitted across the air gap. P'2 is the product of the torque of the re-
'olving field by its angular velocity, or P'2 = 0. 142ri?o where r = torque in
b. ft. and So = rev. per min. at synchronism.

'oJ 8a(J7«^8
j^i^my^l;:ri^^p(56m

* U9 ^XltiXBiA

iO<IB»TIOa tt

Fig. 87. — "Equivalent circuit" scheme for induction mofMO'^'O

178. Torque. But the torque received by the rotor must be the same
J that delivered by the revolving field, and neglecting friction, this is all
ehvered at the pulley. Thus the output (including friction) isPj =0.1427'fir
here Rr = rotor rev. per min.

; P2=P'2§^ = (1-8)P'2, andP'i-Pj = sP'2 = p'jV (watts) (39)

he thus a measure of the secondary copper loss, and the motor is

slip is
lalogous to a friction coupling in which the friction t<wque between the two
ces is proportional to the slip. Since Ro is constant, the torque is directly
.•oportional toP'2; in fact,P'2 is frequently referred to as the torque in syn-
ironous watts, meaning the power-equivalent of the torque at synchronous
)eed, measured in watts. Thus
Tn, =P'2 = r/EiJi cos 92 (watts) (40)

r = 7.05-^' = 7.05p'£2„J2COse, x4- (lb. ft.) (41)

iCo K»
r = /j COS 02 ia called the torque current. .odiem eriT .181

INDUCTION-MOTOH CHARACTERISTICS
179. Exact formulss. From the vector diagram of Fig. 86 or from the
luivalent circuit scheme of Fig. 87, exact formulae may be easily developed
r the currents, fluxes, voltages, powers, torque,
power-factor, efficiency, etc.,
1 m
terms of .Si, 3, and the constants of the motor; but these are such com-
leated functions of the slip as to be too cumbersome for quick computation,
though none too accurate for poor motors. By a poor motor is not meant
•^.^sarily a poor design, but a poor result which may
be due to difficult
ecifications, e.g., relatively low speed or relatively high frequency.

527
Sec. 7-180 A. C. GENERATORS AND MOTORS
180. Approximate working formulso for torque, output and Btartin
current. For moat purposes the following are sufficiently accurate,
will be observed that the constants of the exciting circuit do not enter; this
due to the approximation, which is equivalent to neglecting the excitir
current as far as it affects the quantities considered.
Torque

7.05
T= (lb. ft.) (4;
°
("+7') +(^'+=f«)*
Slip corresponding to maximum torque

(lb. ft.)
r™«x Vn' + Ui + ii)'
Maximum or stalling torque

7.05 v'E\
(lb. ft.) (4-
Ro 2[ri+ Vn> + (a:i+xj)»l
Starting torque

7.05 p'tiE\
T, (lb. ft.)
Ro (n+rj)2 + (xi+a;j)'
Starting current
Ei_
V(n+ri)« + (a;,+X2)» (amps.)
7.05
T , .

ri corresponding to maximum starting torque

rj = \/n*+ (xi +xi)« (ohms)
Output
r«
-(!-«)
(watts) (4

(n + -^')'+(ii+x,)>
Maximum output, i.e., stalling load

(watts) (5
+ V(n+r,)« + (xi+xi)»]
2[ (n +rs)
Slip corresponding to maximum output
»P.» (5
rj + V (n + ri)»+ (ii+xj)»
These approximations are fairly accurate except where the exciting curre
is large. As the primary current and power-factor are both largely affect
by the approximation involved in the formula given above, their formu
are not given. They can be most easily obtained from the circle diagram
181. The method of percentages. For the purpose of discussi
the operating characteristics of an induction machine, as well as in co
nection with problems involved in its design, the following method of val
ing its constants will be found very convenient. Referring to Figs. 80 :

88, and remembering that Et„ = E , let Iin/E = gr,; Iixi/E •=

/jrj/JS =g,j;/ixj/S =gij; gx = 9i, + gij. Let It cos 9j = 7y, be called 1

torque current, since it is the component of It which is effective in produci

torque. Im/Ijt'^Qm; It+h/Ij,'^gc; /o//j, = a.; a = gx+8in = total quadr
ture component. It/Ij,'=>qi; Ji//j."gi; Ei/E'i-q^i; Tma,/T/-^gj^^

628
 =
GENERATORS AND MOTORS Sec. 7-182

here T"/ = full-load torque; etc. All currents, voltages, etc., correspond
I full-load unless otherwise specified- These oould have been expressed
I terms of Ei and /i rather than in terms of E'l and Jj<, but for
ost purposes the latter will be found more convenient. Formul» for
ese percentages are given in Par. 18S to 189. The torque formula given
)Ove, as well as many others involving vital relationships between induction-
otor variables, may
be written in terms of these percentages, with the ad-
intage that while the actual constants n.ari, etc., have values depending upon
e size and voltage of the motor, and are not easily compared as between

% Diagram
Fig. 88. — Percentage vector diagram for induction motor.

o motors of different voltages or outputs, the percentage values are imme-

itely comparable and are direct measures of all the vital relationships,
is advantage is particularly marked in the case of approximate formuue.
lere their simplicity enables one to compute mentally most of the important
iracteristics of an induction motor, starting with only two or three of these
centages. Moreover, it is a very simple matter to memorize the range of
ise percentages in standard machines, as well as the effect of unusual speci-
itions, and thus hold in one's head
al information concerning machines
all sizes and voltages, which would 1.0
lerwise fill many long tables.
182. Power-factor. Referring to
5. 88, the power-factor (cos 0i) is
tained by resolving each vector along
i perj^endicular to Ei. The exact
raula is complicated, but a fair ap-
jximation is

power-factor = —— (52)

curve III is plotted from

tn Fig. 89,
t. 52 and curve I from the complete
nation with the following assump-
ins; gri = 0.02; ge = 0.04; and qxi =
q*i.
Sec. 7-185 GENERATORS AND MOTORS
power-factor. Tmoi/r/ is plotted against «» in Fig. 90, for fcjn=sl.9. Eroi
which, if the lower limit for Tmaz/Tf, qx must not be more than 0.26.
2 is
186. Per cent, stalling torque. Hobart gives the per cent, stallin
torque in terms of <r (Par. 207) and qm as follows ("Polyphase Generators an
 — — - 1 X '

A. C. GENERATORS AND MOTORS Sec. 7-188

188. Starting currant. Neglecting the exciting current, the starting

iurrent is given by Eq. 46; this may be transformed to

/.=/,71 "
°=
;
— (approx.'l (amp.) (55)

fl/,=7.-T-7i/ = iH-(Var»+axO (56)

The ratio (/t//i/) of the starting current to the full-load primary current is
)lotted against gr, for several values of g* in Fig 92; gr, is again taken
"0.02. It will appear. from an inspection of Fig. 92 that the starting current
aken by a squirrel-cage induction motor at full voltage is too large to be
olerated in the case of large motors. In such cases compensators or induc-
ion starters are used to reduce the voltage during the starting period.
189. Compensator starting of squlrrel-eaga motors. To find the
.er cent, starting torque for a given maximum allowable line cuireni, fet
fw = starting torque with compensator; T/ = full-load torque; J{ w'li9P{^uf-j
lent at starting and 7/ = full-load current.
'^'

-•
1 ««

•* .« -8 1. 1.2 1.4 1.6 1.8 2.« .[.

Allowable Line Current at Starting 1 '"",

Full Load Current Jj,
'
FiQ. 93. — Torque relatfons when starting with induction starter or
..o;;r'ii;xi,i compensator.
Then from Eq. 54 and 56 and the compensator relations, it can be shown
"'
at .

T„ 1 1 1.25gr,
AjT ==r-=y- . (approx.) (57)

plotted in Fig. 93 for several values of the ratio (gr/gi).

»iig is
As an
ample, take a large squirrel-cage motor which must be started without
awmg more than full-load current from the line. Assume gi = 0.20 and
, = 0.02. Then r.c/r/= (1.25X0.02)/0.201?s0.124or one-eighth of full-load
rque.
190. Deep rotor bars for starting. The curves of Figs. 91 to 93 show
a striking manner the inherently poor starting qualities of squirrel-cage
auction motors, except when a large full-load sUp js allowed. This defect
iy be eliminated in some degree by a very ingenious device consisting in
•e use of very deep rotor slots and bars, which
gives a high apparent resist-
ce and low reactance at starting, and the reverse near synchronism. The
ly drawback is the reduced stalling torque; but in many cases there is
iple margi n. The resistance multiplier is 0.35 X depth of bar in inches
frequency. See Hobart's " Design of Polyphase Generators and Motors,"
168.
331
 "

Sec. 7-191 A. C. GENERATORS AND MOTORS

191. Summary. Figs. 89 to 93 show clearly the relations of all tht
vital operating cbaraoteristics (except heating) of induction motors ol
whatever size, frequency, or voltage, to a very few constants; and although
the results are only approximate, they will give a fair quantitative grasj:
of induction motor characteristics. The largest errors will occur in small or
low-speed motors with large exciting currents.
The most important of these characteristics are almost wholly determined
by Qm, qz, and qrt- The other g's may be approximated with sufficieni
accuracy, since they play only a small part, and a considerable error in theii
approximation does not seriously affect the results. Of qm, qz, and gr, tht
last may be given almost any desired value without much affecting the othei
constants; whereas qm, and g» are intimately related to one another, to tht
major design constants, and to the details of design. Their computatiot
is given below.
MAaNETIZINO CUSRENT*
IM. Air gap and gap ampere-turns. The air gap is usually reduced
to a comfortable mechanical clearance, and may be taken approximately
as 8=-0.015\/kwT (inches). The gap ampere-turns are computed in tht
same manner as for the alternator (see Par. 40, Figs. 39 and 40). Designate bj
Ol and 02, respectively, the primary and secondary slot-contraction factors
byiiri=»oia2, the combined slot-contraction factor; by Xd the correspondinf
air-duct contraction factor; and by Kt the ratio of gap ampere-turns to tola
ampere-turns. Ki varies from 0.9 in slow-speed high-frequency machine!
to 0.7 in high-speed, low-frequency machines. These are, however, outsidi
limits, and 0.8 may ordinarily be assumed as a fair average for a rougl
approximation. Then the total ampere-turns for the longest complete mag
netic circuit is Nii = {Q.&2&S,S)/KiKiKd.
= peripheral loading corresponding to torque current /p (Fig. 88)
Let A
(B = maximum or crest value of equivalent sine- wave of gap-flux distribu
tion; V = peripheral velocity (ft. per sec.) of revolving field; for hi and k-
see Par. 28-31 (synchronous machines).
Then, assuming that the magnetising current is equivalent to a sinu
soidal distribution of current den.sity, of root-mean-square value Am
= Oll()(Siif/{khkpK\KiKdv) and the per cent, or fractional magnetiMnt
ii.m
current is
g« = Am/A = 0.116(Ba//(A:!,J;pKi/rjXdAii) (58

For a three-phase motor A;6 = 0.955. For five-sixths pitch ^p="0.96. Fo

=
open-slot stator and nearly closed-slot rotor, Xi 0.65 (approx.). For i

well-ducted motor Xrf = 0.9. For a 60-cyole motor, Kj = 0.8 (approx.)

Then, roughly, gm= (0.27(B«/)/(Ar).
LEAKAGE REACTANCE*
193. The four elements of the leakage flux are computed as if sepa
rate from the main flux, whereas they are for the nio.st part only distor
tional as tothe main flux. Consider the
phase-belt as the unit. Figs. 94 and 95.
194. Slot leakage.* This is the
cross-slot flux (Fig. 94). The inch per"

-%^^^m^
I
V,l<f, 94. —Illustrating cross-slot leak- P'lo, 95. — Illustrating tooth-tip
age flux. leakage.

ihea&ce or flux linkage (lines) per amp. in. of primary phase-belt is (se

Fig. 42)
3.2
- /I
, 1 di dt . 2di , d4
+
.
, (5S.
N,pp\ A w. W, -f- M).o

•Transactions American Instritute Electrical Engineers, Vol. XXIV, 190i

p. 338. Also Vol. XXVI, p. 1245.

532
 A. C. OEXERATORS AXD MOTORS Sec. 7-195

le total slot-linkage per amp. in. of phase-belt is

(60)
'here.V.pp = slots per pole per phase, and N, the number of slots.
95. The flux linkage

U.6
Sec. 7-l<)7 A. C. OB X ERA TORS AXD MOTORS
indicates a circumferential current backward through the paper). If fi
ring is set radially inward nearer the shaft, <pf may be increased as muchi

50 per cent, (see the upper curve). Or, if the end ring is placed nearer tl
core, f>j may be considerably increased (25 or 30 per cent.).
197. Belt-lflakage. * For three-phase motors and fuil-pitch winding
the flux linkage per amp-in. of belt is
^Bj = %'*^i'^s'^'"- -^3145 = ii:;5T -^ 3145 '{61

1.6

1.4
 A. C. GENERATORS AND MOTORS Sec. 7-199

A. much more convenient form for many purposes is the per cent, reactance
Its f/xl-^J5'l=8xJ).

qrt-0.78k^-^+28.1kp—^%,+ 1.56K/k»^ + 0.03Ks^ (62a)

KB <&/ Hf(&
SN*
lere JV.p = sIot8 per pole, and S = T«J.6-^3. S varies from 6 to 18 with an
.erageo!l0tol2. ^-

rhe several terms in Eq. 62a represent, in order, the slot, tooth-tip, coil end
i beltleakages.
These equations can be much simplified for any particular type of mgtor by
uming numerical values for some of the minor constants; but the use of
! complete expressions involves only a few minutes in computation, and
jj the advantage of keeping before the mind the factors upon which the
.:.ctance depends. Approximations which are quite allowable in one type
'machine are dangerous in another.
CIRCLE DIAQBAM
199. The circle diagram. If the constants of an induction motor were
lly constant it could be proved that the locus of the primary current
1 »"2 *2
11 7i'-Is ,

^(•i-1)

Fig. 103. —Approximate equivalent circuit diagram of induction motor.

\tor, plotted with respect to a constant impressed e.m.f., would be a circle.

} the purpose of approximate calculation and still more for the visualiza-
li of induction motor characteristics, the circle diagram is invaluable, and is
ilely employed by Continental and British designers. The simplest form
E\ (constant)

^Bg ( 8 - 1 )

"Au O

r' •hlir)
•!ol.

ilK K^
/e+A
Fig. 104. —Approx. circle diagram oorrespopdiug to Fig. 103. r

I hat based upon the approximate equivalent circuit scheme of Fig. lOS,
vch differs from the equivalent circuit scheme of Fig. 87 in having the
e iting-current circuit connected outside of the primary. This renders the
• i-current c'rcuit independent of 7o, and leaves it with a constant react-
*e {Ta = x\-\-xi) and a variable resistance r\i = T\-^(xils) depending upon the
When a constant voltage is impressed upon such a circuit and the
•
Sec. 7-200 A. C. GENERATORS AND MOTORS
resistance varied (variable «), the locus of the current is a circle. The oxei
ing current must be added to obtain the total current.
The corresponding diagram is shown in Fig. 104. If this diagram t
rotated counter-clockwise until Eiia slightly below the horizontal on tl
left, it will correspond with the left-hand side of the regular vector diagrat
Fig. 86. The diameter of the circle in Fig. 104 is £1/(11+12). B, is tl
short-circuit or standstill point; tan ¥><> = —+—
X1
;

X2
1 and BiG,-i-G,H, = ri-i-n.
The approximation involved in this diagram
is such that serious erro
are not introduced in the case of a good motor, i.e., a motor with low excitii
current and low reactance; but the errors become serious in poor motors.
200. Note concerning interpretation of approximate circle dlagran
In what follows £1 and Ii are the volts and amperes of a single phase. If J
be the line voltage multiplied by s/s, and /i the line current, p' should 1

omitted from all expressions for power and torque.

201. The impressed power is, Pi'=p' EJi coaei = p'EiXBK; but sin
p'Ei is constant, BK
is proportional to and a direct measure of the power d
livered to the motor; i.e., a scale of watts or kilowatts can be chosen accordii
to which BK indicates directly the impressed power. Pi.
20 2. Losses, output, torque and slip. According to the same sea
HK indicates the core loss, p'EiIe+h =Pe+h. If In is measured when tl
motor is running light, the corresponding power willinclude the friction lo;
in addition to core loss, and since the friction loss is practically constar

Data
Scales 2.5 per delta p1iai9
Amperei
lorse Power?
g_
| ? ? 1 1
°
rj.1.2 AD~^
Torque in
go- 0.00262 bo- 0.0136 l/g- 0.01384
12 8 4 5
'•'''''
Synchronous
H.P. gj^-.0.50

Bs ff^ = O.U
(T— 0.006

Mjr B- 6 H-P. Operating Point

BF m 5 H.P. Ka
OB m 7.7S Amp. (delta)
Fio. 105. Approx. diagram for a 5-h.p. three phase, 6-polp, 220-v
circle
delta-connected induction motor.

it could be charged to the exciting circuit (Fig. 103 ), by increasing go in \

proper degree. It will be so taken here, i.e., that represents core n HK

friction loss. Similarly_//0 represents the primary copper loss, <5F
secondary copper loss, FB the output (Pt),OB the powerjransmitted acTigi

the air gap (i.e., the torque in synchronous watts) and GF -i-GB the slij>.
203. Efficiency (Par. 210-216). The efficiency is Pa/Pi = BF/B/r.
204. Power-factor (Par. 216). The power-factor, 00s #1, may be:
determined from the diagram by drawing a unit circle about O and :

ing the vertical intercept of the /i vector on this unit circle.

Thus for any point B on the circle, all the important variables |

induction motor may be readily determined from the circle diagram, i

206. Kzperimental determination of cirfffif^Lfgttifn. The el
mental data necessary is, ,1^^' jg^gp.

5:i6
 A. C. GENERATORS AND MOTORS Sec. 7-206

(a) Amperes and watts at normal voltage when the motor is running
ht. This gives the Io = OA of Fig. 104. Thus the point A may be located,
irting with O as the origin, and Ei vertical. , , t
. •

(b) Amperes and watts at normal voltage with rotor blocked. It is

netinies necessary to make this test at reduced voltage owing to the exces-
e currents which would flow at full voltage, and to change the results to the
1 voltage equivalent. This will locate the point B„ which together with A
termines the circle, the diameter being assumed horizontal through A.
The resistance of the primary winding.
.\11 of these tests, particularly the last two, should of course be made at]or
-irthenormal working temperature of the motor.
The diagram thus experimentally determined, expresses with a very fair
»;ree of accuracy the relations between all the important variables of the
: tor.
?ig. 105 shows the approximate circle diagram drawn to scale for a
.'..p., three-phase, 6-pole, 200-volt, 60-cycle induction motor, and Fig. 106
( ws the characteristic curves obtained therefrom.

1200

1000 ^ 10 SlOO

S800 M *

pi
600 e
x
^400 40 4 S40
'
30 I
200 20
10
Sec. 7-208 A. C. GENERATOR,^ AND MOTORS

icing current to tbe short-circuit current, but this is inaccurate for motor
with higli secondary resistances. It is dependent upon the machine pro
portions and independent of the load.
For all practical purposes it is

a=0.93gmgz
.3:95S«
T^
+ MM +1:32X^+0.0052
,,' I

For values of S, A and Kf see Par. 1»5 to 198 and Figs. 96 to 101. S varie
from 6 to 18 with an average of 10 to 12; .1 from 0.2 for open slot
looZ
00^ £7i

Iq locus

Fig. 107. —Approximate and accurate circle diagrams of an induction moto

on one side of gap to 0.42 for nearly closed slots on both sides, and Kf fro
1.5 in good squirrel-cage motors to 2.2 in slip ring motors, see Fig. 101.
Kierstead has proposed a somewhat simpler though leas rational formul

where C varies with the air gap according to the accompanying table

». 039 0.047 0.055|o.063 0.07l|o.079|o.087j0.m

0.024J0.032J0.

C 0.71 0.99 1.09 1.17 1.25 1.31 1.39 1.45 1

Of these equations, Eq. 66 gives results quite as accurate as the avt:

test results can check, and for all types of machines. Eq. 67 gives 1

results for the majority of standard machines, although inaccurate for

<

factor or circle ratio is much used by European dcsig'

The leakage
Reference maybe made to Hobart's "Electric Motors "and "Design of r
phase Generators and Motors" where thedesigning of induction niotorsi-
plained with the assistance of the circle diagram in a simpler though i

accurate manner than is described in Par. 343 to 259 below.

SOS. Maximum power-factor. In terms of », it is given by varn
authors, thus
Maximum power-factor'
l+2<r

Maximum power-factor =
l+<r

538
 .

I -4. C. OEXERATORS AND MOTORS SeC. 7-209

1,6 accuracy and meaning of either of these depend upon the method of
termining or of defining a.
109. Bibliography of articles relating to the calculation of circle
i:io.
Chapter IV (p. 29) of Behrend'a "Induction Motor."
[.

il. "The Magnetic Dispersion in Induction Motors," by Dr. Hans Behn-

::henburg; Jour. I. E. E., Vol. XXXII (1904), pp. 239 to 294.
:il. Chapter XXI on p. 470 of 2d Edition of Hobart's "Electric Motors."
?.V. "The Leakage Reactance of Induction Motors," by A. S. McAllister,
H. World for Jan. 26, 1907.
V. "The Design of Induction Motors," by Comfort A. Adams, Tram.
A. E_. E., Vol. XXIV (1905), pp. 647 to 687.
/I. "The Leakage Factor of Induction Motors," by H. Baker and J. T.
Jdn, /owr. I. E. E., Vol. XXXVIII (1907), pp. 190 to 208.

LOSSES AND EFFICIENCY ^nix/p«

Classification of losses.
;10. The losses of an induction motor are as
tows: (a) the primary copper loss; (b) the secondary copper loss; (c) the
fe loss; (d) friction and windage losses. The copper losses may be com-
I«din the ordinary way, except that in the case of squirrel-cage rotors the
nhod is not quite so obvious. See Par. 212, also See. 24
11. Primary copper loss. Intermsof the design constants and in terms
( he output, it is

^ (l+fe,A;/)10»

xsre m is the circ. mils per amp. Owing to the lower flux density in the
gs there is a greater length of active conductor than for the synchronous
jTnator; but this is partly neutralized by the I arger
I the poorer ventilation of the
m
made necessary
short air-gap machine.
12. Secondary copper loss. In the case of a wound secondary, the
c per loss is about the same as for the primary, for although the current is
1' there is in most cases less slot section available for
, copper. In the case
ci squirrel-cage rotor, it is usually easy to make thesecondary resistance
1'.. Unfortunately this opportunity may not ordinarily be taken advantage
c smce the starting torque requireinents frequently demand a relatively
l::e value of the slip and therefore of grj. Par. 186 and
Fig. 91.
'he squirrel-cage copper loss may be computed as follows: The secondary
crent per bar is 26=ii{r,j where A2 is the secondary peripheral loading
« Tij the secondary tooth pitch. I}? times the ohms per bar times the
tnber of bars = total bar loss. The current in each endringisJr =J» times
t number of rotor conductors per pole divided by 2.22, and
the end ringloss
If. times total series resistance of both end rings.

13. Core losses. The calculation of the core losses of an induction

n ornot so simple a matter as might at first appear, since, in addition
IS
the losses in core and teeth at fundamental frequency, there are tooth
fiiuency losses in both primary and secondary teeth, wave losses in
tooth
tr and losses due to breakdown of
laminations. There are also sometimes,
8 oad, eddy losses in the copper conductors. See A. I. E. E., Vol. XXIV,
p.

14. Calculation of core losses. There is no simple rational method at

P lent available for computing the core losses of induction
motors with
riionable accuracy. The following formulse have coefficients such that
jvn applied to the primary teeth and core, they yield results
large enough
i<-over the indeterminable losses, except in those cases
n uency losses are unusually large, as with open slots onwhere the tooth-
both rotor and
orm cycles
—"Watts per cu. in. =P«o' = 4.1(Bm/10»)«.
or 25 cycles— Watts per cu. in. =P26' = 1.3(Bm/10«)2.
^
» med to be 0.014 in. thick. Nearly all the extra losses are Laminations
due to eddy
ents rather than to hysteresis; hence the
exponent 2 is sufficiently accurate.
'°"f>wne table of data for estimating the core loss of induction motors
Ig v
•Ken from Hobart's 'Design of Polyphase Generators and Motors."

539
Sec. 7-215 A. C. GENERATORS AND MOTORS

Density in stator
(lines per sq. in
 A. C. GENERATORS AND MOTORS Sec. 7-216

117 of Hobart's "Design of Polyphase Generators and Motors" (McGraw

values for the
Publishing Co., New York, 1913) and give representative
of outputs
newer-factor and efficiency of polyphase squirrel-cage motors
1,000 and for a wide range of speeds corre-
ranging from 10 h.p. up to h.p.
sponding to frequencies of 25 and 60 cycles, per sec.
216 Table of representative eflaciencies and power-factori
of moderate-voltage polyphase squirrel-cage induction
motors at their rated loads
 Sec. 7-218 A. C. GENERATORS AND MOTORS
Data of complete weight (exclusive of shaft and bearings) of five 33-cy;o
squirrel-cage induction motors for a synchronous speed of 124 r.p.m.

Rated output Weight

1,000 horse-power 15 metric tons

2,000 horse-power 25 metric tons
3,000 horse-power 34 metric tons
4,000 horse-power 42 metric tons
5,000 horse-power 50 metric tons

S18. Weights per horse-power. A iVh.p. 1,200-r.p.m. po yphase ii

duction motor weighs a matter of 19 lb. while a 10,000-h.p. 120-r.p.r
polyphase induction motor would weigh some 176,000 lb. It is interestit
to note that while the large motor has 150,000 times the output of tl
smaller, it only weighs about 9,000 times as much. Moreover its speed
about one-tenth as great as that of the smaller motor.
219. Starting apparatus for standard polyphase induction motori
Ninety per cent, of all the induction motors built in America are of the squi
rel-cage type. Whereas the squirrel-cage motor when of small size is switche
directly on the line at starting, it is necessary in starting larger squirrel-caf
motors to employ induction starters or else the star-delta method. Slip-rir
induction motors are started by means of a rheostat connected into tl
rotor circuits, and gradually cut out as the motor acquires speed. Wit
the growth of electricity-distributing net-works, it has become expediei
to relax the earlier onerous requirements imposed in the matter of permi
Bible starting currents. On some systems fairly large squirrel-cage motoi
are permitted to be started by switching directly upon the line without ii
duction starters. Designs in which the "deep-slot" effect (Par, 190) is oo
rectly employed may be started directly from the line with a more moderaf
rush of current, and hence are the more appropriate as regards the leesi
line disturbance at starting.
220. Induetion-nxotor starting cturents. The currents taken b
good three-phase squirrel-cage induction motors at the moment of startinj
have values approxinriately in accordance with the following table, whic
corresponds to gt = 0. 13 and i = q^ =0.04, see Figs. 91 and 92 and accon
panying text. '

Pressure at motor Line starting cur-

Motor Starting torque
starting ci(

motor in per cent

current in per
in per cent, of line rent in per cent, of
cent, of full-load of its fuU-load
pressure full-load current
current running torque

40 112 280 32
60 250 420 72
80 450 560 128
100 700 700 200

221. Calculated starting characteristics. The following table, take

from page 451 of the 2nd Edition of Hobnrt's "Electric Motors" (Whi'
taker & Co., London, 1910) gives the calculated starting characteristicai
a 6-r)ole 25-cycle 200-h.p. 5()0-rev. per min., squirrel-cage, three-phase, ilj

duction motor.
The motor to which these last results correspond, was designed for vet
high eflBciency and without any regard to starting torque (gi = 0.12 and •<
^

0.02). Consequently, we find that when started on the six-tenth taps of it

induction starter, the starting torque is only 55 per cent, of full-load rurinii
torque and the line current is practically three times fiill-load curreut,_
worse result than that of the average motor correspondinif to the earlic
table. By employing the "deep-slot" principle in the design of 60-cyc;
squirrel-cage induction motors, the application of the full-line pres-sure i'

Starting will be accompanied by a much smaller flow of current from the hi

than that shown in the table for the average motor. While the torque ma;
542 I
 A. G. GENERATORS AND MOTORS SeC. 7-221(a)

also be smaller, it will nevertheless be as great as the torque

correspondmg
(in the average motor)
to the tap on the induction starter, which corresponds
the lower line current. Thus nothing is sacrificed except that the motor s
power-factor will be a few per cent, lower at full-load and the customer is
spared, the outlay for an induction starter. Further, the operation of start-
ing is reduced to elemental simplicity.

Pres-
sure at Alotor's Line Starting
motor starting starting Starting torque in
1

Stator Input torque per cent,

termi- current current j
Input copper
nals ir in per in per to stator to rotor (meter of full-
loss
per cent cent, of cent, of (watts') (watts') kilo- load
(watts) running
of full-load full-load grams)
normal current current torque
pressure

33 274 91 56,600 33,300 23,300 44.3 15.1

40 330 132 86,000 48,000 38,000 72.3 24.3
60 495 297 194,000 108,000 86,000 164.0 55.0
80 660 528 344,000 192,000 152,000 289.0 97.0
100 824 824 540,000 299,000 241,000 455.0 153.0

221(a). Characteristics of very-low-periodicity induction motors.

It is often desirable to have certain pieces of apparatus run at a slow speed,
say from 80 to 200 r.p.m. Sixty-cycle induction motors of medium output,
say 500 horse power, and for such slow speeds, would have many poles and
large diameters and poor characteristics with respect to magnetizing current
and stalling load. The power factor of such motors would be low at full load,
Siiy from 0.60 to 0.75. From quarter to half load, the power-factor would
be far worse, say 0.4 to 0.5. Using a low frequency induction motor, for
example some 8 to 10 cycles, one obtains a small number of poles, a power-
factor at full load which will be of the order of 0.95 and which will still be
some 0.90 at quarter load. The full-load efficiency of such a motor is from
2 per cent, to 3 per cent, higher than that of the 60-cycle motor, and is also
very high (some 0.90 per cent.) at quarter to half load. Hence the apparent
efficiency of such a low-frequency 500-hp. motor is a matter of 90 per cent,
as against not over 70 per cent, for a 60-cycle motor. This permits of
important savings in the line, transformers and generating equipment.
221(b). Characteristic and applicability of very-high-frequency
induction motors. For applications where many small and very-high-
speed motors are required, a frequency-changer set is employed by the
General Electric Co. to obtain the necessary frequency transformation.
These frequency changers are wound to give 225 volts at 120 cycles, in one
series, and 115 volts at 200 cycles in the second. However, in the first
8(?ries the frequency changers can be run at speeds to give from 100 to 199
cycles and in the second series from 200 to 300 cycles. The high-frequency
motors are designed to operate throughout the range of frequency in the
series for which they are wound. They are all bipolar. In the first series,
synchronous speeds from 6,000 to 12,000 r.p.m. are obtained, and in the
second series, from 12,000 to 18,000 r.p.m. Weights and other data are
given in the following Table:

1
Sec. 7-222 a. c. generators and motors
Thousands of these motors are in use at these frequencies, for such purposes
as the grinding of small bearings, especially ball races, where, in order to
secure a satisfactory cutting speed, speeds up to 18,000 r.p.m. have been used;
also oil separators of the centrifugal type, for which, in some cases, speeds
up to 16,200 r.p.m. have been used. They are also used for driving wood
snapers and wood carving machinery, where, in order to get a reasonable
cutting speed, high rotative speeds are necessary. The manufacturer of the
special apparatus usually mounts the motors directly on the shaft or spindle
of the machine to be driven and provides, at the same time, the outside
casing to support the stator.

INDUCTION GENEBATOB
322. Theory of operation. If a polyphase induction motor, while
running light, and still connected to its supply circuit, be mechanically
driven above synchronism, the slip will be negative, the secondary con-
ductors will cut the revolving flux m the opposite direction, the secondary
e.m.f. and current will reverse with respect to the flux, and the torque reac-
tion of the secondary current will oppose the rotation. This means mechan-
ical power absorbed and a reversal of the direction of power flow across the
air gap, i.e., generator action. A little consideration will show that the
torque characteristic above synchronism will be approximately symmetrica
with that below synchronism, referred to the point of synchronism, see
Fig. 111.
Induction generators are dependent for their excitation upon laggins
current drawn from synchronous generators, or leading current delivorec
to synchronous motors connected to the network into which the inductior
generators deliver their output. Therefore the induction type of generatoi
requires no separate exciter for the purpose of supplying continuous current
to its field windings, and is consequently much simpler in its electrical con-
struction than the synchronous type.
However the induction generator is subject to the very definite limitation
that it is operative only when connected in parallel with a synchronouf
generator, or in parallel with a supply network to which there is at least one
synchronous generator connected, as otherwise it would be cut off from ite
source of exciting current.
223. Circle diagram of induction generator. The characteristics ol
the induction generator can be most easily determined from the circle dia-
gram. For this purpose we may still use the induction-motor approximate-
equivalent circuit scheme of Fig. 103 with the understanding that s is negative
which means an apparent negative reactance sij, and an apparent negative
resistance (ri/s)(l — s). This means that the power delivered to this resist
ance is negative, and simply an electrical equivalent of the source of me-
chanical driving power. Upon this basis, it is evident that the locus of the
extremity of /i is a circle for the induction generator as well as for the induc-
tion motor, as there is no abrupt change in the vector diagram when s passei
through zero.
224. Interpretation of circle diagram. The approximate circle diagran
of theinductiongeneratorisgiveninFig. 110, where the notation corresponeL
to that of Fig. 104 for the induction motor. The principal characteristics de
rived from the circle diagram areshownin Fig. 111. Referring to Fig. IIOJ^
represents the total power delivere d to the generator (shaft-friction, wmi
age, and rotor-core loss excluded); FO represents the rotor copper loss
the total power transmitted across the air gap to the stator; GH
the st i'
copper loss; HK the sta tor-core le>ss; andKBthe output Egli cos dg. Tb<
Blip is s=FG/GB.
226. Power-factor and excitation. Thus the induction machine
driven above synchronism, pumps power back into the line, the anioun'
depending upon the slip. But tne power-factor of the outputis fixed, no
by the nature of the load but by the slip and the constants of the maohim
itself. The induction machine always carrios a quadrature current whei
operating either as motor or as generator. It may De said to receive a quad-
rature lagging current, or to eleliver a quadrature leading current. Thii
quadrature current is the excitation of the machine, a part Im for the niair
flux, and the remainder (or its equivalent in quadrature volt amperes) fo)

544
 A. C. GENERATORS AND MOTORS See. 7-225

Motor

:i^ I H
l^e+A
4>,

'Oa

Y-'ir^\
Generator

Fig. 110. —Circle diagram of induction generator.

18 16 14 12 10 8 6 4 2 2 4 6 8 10 12
ToMue in Synchronous K-.W.
|Fia. 111. — Generator and motor characteristics of induction machine.

545
Sec. 7-226 A. c. generators and motors
the leakage fluxes. This exciting current is absolutely necessary to th«
operation of the machine, and must be supplied from the line in just as rea
a sense in the case of generator operation, as in the oaee of motor operation
826. Condenser excitation. An interesting though uncommercia
method of supplying this excitation is by means of condensers. With con-
denser excitation an induction generator acts very much like a direct-
current shunt-wound generator, except that it has a separate characteristic
curve for each power-factor.
The amount of capacitance required for the excitation of a large induc-
tion generator is somewhat appalling. E.g., even a very large inductioii
generator with the best constants will require about 25 per cent, reactive
current at full-load; but as capacitance costs from $10 to $20 per kv-a,
(higher for lower frequencies), this will add from $2.50 to $5 per kv-a. to
to the cost of the induction-generator, which renders it prohibitive.
227. Excitation from synchronous machines. The usual arrange-
ment for excitation is to operate induction generators in parallel with one oi
more synchronous machines, motors or generators, usually the latter. The
synchronous machines supply not only their own excitation but also that foi
the induction generator, as well as the quadrature or reactive current de-
manded by the receiving apparatus connected to the system.
228. Low excitation required by induction generator. The no-
load exciting current of large high-speed induction generators may be af
low as 12 per cent, of the load current. The full-load lagging reactive
component or what might be called the full-load excit ation, is so metimes a:
low as 25 per cent., which means a power-factor of l/V 1 -|- (0.25)^ = 0.97.
229. Equivalent exciter capacity. Although the excitation of the induc-
tion generator issmall in ampere- turns, it is large in kv-a. since its power-
factor is low. If this excitation is supplied by a special machine used foi
no other purpose, its kv-a. capacity must be at least 25 per cent, of that of the
induction generator, whereas the capacity of the direct-current exciter for t
synchronous machine is rarely more than 2 per cent., and in large machine!
about 1 per cent. If, however; there be enough synchronous-machine capa-
city installed, so that the total reactive exciting current is a small part ol
the load current of the synchronous machines, their resultant capacity neeei
not be much increased. In some cases, a part of the excitation of inductioi
machines can be supplied by the charging current of large underground cable
systems.
230. Voltage regulation. The induction generator when excited froir
synchronous machines has no inherent regulation as to voltage, since in thii
respect it is quite as passive as an induction motor and depends wholly upoi
the voltage and corresponding excitation supplied to it by the system. Ii
other words, the voltage must be controlled by the excitation of the synchro-
nous machines connected to the system.
231. Frequency regulation. If the frequency is kept perfectly constan
by the synchronous machine, induction generators can only deliver an in
creased output by increasing their speed and slip, see Fig. 111. If, however
the speed of an induction machine is kept constant, it can deliver moti
load only by a decrease in frequency, i.e., by a decrease in the speed of thi
synchronous machines which set the frequency.
232. Division of load. If the induction generator be driven by i

governed prime mover, its speed will drop slightly with the load, whicl
means that the frequency and therefore the speed of the synchronous ma
chines must drop still more. Another method of dividing the load t(
i.^i

drive the induction machine with an ungoverned prime mover, e.g., a st i

engine with fixed cut-ofl. In this case its output will be constant, ain;
speed-governed synchronous machine or machines will assume the !

fluctuations, and the frequencj; regulation will be the same as that of th

synchronous machine. Large induction generators can be designed with !

full-load slip of a fraction of 1 per cent., consequently the necessary varia

tion of speed is very small.
233. Induction generators and low-pressure steam turbines. J
very good place for this method of dividing the load, is where low-pressur
turbines are operated by the exhaust steam from other paralld-ronncctei
steam units. The exhaust turbines can be operated without governori
thus utilizing all the exhaust steam, nnd yielding the highest economy.
546
 A. C. Generators and motors Sec. 7-234

234. ESect of angular variation of prime movers. Since the division

of load in the case of parallel-connected induction generators is dependent
upon the relative speeds rather than upon the relative angular positions of
the rotors, the relative angular displacements within one revolution of a
reciprocating steam or gas engine do not produce objectionable power surges
between the various generators, as frequently occurs in the case of synchro-
nous machines. Even gas engines are quite satisfactory in this connection.
235. Effect of e.m.f vrave shape on parallel operation.
. The induc-
tion generator is largely passive as to wave shape, the latter being im-
pressed from without, and in the presence of e.m.f. harmonics, behaves like
an inductive reactance which tends to damp the harmonic currents.
236. "Switching in." It is not necessary to synchronize when throwing
n an induction generator, since the latter has no e.m.f. until excited from the
ine and when so excited is always in phase. It is only necessary to get the
'

nduction machine up to speed and throw it in. As the machine cannot pick
^jp its load until the field is established, the first rush of current is wholly
jxciting current and practically independent of the slip. This initial current
^•ush is quite analogous to that experienced when switching in transformers,
md is explained on the same basis. Since with large units this exciting
mrrent rush is undesirably large, leactance coils are inserted while switching
n, and then cut out as soon as the steady state is reached.

_
237. Hunting. The connection between the speed of a synchronous
^nachine and its circuit frequency is exactly analogous to a mechanical
lastic coupling, and that between an induction machine and its impres.sed
!

,requency, to a friction coupling in which the friction grip is proportional to

fhe slip. The latter tends to damp out any oscillations of the system, while
'he former has a natural period of its own which may tend to amplify some
»ieriodic disturbances of the system. The induction machine is thus de-
idedly superior on the score of hunting.
238. Short-circuits. The short-circuit current of a synchronous alter-
ai or consists of two parts: first, the transient part limited only by the
oiiibined equivalent leakage reactance of armature and field circuits; and
Kond, the steady part determined by the much larger synchronous reactance
jf he armature. The former is the serious element, from three to five times
1

ie latter. It is this transient effect that twists the armature coil ends as if
icy were made of rope. With the induction generator the case is quite
ifTcront. There is no steady portion, since the source of exciting cur-
;iit disappears when the short-circuit occurs, just exactly as in the case
:i direct-current shunt-wound generator. The transient effect is present,
ut m
only small degree since, with the same flux as in the synchronous
a'hine, the reluctance of the magnetic circuit (and hence the energy of
le field) is only a fractional part (sometimes less than 10 per cent.) as
•eat.
239. Low resistance squirrel-cage rotor. Since the induction gen-
ator requires no starting torque, the rotor is always of the squirrel-cage
^po and of as low resistance as is consistent with the cost of the copper
id the available space. This means a very low secondary-copper loss,
id a sHp of less than 0.5 per cent, in large machines.
240. First cost and ventilation. Owing to the exceedingly simple rotor
iistruction, theinduction generator would be cheaper to build than a syn-
rrnous machine of the same capacity, were it not that the short radial
pth of the air gap makes ventilation very diflficult, and the more so in those
jtings which are otherwise the best suited to this type of machine. This,
tgether with the tooth-frequency losses incident to the short air gap,
r.ikes the induction generator of doubtful superiority except in special cases.
le switchboard is, however, very much simpler, and the switching
opera-
>ns are of reduced complexity.
241. Best field of application for induction generators. The
ecifications from which the best induction machines can be produced are
^P^^"^' '^""Se output, and low frequency, which means steam-turbine or
u
j?h-head water-whee! drive in large power stations. Unfortunately these
the specifications which lead to great difficulties in ventilation, owing to
,!

short air-gap.
•? A large city-railway system with the load considerably
*?% '^P , "f synchronous converters with underground-cable distribution,
asSes the conditions as to excitation.

547.
Sec. 7-242 .4. C. GENERATORS AND MOTORS
242. Bibliography.
Danielson.— "Reversibility of the Polyphase Induction Motor." Elec
World, Jan. 21, 1893, p. 44.
—
Steinmetz, C. p. "Alternating-current Induction Motor." Train
A. I. E. E., Vol. XIV, p. 185, July 26, 1897.
Steinmetz, C. P. and Behq, E. J.— "Alternating-current Phenomena.'
—
Chapter 15, Par. 156, First Edition.
McKissiCK, A. F. "Some Tests with an Induction Generator." Tram
A. I. E. E., Vol. XV, p. 409, 1898.
—
Leblanc, Maurice. "The Induction Generator." L'Eclairage Electriqu
18, pp. 101-167 and 376-379, 1899.
—
McAllister, A. S. "Excitation of Asynchronous Generators by Mean
Elec. World and Eng., Jan. 17, 1903.
of Condensers."
—
McAllister, A. S. "Asynchronous Generators." American Electriciar.
November, 1903.
Stanley, W. and Faccioli, G.— "New Type of Induction Alternator an
Trans. A. I. E. E., July, 190o.
Exciter."
—
Waters, W. L "Non-synchronous Generators." Trans. A. I. E. E
Spooner, T. and Barnes, A.
—"Induction Generator— Effect Shon
J. of

AND Knowlton, E. — "The Squirrel-cage Induction Gei

circuits." Elec. World., Feb. 24, 1910.
HOBART, H. M.
erator." Trans. A. I. E. E., 1912, Vol. XXXI, p. 1721.

THE DESIGN OP INDUCTION MACHINES

243. Specifications. For an induction machine the principal specific:
tions are as follows: frequency; number of phases; speed; terminal voUag
rated output; nature of duty, continuous or intermittent service; maximu
allowable temperature rise; insulation tests; stalling torque; startii
torque; starting current; and, sometimes, speed regulation; power-facto
and efficiency. See also Sec. 24.
244. Symbols.
A = tooth-tip constant for tooth-tip leakage calculation
01 and 02= primary and secondary slot contraction factors
(B= crest value of air-gap flux density (lines per sq. in.)
(B/r = maximum flux density in narrow part of tooth (lines per sq. u
C = constant in Kierstead's formula for leakage factor
C" = copper section (sq. in.) per in. of periphery
D = air-gap diameter (in.)
d, = 8lot depth (in.)
jB'i=induced voltage per phase
e" = volts induced per in. of active primary conductor
/= frequency (cycles per sec.)
Ac = copper loss per sq. in. of gap surface (watts)
a: = Total kw. developed = P'l^ 1,000
if = aiO! = combined slot contraction factor
1

K2 = ratio
of air-gap amp-turns to total amp-turns
Kd = dnc.t contraction factor
Kf=km, Fig. 101
k = ratio pole pitch to core length
fco = belt reactance factor. Fig. 102
fc6= belt differential factor. Par. 31
A;/= length of coil end pole pitch -i-

A;o= h.p. output per sq. in. of projected area of air-gap cylinder
kp = pitch differential factor, Fig. 22
kt = slot-reactance constant
/tM = slot space-factor
I = gross length of core

Nepp = conductors per pole per phase

//i = ampere-turns
Ar,p = No. of slots per pole (average of primary and secondary)
N,pp = slots per pole per phase
P'l = Power transmitted across air-gap
p = No. of p.airs of poles
p' = No. of phases
g = total quadrature component ( = gm+9»)
.548
 A. C. GENERATORS AND MOTORS SeC. 7-245

gji = net iron length -^ gross core length

g„=> ratio of exciting current to torque current
gp = ratio of coil pitch to pole pitch
gr = resistance drop -i- induced volts
g«) = slot opening divided by tooth pitch
g«o = slot width -^ tooth pitch
gj = leakage reactance volts -^ induced volts
g,p = belt-leakage reactance volts -^induced volts /

= coil-end reactance volts induced volts

gi/ -j-

gn = slot reactance volts induced volts -f-

gx( = tooth-tip leakage reactance volts -^ induced volts

R = rev. per min.
S = 8lot factor
3 = slip
%w.c. = total works cost (dollars)
Fern = total volume primary copper (circular-mil in.)
= peripheral velocity at synchronism (ft. per sec.)
t)

w, = width of slot (in.)

A = torque-current amp. conductors per in. of periphery
Ai = primary amp. conductors per in. of periphery
Am = magnetizing current amp. conductors per in. of periphery
S = radial depth of air-gap (in.)
£ = output coefBcient, h.p.
f * = output coefBcient, kw.
= leakage factor (sometimes also termed the circle ratio and some-
<r

times the dispersion coefficient)

= pole pitch (in.)
r
\

\
]' T( = tooth-pitch (in.)
v)/ = flux per amp. in.
'

r of phase belt bundle of coil-ends, Fig. 100

'
Subscript 1 refers to primary.
Subscript 2 refers to secondary.
245. The output equation. The volt-amperes induced per sq. in. of
)eripheral surface are, i^e" = 9,.bkbkpvBWQ~^, see Par. 23.
md the total kw. developed are
K
= ^.5XTrkhkp\vBDllQr^^ (kw.) (71)
"his is the power P'\ transmitted across the air gap and not the output,
thich less by the secondary copper loss and the friction and windage loss.
is
Assuming the latter to be about 1 per cent, and remembering that gr, = s,
e get as the horse-power output

h.p. =3.55 (1-s) khkp^(S,vDllQ-^'> = koDl (72)

here fc„= 3..55 (l-,!)fc6^-pA(BvlO-'» (73)
> the specific output in horse-power per sq. in. of projected area of the
irgap cylinder. Assuming a three-phase motor (A;6 = 0.95), of moderate
apacity, with squirrel-cage rotor (s = 0.03), and five-sixths pitch of coils
'cp = 0.96),

^o = 3.2A(Bd10-h> (74)
y substituting for » in equation 72, its value [wDR/720), we get
h.p. = 1.55 {\-s)khkpA(S,DnRlQr^^ = iDHR (75)
here f is called output coefficient. With the same assumptions as
3ove,
1.38A(B10-"f = (76)
horse-power be replaced by kilowatts in Eq. 75,
J*=1.03A(B10-»2 (77)
Sometimes the output equation is more convenient in the form of Eq*
I, and sometimes in that of Eq. 75. Referring to Eqs. 72 and 75, and
isuming R specified, (B, A, and v determine Dl, and D = (720v) / {-kR) or \

and A determine DH, and k3=T/l = (irD)/{2pD, determines the ratio of

toZ. As the cost of the machine increases approximately with Di and with
^l, A(B should be as large as possible.

246. Representative values of output coefficient. (" Design of Poly-

lase Generators and Motors," Hobart.)

549
Sec. 7-247 A. c. generators and motors

Pole
pitch
in.
 I I I I I ,

A. C. GENERATORS AND MOTORS Sec. 7-254

i»= j9p (see Fig. 114) which is too small on the score of ventilation.
However, as the minimum is a fairly flat one ^3 and 11 may be consider-
ably increased without seri-
22001 — —— —— —— —
1
I
1
I
1
I
1
ously increasing the copper
volume, to the great gain
of Qm and the ventilation.
There is a pretty decided
limit, however, since the
1000
coil-end copper increases as
t)2 and the coil-end leakage

as i)'. Assuming h.p. = 10,

«= 1,200,/= 60, (B = 25,000,
•g 800 A = 400, OT = 600; the weights
of copper are as given in
Fig. 114; D. I, Qxf and *:«
( =t/1) are also shown.

254. Total works cost.

£•5600
A very useful criterion of
k% (and therefore of 11)
^
from the cost standpoint,
a.
may be obtained by the use
'400 of the following empirical
formula for the total works
cost (t.w.c.) taken from
Hobart'a "Electric Mo-
tors," 2d Edition, page 594.
200
t.y/.c. = KcD{l+0.7QpT)
(dollars) (79)
where Kc is a factor which
varies but slightly with the
size and proportions of the
rnotor. By substituting,
differentiating, andsolving,
the value of kz for a mini-
murn twc is ki = Q.7\/qp.
Again the minimum is a
fairly flat one and considerable leeway is available. If larger values of v and
fcs are taken, larger B and A may also be employed, which, having been as-
Sec. 7-255 A. C. GENERATORS AND MOTORS

sumed cyastantin determining the above value of fca, will flatten the mini-
mum still more and raise the
desirable values of v and ks.
Fig. 115 shows for a series of
100-h.p., 25-cycle, three-
phase, squirrel-cage motors
at various speeds, the influ-
ence which ^3 exerts on the
cost, and Fig. 116 shows the
corresponding values of the
circle ratio.
It is instructive also to
regard the cost from another
standpoint. The cost of the
copper andlaminationsisifirst
estimated, and is designated
aa the cost of net effective
material. If we designate the
overall diameter[ininches]by
Do and the gross core length
[in inches] by/, we may take '""q
0.20.40.6 0.81.01.21.41.61.8 2.02.2 2.4 2.6
the cost of thelabor, theover-
^'
head charges and the struc-
tural material, in dollars, as Fig. 115. — Total works cost of 100-h.p. in-
(DoVll) + Q.2OD0I. It isduction motors as function of ratio pole-pitch
seen from this formula that a to gross core length. Full-pitch winding as-
motor with an overall diam- sumed.
eter of 80 in. will have an
overhead cost approaching {85''/ll) = $580, aa I approaches zero. If i is
equal to 16 in., the cost to be debited to labor, overhead charges and struc-
tural material amounts to (580 -^ 0.20 X 80 X 16) = $836. The total works cost
is $836 plus the outlay for the net effective material. While such rnethods
require adjustment to the varying con-
00,7 ditions in different works, it is never-
theless instructive to ernploy them.
The above' investigation is based on
pre-war data. Costs of labor and ma-
terial are still too unsettled to justify
establishing equivalent formulte for
future use.
From the relation A:3 = 0.71/gp for
minimum total works cost, it can be
shown that:
 A. C. GENERATORS AND MOTORS Sec. 7-256

266. Coil-end-leakage limit of peripheral velocity. The other limit

too is the coil-end leakage, which is proportional to v^ (see Par. 196, Eq. 62a,
and remember that fea is proportional to v^). gi/has been computed for the
10-h.p. motor of Fig. 114, and is plotted in Fig. 1 17. If A were taken larger,
both the total copper and the 2i/ curves of Fig. 114 would be higher.
A change in (B would not affect either appreciably. By using a fractional-
pitch winding, both of these curves would be lowered somewhat, but there
is a limit to this, owing to the necessity for more active conductors to generate
the same e.m.f., or larger values of CB and qm. A larger value fori? would
lower both, and alargerh.p. wouldlowergi/; but these are specifications. The
curves of Fig. 117show without necessary comment why v may not be carried
above a pretty definite upper limit for any given specifications.
267. Fractional-pitch windings. The use of any considerable pitch
reduction or chording (beyond the five-sixths used for the curves of Figs.
118 to 121) means an in-
0.15
creased exciting current
In (gm) and a decreased reac-
tance (gj), other things be-
ing equal. If the motor
|jg0.10
in question were properly
designed for full pitch, the
pitch reduction should be
accompanied by a decrease
i -30.05 of (B, an increase of A
and of This will not us-
V.
ually increase either the
power-factor or the specific
output (fco or J), but rather
the reverse. It will, how-
ever, increase the diameter
Sec. 7-259 A. C. GENERATORS AND MOTORS

85 Cycles Horse- rawer

FiQ. 119. —Vital constants of motors of Fig. 118.
Figs. 118 and 119. — 25-cycle 3-phase squirrel-cage induction motors.
Stator slots open. Rotor slots nearly closed,
554
A. C. GEXERATORS AND MOTORS Sec. 7-259
-Sec. 7-260 A. C. GENERATORS AND MOTORS
THE SINQLE-PHASE INDUCTION MOTOB
260. Theory of operation. Assume the primary current to produce a
sinusoidally distributed (in space) and sinusoidaliy alternating (with time)
m.m.f. This is the exact equivalent of two equal half-value sinusoidally
distributed m.m.fs. which revolve or glide around the air gap at syn-
chronous speed in opposite directions. This is illustrated in Fig. 122
where 00 is the air-gap circle, developed out into a straight line, I and II are
the two oppositely revolving sinusoidally distributed m.m.fs., and A their
resultant (the alternating sinusoidally distributed m.m.f.). When I and II
are 180 deg. apart (space phase) their resultant A will be zero, and then
negative while / and II differ in space phase by from 180 deg. to 360 deg.
Thus / and II will each have a magnitude one-half the maximum value of A.
See Lamme, B. G., 'A Physical Conception of the Operation of the Single-
'

phase Induction Motor," Trans. A. I. E. E., Vol. XXXVII (1918), Part I,

p. 627; also Hellmund, R. E., 'No-load Conditions of Single-phase Induction
'

Motors and Phase Converters," Trans. A. I. E. E., Vol. XXXVII (1918),

Part I, p. 539.
261. Comparison of revolving fields with those of three-phase
motors. It is entirely legitimate to determine the effect of the alter-
nating m.m.f. upon a short-circuited secondary (e.g., a squirrel-cage second-
ary) by superposing the effects of the two equivalent revolving m.m.fs. These
effects may be found by the ordinary polyphase induction motor analysis.
Let I be the forward and II the backward-revolving m.m.f. and let Ji
and t/j be the two equal, to. to./. -equivalent, three-phase currents. Assume
that the squirrel-cage rotor is revolving forward at a small slip, s, with respect
to J, and therefore at a very large slip,
2-s, with respect to //. The total ap-
parent impedance to Ji is relatively
large, and that to/frelativelysmall, so
(BotorSp
that the e.m.f. En, absorbed by Ji, will
be large as compared to the e.m.f. E12
absorbed by J2. The total impressed
e.m.f. will be .Ei, the vector sum of En
and £12. El is assumed constant.
The flux of the forward-revolving field

Fig. 122.— Sinusoidally distrib- Fig. 123.— The torque curves of

uted alternating m.m.f. resolved into the two hypothetical fields of the
two equal sinusoidally distributed single-phase motor, and their result-
oppositely revolving m.m.fs. ant.

will then be much larger than that of the backward-revolving field, within
the forward working range. With the rotor stationary, En = En, the fields
are equal and produce equal and opposite torques. :

262. Speed-torque characteristics. The torque curves of the twoj

fields are shown approximately in Fig. 123, as Ti and Ti with their sum
T = Ti + T2. These are not normal polyph&se speed-torque curves, since the
impressed voltages En and £12 are not constant, each decreasing as its own
slip increases.
263. Starting torque zero. The single-phase induction motor thus has
no starting torque, but will run in either direction when once started.
Near synchronism it behaves very much like a polyphase motor. The com-
bination of the large forward field with the small backward field yields an
elliptical revolving field, the major axis of which is the sum of the two fields
and the minor axis of which is their difference. This elliptical field becomes an
alternating or straight-line field at zero rotor speed, and a circular revolving;
field at synchronism.

556
 A. C. GENERATORS AND MOTORS SeC. 7-2G4

264. Comparison of single-phase and polyphase operation. A Y-

connected three-phase motor with one terminal cfisconnected from the line
will constitute a fairly normal single-phase motor, see Fig. 124.
265. Exciting current. This is nearly twice as large as for the three-
phase case, approximately half of it being the reflection in the primary of the
no-load secondary current which supplies an m.m.f. in space and time quad-
rature with the primary m.m.f. and thus produces a revolving field.
266. Output and rating relative to polyphase machine. The safe
single-phase rating of a three-phase motor at rated voltage is about 60 per
cent, of the three-phase rating at the same voltage, but a better balance of
losses is obtained at a slightly increased line voltage, when the safe output
may be increased to about two-thirds that of the polyphase case.
267. Secondary current and copper loss. Unlike the three-phaae
motor, the rotor current of the single-phase motor is not zero at synchron-
ism, but has a definite value. This riiay be looked upon as a part of the
exciting current, and is present in lesser degree at higher slips. The secondary
copper loss is also not zero at synchronism and is no longer proportional to
the slip. It is obviously larger at all loads than when running three-phase.
268. Methods of starting. The most common method of starting
single-phase induction motors is known as the split-phase method. The
motor is supplied with an auxiliary winding in space quadrature with the
Primary
50 100

40„80

. 30 ; 60

i 20" 40
Sec. 7-270 A. C. GENERATORS AND MOTORfi
270. Winding data for 0.126-h.p., 60-cycle, 4-pole, 110-volt, ulf-
Btarting, single-phase induction motor. See Figs. 125 and 120. The
main or working winding is wound with No. 20 wire and has 1,064 active
conductors. The starting winding is wound with No. 25 wire and has 576
active conductors. For each winding the active conductors are connected
in series. Numbering the slots for 1 pole from 1 to 9, the following table
shows the distribution of the two windings.
20 2000
i A. C. GENERATORS AXD MOTORS SeC. 7-273

obtained with increasing resistance steps. In Fig. 128 the current-torque

curve for the above speed-torque curves, is shown, the torque per amp. being
independent of the speed for this type of control. Since with this method
speed variation is obtained by wasting energy in rheostats, it is not suited to
continuous running at speeds much below synchronous speed.
273. Disadvantages of secondary-resistance control. For any one
value of the resistance the speed changes greatly with variations of the load
and rises to practically its synchronous value at no-load, whatever be the
resistance. The higher the resistance, the more the speed will vary for a
small change in load. An amount of power proportional to the speed
reduction is lost in the resistance, that is, if the speed is decreased to 30 per
cent, below normal, 30 per cent, of the energy taken from the line is lost.
274. Advantages of secondary-resistance control are simplicity of
connections and relatively small increase
100
in cost of motor, over that of a constant-
speed induction motor. This method is
exactly equivalent to the armature-series-
Sec. 7-278 A. C. GENERATORS AND MOTORS
duction motor with a short-circuited secondary, and the shafts of the two
motors coupled together, the two motors will run at a speed the same as that
of a motor having as many poles as the two motors together. This holds if
the two rotors tend to revolve in the same direction, which is called con-
necting the motors in direct concatenation, or direct cascade. If the motors
are so connected that the rotors tend to revolve in opposite directions, the
speed of the set will be that of a motor having a number of poles equal to
the difference of the numbers of poles of the two motors. This connection
is called differential concatenation or differential cascade.
278. Possible speed adjustments with concatenation control.
Thus it is evident that by connecting two motors of different numbers of
poles in either direct or differential concatenation, and by using either motor
separately, four different speeds can be obtained. If the second machine
has a wound rotor, a resistance can be used to obtain speeds between the
different concatenated speeds. By providing each motor with pole-changing
windings, it is obvious that the number of speeds may be great. It is rare,
however, that this combination is desirable.
279. The chief objection to cascade control is the poor utilization
of material, and the poor operating characteristics. One reason for this is
that the exciting volt-amperes of the second motor must be supplied by the
secondary of the first motor, and are reflected in its primary. Thus the ex-
citing volt-amperes of the set is the sum of those of the individual motors.
Another cause is that the two motors are substantially in series and their re-
actances add together to furnish the reactance of the set. Thus in the case
of two equal motors, their combined output at breakdown will be only half
that of one of them alone. In fact it' will be less than half, owing to the
double exciting current in the first motor. Both causes work to produce
an unusually low power-factor. Finally the losses are those of two motors
(although some of the losses are less than when the motors are running alone
at full-load) with a combined output about one-half that of A single motor.
The efficiency ia thus very low.
280. Actual operating data of cascade control. These points are
illustrated by the curves of Figs. 129 and 130 taken from actual tests: the

100
 A. C. GENERATORH AXD MOTORS SeC. 7-281

rating. If, however, a 16 h.p. 16-pole motor be concatenated with a 4-h.p.

4-pole motor, their combined synchronoua speed at 60 cycles will be 360 rev.
per min. Neglecting losses, four-fifths of the electrical power delivered to the
16-pole motor will be converted to mechanical power and one-fifth trans-
mitted to the 4-pole motor and there converted into mechanical power. In
this case, the breakdown output of the set will be a little less than four-fiftha
that of the large motor, which is not a sufficient reduction to influence the
rating of the set, which on a heating basis will be only a little less than that
of the larger motor, or a little less than four-fifths that of the two motors
combined. The same is true of the differential concatenation with a speed
of 600 rev. per min. —
This set thus has three speeds 360, 4.50, 600 (rev.
per min.), all with approximately the same power, and a speed of 1,800 rev.
per min. with the small motor alone, but at only 4 h.p. In differential cas-
cade the small machine acts as aninduction generator and frequency changer.
This arrangement will not start itself except by connecting the small motor to
the line until the speed is nearly that desired, then throwing over to the dif-
erential cascade connection. The cascade operation is thus much more eco-
nomical and efficient for moderate speed changes, while the pole changing
method is more satisfactory for a two- to one-speed ratio.
281. The spinner motor. Different speeds are secured with the spinner
motor by a combination of electrical and mechanical features. The motor
consists of a "stator" or fixed primary, a "rotor," and between them a
"spinner" rotating independently of the rotor, and having a short-
circuited winding which is the secondary for the stator, and a slip-ring
winding which is the primary to the rotor. The primary on the stator
and that on the spinner are wound for different numbers of poles, the stator
being usually wound for the larger number of poles, owing to the larger
diameter.
282. Securing various speeds with spinner motor. By clutching
together the spinner and rotor, and exciting only the stator winding, one
speed is obtained; by exciting only the spinner and locking it to the stator,
a second speed of the rotor is obtained; by allowing the spinner to run free
and exciting both winding so that the m.m.f. of each travels in the same direc-
tion, gives a third speed, the sum of the two elementary speeds, and by
exciting them so that the m.m.f. travels around them in opposite directions
gives a fourth speed, the difference between the two elementary speeds.
283. Bibliography of spinner motor. The development of the spinner
motor is due Mr. Henry A. Mavor, who has described it in the following
papers: "Electric Propulsion of Ships" read before the Institute of Engi-
neers and Shipbuilders in Scotland, on Feb. 18, 1908; and " Marine Pro-
pulsion by Electric Motors," read at the Institute of Civil Engineers, on
Dec. 7, 1909 (see p. 134 of Vol. CLXXIX
of Proc. I. C. E.). The develop-
ment of this type of motor has recently been taken up by the Oerliken Co.,~*
and a line of spinner motors developed by them is described on page 1247 of
the Electrical World for May 30, 1914, in an article by A. HoefHeur and M.
P. Misslin entitled "Adjustable-speed Polyphase Induction Motors." The
article contains complete data of the efficiency and other properties of theses-
motors at various speeds.
284. Multiple motor. This is also the invention of Mr. Henry A. Mavor.
A 500-h.p. motor of this type has been employed on the electrically equipped
cargo boat Tynemount (Sec. 18). The rotor is of the squirrel-cage type.
The stator has two independent mutually non-inductive windings of different
pole numbers. For full-speed and power these two windings are fed with
electricity of frequencies proportional to their pole numbers and hence coop-
emte to drive the rotor at a given speed. For low speed and power, the
winding of greater pole-number is fed from the supply of lower frequency
and drives the motor at the corresponding low speed. The motor is de-
scribed in British Patent, No.l2917, of 1909.
286. The "Hunt" internally concatenated motor.* This machine
operates upon the "cascade" principle, having two superimposed magnetic
systems in the stator, one field being generated by the stator winding, and
•-he second by the rotor winding which reacts upon the stator producing the
second magnetic field and giving the cascade effect. Consider the case of a
• Hunt. Jovrn. I. E. E.; Vol. LII, 1913, p. 406.

I 561
 '

Sec. 7-286 a. c. generators and motors

motor wound for a 12-pole cascade speed. The stator is provided with an
ordinary 8-pole winding, divided into sections which are connected in parallel.
The rotor is wound in such a way that either an 8-pole or both an 8-pole and
a 4-pole winding can be obtained by either short-circuiting or open circuiting
the rotor slip-rings, producing either an 8-pole or a 12-pole speed of the motor.
The starting rheostat is connected across the rotor slip-rings. The Hunt
motor gives constant torque at the different speeds, the output being there-
fore proportional to the speed.

ALTERNATING-CURRENT COMMUTATOR MOTORS

286. Classification. Alternating-current commutator motors may be
grouped into two classes, as follows:
(a) Those motors in which the resultant m.m./. providing the flux, increases
with the load. When operated from a source of constant pressure, the speed
of such motors decreases with increasing load. They are termed series motors
from the similarity of their characteristics to those of series-wound direct-
current motors, (b) those motors in which the resultant m.m.f. providing
the flux, is substantially constant irrespective of the load. For operation
from a source of constant pressure, the speed of such motors is approximately
constant. The speed may, however, be increased or decreased (independ-
ently of the load) by increasing or decreasing the pressure at the terrninals
of the motor, or by the provision of suitably disposed and connected auxiliary
coils. Such motors are termed shunt motors.
Alternating-current commutator motors are either single phase or poly-
phase.
287. Single-phase straight series. An ordinary direct-current series
motor if constructed with a well-laminated field circuit, will operate (al-
though unsatisfactorily) if connected to a suitable source of single-phase
alternating electricity. Since the armature is in series with the field, the
periodic reversals of current in the armature will correspond with simultane-
ous reversals in the direction of the flux, and consequently the torque will
always be in the same direc- '-

tion. But the inductance of

the motor will be so great that
the current will lag greatly
behind the voltage, and the

mt^
,_ -^
^N. 'R*>iiQ'hoq

Fig. 131. —motor.

Circuit of series Fio. 132, — Diagram showing location of
high-resistance leads between the winding and
the commutator segments.
motor willhave a hopelessly poor power-factor. Such a motor is shown dia-
grammatically in Fig. 131, in which F represents the field and A the armature.
When the motor is first thrown on the circuit and before the armature has
moved from rest, the field constitutes the primary of a transformer and sends
flux through the armature core. Those armature turns which at that instant
are short-circuited under the brushes, act as short-circuited secondary coil^
and are traversed by heavy currents which serve no useful purpose what."'
ever and occasion serious heating. As soon, however, as the armature star'
to revolve, these short-circuited turns are opened as they pass out from und'
the brushes and they are replaced by other turns which are momentaii'
short-circuited and then opened. These interruptions of heavy currcm
are accompanied by serious sparking since the heating is concentrated at tl
few segments on which the orushes rest. As soon, however, as a certain
speed is acquired, the heating is distributed over all the segments and tht
conditions become ameliorated. This source of sparking is, then, most serious

562
i A. C. GEXERATORS AXD MOTORS SeC. 7-288

at the moment of starting. One way in which it has often been sought to
decrease this difficulty, has been by the employment of leads of high resist-
ance connecting the winding to the commutator segments as indicated in
Fig. 132. The extra-heavy lines in this diagram indicate the coils which, at
the particular instant considered, are short-circuited under the brushes. This
practice of introducing resistance leads between the winding and the com-
mutator segments has often been carried so far that notwithstanding the
brief time during which each lead is in circuit, the loss in the leads has been
sufficient to decrease seriously the efficiency, and to constitute a considerable
component in the total heating of the motor. Obviously, however, the
method affords a means of limiting the short-circuit currents occasioned by
transformer action, and consequently improves the commutation during
starting. • ,• i
Thealternating current in the intermediate conductors (shown in lighter
lines in Fig. 132) is always in such directions relatively to the alternating
magnetic flux set up by the field winding, as to occasion in the conductors a
torque in a constant direction. The motor consequently has the necessary
properties and it becomes of interest to investigate means for overcoming its
faults. How can the power-factor of the motor be improved; how can we
decrease its inductance? We
can reduce the inductance of the field winding
by employing few turns. This requires designing the magnetic circuit for low
magnetic densities (which, in turn, tends to make the motor large and heavy),
and with small air gaps.

—
Fig. 133. Loop of wire with Fig. 134.— Doubled-back loop
considerable inductance. with negligible inductance.
S8S. Single-phase compensated series motor. At the conclusion of
i?ar.287 we had discussed a way of decreasing the inductance of the field
/binding. Let us consider now how we may reduce the inductance of the
irmature winding. A loop of wire, for instance that shown in Fig. 133, has
!onsiderable inductance. A doubled-
lark loop such as that shown in Fig.
,34 has but little inductance. The
•urrent returning in the doubled-back

— Wlndins

A'WWV-'

Field

Winding

, Fig. 135.
ensated motor.
— Circuits of series-com-
[The inner circle
Fig. 136.— Usu diagrammatic
representation of a series-compen-
tepresents the rotor winding and the sated motor.
•uter circle represents the compensat-
Qg winding, which is on the stator. ]

oop neutralizes the effect of the outgoing current in the first loop. Such a
t'inding is practically non-inductive.
We may crudely imitate this in a motor. If the current after flowing
hrough all the turns of the armature winding is compelled to flow in the re-

503
 —
Sec. 7-289 A. C. GENERATORS AND MOTORS
verse direction through a winding of just the same number of turns arranged
in as close proximity as possible to the armature winding, then the mag-
netomotive force of the second (or compensating winding) balances the mag-
netomotive force of the armature winding, that is to say, it renders it non-
inductive. Unfortunately in applying this principle to our single-phase
motor, we are constrained to locate the compensating winding on the stator,
I.e., on the side of the air gap remote from the armature winding. Conse-

Fio. 13 7. —-"Equivalent" Fig. 138. —Diagram of a series-compen-

armature winding. sated motor indicating that the compensat-
ing winding lies in the same axis as tht
"equivalent" armature winding, and op-
poses it
quently, we fall considerably short of rendering the system completely non
inductive; nevertheless, it is by means of this plan that single-phase moton
are made commercially effective. In order to obtain the best results, thi
compensating winding should be distributed around the stator surface simi
larly or equivalently to the manner in which the armature winding is distrib ;

uted around the rotor surface. It does not suffice to have the same tola i

m.m.f. in each, but it is important that, at each part of the periphery, thi
j
neutralization shall be as complete as practicable. The arrangement mai
be indicated as shown in Fig. 135, in
|

which the outer circle represents the

compensating winding. For diagram-
matic purposes, however, it is more
usual to replace the outer circle by a _, ,.
coil whose axis is in the direction of the
windtog
m.m.f. set up in the compensating . • . Tfi <

winding when the current flowsthrough

it. Whereas the main field coil is in
• VWWW
space-quadrature with the m.m.f. of
the armature winding, the m.m,.f. of
the compensating winding is in the
same space phase as the armature
m.m.f., but in the opposite direction.
In Fig. 136 the compensating winding
is represented diagrammatically by a
coil with its axis coinciding with the
brush axis. That this is the required
location may be more clear if atten-
tion is drawn to the fact that the ar-
mature winding, considered by itself,
constitutes a source of m.m.f. whose
direction ia in a line through the Fig. 139.
brushes. Whatever the actual form
— Inductively compensated
series motor.
adopted for the armature winding, it
is at any instant equivalent to the winding shown in Fig. 137 as far asm
lates to its m.m.f. As.sembling around the armature, the field coil and tb i

compensating coil in their appropriate angular po.sitions, as in Fig. 138, w -

obtain an instructive diagrammatic representation of a single-phase con

pensated serie.s motor.
289. Inductive and conductive compensation. Compensation ma
be " conductive," as shown in Figs. 135, 136, and 138, or it may be "inductive
 A. C. GENERATORS AND MOTORS SeC. 7-290

as shown in Fig. 139. With the latter arrangement the compensating cur-
rents are induced in the short-circuited compensating coil just as current is
induced in the short-circuited secondary of a transformer. And similarly
to the case of the transformer, the secondary current automatically rises
to such a value as to occasion a m.m.f. approximately equal and opposite to
the primary m.m.f. But "conductive" compensation is preferable, for it
permits of control and adjustment of the compensating m.m.f. Under some
circumstances it is desirable to be able to orercompensate, i.e., to set up in the
compensating coil a m.m.f. which shall slightly exceed the armature m.m.f.
This is readily effected with
"conductive" compensation,
•
Field but not with "inductive"
Winding compensation.
290. Speed control.
Fairly good single-phase mo-
tors have been constructed
on the principles which have
been set forth in Par. S88
Variable and 889. Such motors have
Batlo Trausfomer series characteristics, their

1 Fig. 140. —
Series-compensated motor supplied
from a variable-ratio transformer.
speed decreasing as their
load increases. This must
obviously be the case, for
the field excitation is occa-
noned by the flowof the armature current through the field winding. Thus
the flux increases with the load and the armature will decrease in speed since
the counter e.m.f. must, as in a direct-current motor, be slightly less than the
terminal voltage. But, while for a given terminal voltage, the speed de-
:creases with increasing load; nevertheless we can readily arrange that such a
motor shall, for any load, be operated at any desired speed over quite a wide
range. This is done by supplying the motor from taps out of a transformer
across the main circuit. The arrangement is shown diagrammatically in
Rg. 140. By varying the position at which the adjustable terminal of the
motor is tapped into the secondary of the transformer, we can vary the vol-
tage impressed on the motor and thus readily control and adjust its speed. An
alternating-current series motor has in this respect an important advantage
over a direct-current series motor, since in the latter the speed control can

winding

-The Atkinson repulsion Fig. 142.- -The Thomson repulsion

motor. motor.
simply only by varying the amount of resistance in series with the
oe effected
motor, and consequently with a serious loss in efficiency.

291. Single-phase repulsion motor. It is only a step from the in-

ductively compensated motor illustrated in Fig. 139 to a motor in which
current is induced in the armature circuits by means of the m,.m.f. set up in the
3ompensating winding when current is sent through it. The motor at which
«ve thus arrive is shown diagrammatically in Fig. 141. Instead of short-
Jirouiting the compensating winding, we short-circuit the armature winding.
Xn oiher words we simply exchange the relations of compensating winding
ind armature winding which were shown in Fig. 139.

565
Sec. 7-292 A. c. generators and motors
292. Evolution of the repulsion motor. The connection shown in Fig.
141 is known as the Atkinson repulsion motor. It was suggested by
Atkinson many years after the invention by Prof. Elihu Thomson of the
simple repulsion motor. In the original Thomson repulsion motor the
field coil and the compensating coil shown in Fig. 141 find their equivalent in
a single coil which may be looked upon as supplying a m.m.f. of which the
field m.m.f. and the compensating m..m,.f. in Fig. 141 are the components.
The Thomson repulsion motor is shown in Fig. 142. The stator coil has, in
this figure, been drawn in a position intermediate between the positions of the
compensating coil and the field coil in Fig. 141 in order to emphasize the idea
that these two component coils have been replaced in magnitude and direction
by their resultant. As must be evident from the nature of its evolution, the
Thomson repulsion motor also has the characteristic of a series motor in that
its speed decreases with increasing load.
293. Single-phase compensated repulsion motor. Many pioneers
in the design of direct-current motors have long ago sought to bring the field
coil close down around the armature in order to obtain the full effect of the
field m^m.f. right at the armature where it is desired. Eickemeyer's name is
closely associated with designs of this sort. What could more closely approxi-
mate to the desired result than to employ the armature winding itself as the
locus for the excitation? Several inventors conceived this idea practically
simultaneously. They accomplished their purpose by applying to the
 A. C. GENERATORS AND MOTORS SeC. 7-259

which rest three equidistant brushes per pair of poles. The diagram indi-
cates a bipolar motor. The brushes are connected to the terminals of the
three stator windings, which, in turn, are supplied either directly from the
line, or else, as indicated in the diagram, from the secondary of a step-down
transformer. Usually the most suitable voltage for the stator windings will
be higher than that most suitable for the commutator. Consequently, the
. arrangement shown in Fig. 146 is often to be preferred. This latter arrange-
I ment perm'ts of employing, for the rotor, the 1 ow voltage which is essential
' to obtaining good commutation. Such motors have a series characteristic;
that is to say, the speed decreases as the load increases.

Line

Comm-
utator
of
Botor

145. —between
Gorges motor with Fig. 146. —
Gorges motor with trans-
former between stator and rotor.
sf ormer line and stator
lings.

r 296. Variable-speed polyphase commutator motors. The speed can

be adjusted, for any load, by shifting the brushes through an appropriate
angular distance, maintaining the 120-deg. relation between the three brushes.
This is done in the General Electric Co.'s brush-shfting type of variable-
'jpeed polyphase motors. See also, 'The Brush-shifting Polyphase Series
'

Motor," by W. C. K. Altes at pp. 115 and 199 oi General Electric Review for
1916 (Vol. XIX).
296. Compensation of polyphase commutator motors with series
characteristics. For the reasons already discussed in connection with the
compensation of single-phase commutator motors, it is of advantage in
Dolyphase commutator motors to fit them with compensating windings at
ight angles to the exciting windings. The cost, however, is necessarily
ncreased, and in America the use of compensating windings is not customary
or such motors. The arrangement, when compensating windings are em-
jloyed, is indicated diagrammatically in Fig. 147, in which the three exciting
vindings a^b^c'- on the stator are supplied from the three lines abc. After
)assing through the three exciting windings the current passes through the
qmpensating windings def which are located with their magnetic axes in line
rith the magnetic axes of the rotor brushes. The addition of these compen-
ating windings improves the power-factor and permits of obtaining better
ommutation. Since the most suitable voltage for the main field windings on
he stator will often be different from that most suitable for the commutator,
nd for the compensating windinsts on the stator, it would be preferable to

567
Sec. 7-297 A. C. GENERATORS AND MOTORS
employ in place of the arrangement indicated in Fig. 147 a modified arrange-
ment in which the main field windings are located between the supply circuit
and the primary windings of the transformer, while the compensating and
rotor windings, connected in series, are supplied from the secondary of the
transformer.
297. Single-phase commutator motors with a shunt characteristic
for operation at a single speed. The only object in employing a commu-
tatori n the construction of a single-phase motor to operate at but one constant
speed, is to provide control of the power-factor. Otherwise the single-phase
induction motor with a squirrel-cage rotor would be preferable. The Atkin-
son commutator induction motor indicated diagrammatically in Fig. 148
is the forerunner of all single-phase commutator motors with shunt character-
istics. It consists of a stator with a distributed winding, and a rotor fitted
with a commutator and with two sets of short-circuited brushes xx and yy.
There is no torque when the motor is at rest. If, however, the motor is
started in either direction, interactions occur which occasion in the xx axis
a current in phase with the line voltage applied to the stator. This current
sets up a flux along the xx axis. As the rotor acquires speed, the current
induced in the yy axis by the stator winding, comes more nearly into phase
with the flux in the xx axis and consequently the torque increases. In this
motor the torque increases in proportion to the speed, from the zero value
corresponding to standstill. When the
speed of the rotor nears synchronism,
the* motor is equivalent to a squirrel-
cage induction motor, except that in
place of having end-rings effecting a
good simultaneous short-circuit of all
the rotor conductors, there areonlytwo
short-circuiting connections by means
of the two pairs of brushes._ Obviously
there is no feature in this elementary

Ststor
binding

Fig. 147.- -Compensated Gorges

motor.
FlQ. 148. — Atkinson commutator
induction motor.
commutator motor which will improve the power-factor as compared with
that of the single-phase squirrel-cage induction motor.
298. Compensation of single-phase commutator motors with shunt
characteristics. Various inventors have indicated methods of " compen-
sating" such a motor, i.e., of improving its power-factor. These methods
resolve themselves into the following classification> (a) introducing in the
circuit of the yy brushes a stator winding in the xx axis; (b) introducing
in the circuit of the xx brushes a stator winding in the yy axis; (c) intro-
ducing in the circuit of the xx brushes an e.m.f. in phase with the line
pressure. These three methods are shown in Figs. 149, 150, and 151.
299. Single-phase commutator motors with a shunt characteristic
and an adjustable speed. There is quite a demand for single-phase com-
mutator motors with a shunt characteristic and with means for aujusting the
speed. For any particular adjustment the speed will be substantially con-
stant at all loads. The usual methods for accomplishing this are based upon
the investigations of Punga, Fynn, Creedy and Milch. The simplest method
consists in introducing in the yy axis an electromotive force of the same ,

phase as the line pressure. This may be done by means of a transformer M||
shown in Fig. 152. If the secondary coil A in the above figure provides^ I
568 I
 A. C. GENERATORS AND MOTORS Sec. 7-300

m.m.f. acting in the same direction aa the coil B, the speed of the motor will
be increased. If A is connected to oppose B, the speed of the motor will be
decreased. Speed control may also be obtained by introducing into the

FiQ. 149. —
Single-phase commu-
tator motor with power-factor-
—
Fia. 150.
tator motor
Single-phas commu-
with power-factor-
modifying coil supplied from the modifying coil supplied from the
yy brushes. XX brushes.

circuitof the xx brushes a stator winding A located in the xx axis as

shown in Fig. 153. Connecting .4 in the one direction increases the speed:
connecting it in the other direction
decreases the speed. Still another
method of obtaining speed control is
shown in Fig. 154 and is the invention
of Creedy. In this case the field along
the XX axis is weakened or strengthened
and the speed varied, by varying the
amount of inductance or capacity in
the circuit of the xx brushes.

Supplj Clrouit

Fig. 151. — Single-phase commutator

jQotor with power-factor modified by
Fig. 152. — Single-phase comrnu-
tator motor with 8pe«i modification
,.n e.m.f. interpolated in the xx axis by by means of an e.m.f. interpolated
aeans of a transformer supplied from into the yy axis by means of a
he line. transformer supplied from the line.

300. Single-phase repulsion-starting induction motor (Arnold

aotor). This motor which is built under the patent of the late Prof. E.
vrnold of Karlsruhe, in Germany, is extensively used in the United States.
5«9
Sec. 7-301 A. C. GENERATORS AND MOTORS

The connections at starting are those for a reptilsion motor as shown in Fig.
142, the brush axis standing at an angle with the axis of the stator winding
and the brushes being short-circuited. This connection permits of starting
with high torque. When a certain speed is attained, a centrifugal governor
acts to short-circuit all the commutator segments and to remove the brushes
from the commutator. The motor then operates just like a squirrel-cage

wmmmj
Fig. 153. —
Single-phase commutator Fig. 154. —
Greedy single-
phase commutator motor with
motor with speed modification by
means of a coil fed from the xx brushes speed variation by inductance
and located on the stator in the xx axis. in the xx circuit.

induction motor and maintains approximately constant speed at all loads.'

It is usually preferable to employ starting boxes in sizes above 7.5 h.p., but
smaller sizes are usually thrown directly on the line. The motors develop a
starting torque (when thrown directly on the line) of some 250 per cent, of
full-load torque, consuming approximately 250 per cent, of full-load current.,
(See Fig. 155.) T V |

200 400 6U0 800 1000 1200 1400 ICOO 1800 U.P.M. |

F^G. 155. — Starting(Taken

motor.
characteristics
from the
of Arnold single-phase commut^
manufacturer's publications.) ''

301. Motor with repulsion starting, gradually converted

"Induction" operation. (Schiiler motor.) This type was develci
by Schiiler for the Ferranti Co. in England. It started as a repulsion mote-
and was gradually converted into a single-phase induction motor by tt
gradual decrease in resistances connected to slip-rings. These resistanci

570
 —
A. C. OENERATORS AND MOTORS See. 7-302

are great at starting and are reduced to zero at full speed. This sequence of
operations results in giving the motor excellent characteristics. The Schaler
motor is described on pp. 712 to 720 of the 2nd edition of Hobart's "Elec-
tric Motors."
>
The Wagner "Unity Power-factor" Type BK motor. In 1911
302.
>the Wagner Electric Co. placed upon the market a constant speed single-
phase commutator motor so constructed as to provide a leading power-factor
at no-load and at light loads, and unity power-factor at rated load. The _

.<% arrangement is represented diagrammatically

in Fig. 156. As indicated in this diagram
I
^—-_ there are two stator windings 1 and 2. Dur-
J
~r--^ I ing starting, the switch (9) is open, so that
T -^^ only the stator winding (1) is in circuit. The
motor consequently starts up with good torque

Fia. 156. — Diagrammatic repreaen- Fig. 157.— Diagrammatic rep-

ation of the Wagner "Unity-Power- resentation of design of rotor slot
/actor" (Type BK) motor. 1. —
Ini- ofWagner" Unity-Power-Factor"
ial field magnetization winding. 2. (Type BK) motor.
iu.\ihary winding which controls the
ower-factor or compensates the motor.

s a series motor. The rotor slot design is shown in Fig. 157. During start-
iH, the squirrel-cage winding (4) is more or less inert as it is protected by the
lagnetic separator shown in Fig. 157. The magnetic separator is described
'i the manufacturer's publications as consisting of a rolled-steel bar. The
pper winding (3) is termed a" commuted" winding. It is connected to a
jmmutator in the manner usual in motor armatures. As
direct-current
leed is and it contrib-
acquired, the activity of the squirrel cage increases,
tes a torque which increases very rapidly as synchronism is approached.

2000

ISOO
 o

Sec. 7-304 A. C GENERATORS AND MOTORS

speed at all loads." This is indicated in Fig. 158 in which are plotted spe^d
curves for the compensating circuit open and closed, (d) The squirre
'

cage absolutely prevents the unity power-factor motor from running away oi
racing. No possible accident to the commutator, brush gear or automatic
switches of this motor can cause the speed variations between no-load and
full-load to exceed 4 per cent. When the compensating circuit (which in-
cludes the winding 2 of Fig. 156) is closed, the speed variation is shown by
the least sloping curve of Fig. 158 and does not exceed 1.5 per cent. Should
the compensating circuit be entirely interrupted, then the speed variation
will not increase to more than 4 per cent., as indicated by the more sloping
curve of Fig. 158."
304. The Oeneral Electric Co.'s RI (repulsion-induction) motor.
Diagrammatically the General Electric Co.'s single-phase commutatoi
motor of the RI type may be rep-
resented by Fig. 159. Leaving
out of consideration the compen-
sating brushes and winding, the
motor is seen to be a Thomson re-
pulsion motor (see Par. 292). Sucb
a motor would, however, have twc
faults. In the first place, it would
Main
have a low power-factor, and in
Starting the second place its speed would
Winding '

vary greatly with varying loads

The addition of the compensating
winding improves the power-facto:
and also decreases the amount o
the variation of the speed witt
the load. The motor is not de
Oomp, Brush signed for constant speed but f
such a moderate decrease in speei

Compensating
Brush

Compensating
Winding
Fia. 159.— Diagram of circuits of Gen- Fig. 160.— Diagram of P
eral Electric Co., Type RI motor with motor with compensation by tai
independent compensating circuit. ping the main stator winding.
with increasing load as is considered desirable in a compound-wound contin
ous-electricity motor. An RI motor may be started by simply closing tl
line circuit of the motor. It will have a starting torque of 200 to 250 p
cent, of full-load torque. If it is desired to reduce the starting current,
resistance box with low-voltage release may be used. This is proportiom
to give 150 per cent, of full-load current on the first step. These moti
are built for 25, 40 and 60 cycles and for synchronous speeds (at 60 cycli
of 1,200 and 1,800 rev. per min. See Altes, W. C. K. and Currie, N., "Sinji
'

phase Alternating Current Motors," Oeneral Electric Review, Vol. XI

(1916), p. 679.
306. Compensation. In some of the smaller sizes the compensation
obtained by taps from the main winding instead of from a separate windi
aashownin Fig. 159. The tapped arrangementisindicated diagrammatica
in Fig. 160.
806. In reversible repulsion-induction motors (Par. 304) an auxilia
winding in space-quadrature with the main winding is provided. TI
572

I
 A. C. GENERATORS AND MOTORS SeC. 7-307

iwinding is connected in the one or the other direction with respect to the
,main winding according to the direction of rotation desired. The scheme
:s indicated diagrammatically in Fig. 161. To reverse the direction of
rotation, a would be connected to c, and b would be connected to d. It
s to be observed that in Fig. 161, the axis of the main brushes coincides with
;he axis of the main stator winding but has the same angle to the resultant
)f the main and reversing stator windings, which, in Fig. 159, it had with the
Inain stator winding. Were no reversing winding provided, then in order
to reverse the direction of rotation it would
^ d he necessary to shift the brushes over to
the corresponding angle on the other side
from the position for normal direction of
rotation.
307. Bepulsion-induction motors
may be fitted for adjustable-speed
operation (Par. 299) by employing a
transformer with its primary excited from
the line circuit and its secondary interpo-
lated in the circuit of the energy brushes.
Such motors are arranged for a speed
range of about 2:1, approximately one-
half of this range being below and one-
half above synchronous speed. Finally,

. 161. — Diagram of circuits of revers- Fig. 162. — Diagram of D6ri brush-

h RI motor (General Electric Co.). shifting motor.

Itmotors are also arranged to give variable speed by shifting the brushes.
Speed variation of 2 1 is provided in this way.
:

08. The p^ri single-phase motor with speed control by brush

Bfting. Fig. 162 is a diagrammatic representation of the D6ri single-
p.se motor. In this motor the speed is varied by varying the position of
t- brushes. Two of the brushes (those lying in the axis of the stator
wding) are of fixed position. The other two are mounted on a movable
y e. For any given brush petition the speed decreases with increasing load,
lis the motor has a series characteristic. The motor has good starting
tque, the maximum value occurring when the movable brushes are at an
a le of some 150 deg. to 160 deg. from
the fixed brushes.
he motor is widely employed abroad for driving textile machinery,
^simple mechanical arrangements required to eflFect the shifting of the
D^ines are less expensive than equivalent
control devices which permit of

573
 .

Sec. 7-309 A. c. generators and motors

accomplishing the speed
variations without brush
movement. Schnetzler has
described the D6ii motor
in a paper published in the
E. T. Z. for Nov. 14 and
21, 1907 at pp. 1097 and
1128. There is also a de-
scription of the Dftri motor
occupying pages 669 to 685
of the 2nd Edition of Ho-
bart's "Electric Motors."
309.ThePunga-Creedy o 10 20 30 40 50
single-phase commuta- ^ ^^ 1 P^j^
tor motor. Adjustable- c «
ti p Motor. min qnn n
600-900 B. p
P.M. m
single-phase, com- 6.H.P. t*

speed,
mutator motors built under Fio. 163. —
Speed-torque characteristics of a
the Punga-Creedy patents 6-h.p. Punga-Creedy single-phase motor for
have been placed on the printing-press work. [Speed range is from 600
British market by Messrs. to 900 rev. per min.] [Messrs. F. Parkinson &
F. Parkinson & Co., of Co. of Leeds, England.]
Leeds. The motor is , , , • ,, ,.

jQQ, 1 1
[-
p 1
started by bemg thrown di-
rectly on the line and yields
1 1 1
'

a starting torque of twice

full-load torque, consuming
twice full-load current. Figs.
163, 164 and 165 show (1)
the speed-torque, (2) effi-
ciency, and (3) power-factor
curves for a 6-h.p. Punga-
Creedy motor for printing-
press work. Allusion has al-
ready been made in Par. 299
employed in
to the principles
motors of class. The this
chief employed in
patents
the Punga-Creedy system are
700 800 IDOO Punga's British Patent No.
600
K.P. M. 10585 of 1906 and Creedy's,
British Patent No. 5136 of
6-H,P._Motor, 600-900 B.P.M. 1906. Punga and Greedy
Fig. 164. —Efficiency curves for a
Punga-Creedy single-phase motor for a speed
6-h.p. „^„„^„
tested motors embodying
_.„^ i

these principlesat early dates

range from 600 to 900 r.p.m. [Messrs. F. ^he results of a number of
Parkinson & Co. of Leeds, England.] these tests have been pub-
lished in the Trans. A. L E.
E..V0I. XXVIII (1909), p.
475, in a paper by Greedy
entitled "A sketch of the
theory of adjustable-speed,
single-phase commutator
motors."
310. Polyphase shunt
commutator motors.
The most usual arrange-
ment of a polyphase shunt
commutator motor is that
known as the Winter-
Kichberg type. It is
shown diagrammatically in 600 700 800 low
Fig. 166 and is seen to con- B.P. M.
motor with a three-
sist of a 6.H. P.Motor. 600-900 B .P. M
phase stator and a -com-
mutator rotor. The __^_
speed Fig. 165. —
Power-factor curves for a ft-h.p
will depend upon the pres- Punga-Creedy single-phase motor for a speP'
sure applied to the commu- range from 600 to 900 rev. per min. [Messrs. i
tator brushes. By using a Parkinson & Co. of Leeds, England. ]

574
 A. C. GENERATORS AND MOTORS See. 7-311

variable-ratio transformer as indicated in the diagram, the speed will be

greater, the smaller the secondary voltage applied to the brushes. Such
motors have not come into extensive use. They are large and expensive for
their output and the cost for the variable-ratio transformer is a serious con-
sideration. The whole equipment will cost over twice as much as an equiva-
lent continuous-current equipment.
311. Quaxter-phase shunt commu-
tator motor with adjustable speed by
field control. In Fig. 107 is shown a
type of motor in which the compensating
winding and the armature winding are fed
from one phase of a quarter-phase system
while the exciting winding is fed from the
other phase. Since the compensating and
armature winding constitute a circuit of
low inductance, the current in this circuit
phase with the pressure of
is pra,ctically in
the circuit from which they are supplied.
But the exciting circuit is highly induc-
tive and its current lags practically 90 deg.
behind the pressure of the circuit to which
it is connected and 180 deg. behind the
current in the armature. The armature
current and the magnetic flux are conse-
quently in phase, just as in a simple sin-
gle-phase series motor. The motor is thus
the equivalent of a direct-current motor
\vith shunt excitation. Its speed for any
given field strength is practically constant
at all loads. But any desired speed can
be obtained by inserting reactance of suit-
able amount in series with the excitation
Fig. 166.— Diagrammatic rep- winding. Speed control can also be ob-
resentation of Winter-Eichberg tained by supplying the main circuit from
type of polyphase shunt com- a variable-ratio transformer. On page
mutator motor. 2488 of Part III of Vol. XXX
(1911) of
the Trans. A. I. E. E., Mr. B. G. Lamme
discusses this type of motor and alludes to a 20-h.p., 25-cycle motor built in
this way which gave excellent satisfaction and with which the speed was
adjustable from practically zero up to 1,000 rev. per min. The speed was
controlled by adjustable armature pressure from transformers.
Mr. Lamme also mentions the equivalent arrangement shown in Fig. 168.
In this arrangement the armature circuit instead of being conductively

F^a. 167. — A type of quarter-

phase, variable-speed commutator
Fig. 168. —A modified type of
quarter-phase, variable-speed, com-
motor. mutator motor.
lonnected to the supply as in Fig. 167, is closed on itself, the armature cur-
lent being set up by induction from the winding which, in Fig. 176, served
|.S compensating winding.

812. The polyphase commutator motor with shunt characteristics

jud with speed control by brush shifting. The expense of the control
l^mngements limits the application of variable-speed polyphase motors of
575
Sec. 7-313 A. c. generators and motors
types of which that described in Par. 310 (Winter-Eichberg) is represent-
ative. It is often considered that brush-shifting types are preferable.
One such type which is exploited by the Siemens-Schuckert-Werke and
is described by Schenkel on pages 1059 and 14 of the Electrician foi
Oct. 4 and 11, 1912, is illustrated diagrammatically in Fig. 169. In
this figure, the stator windings are represented by S. These windings are
(in the particular variety illustrated in Fig. 169) supplied directly from the
line. A transformer T is interposed between the stator windings <S and
the rotor brushes Ki and Ki. One of these sets of brushes is fixed, and the
other is movable. By varying the relative angular positions of Ki and K:
the speed of the motor may be controlled. Each
of the two brush gears is fitted with three brush
sfjindles per pair of poles for multiple-circuit rotor
windings, or some suitable equivalent for two-cir-
cuit rotor windings. These motors have shunt
characteristics and are to be distinguished from
the Gorges motors to which reference has been made
in (Par. 294), which have series characteristics.
Such motors are the subject of other articles
published by Rudenberg in the Electrician for
April 7 and July 21, 1911, and by Meyer in The
Electrician ioT Feb. 2 and 9, 1911.
313. The D^ri brush-shifting motor for
polyphase circuits. It is often considered that
for obtaining variable speed drive from polyphase
circuits, the best plan consists in employing two
D6ri single-phase motors (of the brush-shifting
type already described in Par. 308), coupled to
the same shaft and connecting one motor to each
ghase of a quarter-phase system. This plan has
een employed by Messrs. Brown, Boveri & Co. Yi<3 169 PolvDhase
Among other applications of the method may be commutator motor witl:
mentioned some heavy hoistmg work. speed control by brush-
313(a). Bibliography of polyphase commu- shifting.
tator motors.
—
Altes, W. C. K. "The Polyphase Shunt Motor," Trans. A. I. E. E.
Vol. XXXVII (1918), Part I, p. 295.
KarapTetofp, v. — 'The Secomor, a Kinematic Device which Imitates th(
'

Performance of a Series-wound Polyphase Commutator Motor," Trans

A. I. E. E., Vol. XXXVII (1918), Part I, p. 329.
—
Shuttlewobth, N. "Polyphase Commutating Machines and Thei
Application," Jour. I. E. E., Vol. 53 (1915), p. 439.

SYSTEMS OF SPEED CONTROL REQUIRING AUXIL-

IARY COMMUTATING MACHINES
,314. The Kr&mer system of speed control. This system is appro
priate for applications where the desired range of speed is a moderate per
centage of the normal speed. It consists in the employment of a singl>
slip-ring induction motor which at practically synchronous speed carrie
the entire load. For lower speeds the slip-rings of the rotor of the mail
motor supply energy to the commutator brushes of an auxiliary moto
on the same shaft. The arrangement is indicated diagrammatically ii

Fig. 170. A, the main motor, is of the induction type. B, the auxiliar
motor, is fitted with a commutator. The counter e.m.f. of the auxiliar,
motor may be controlled by the po.sition of the points of the secondary of
transformer C from which the connections to the commutator brushes ar
tapped off. In American practice, however, it is much more usual to maK
use of a small direct-connected polyphase exciter similar in design to th
auxiliary regulating motor, as shown in Fig. 171, where the stator of th
exciter C is supplied from the slip-rings of the main motor A, through
three-phase resistor D. Speed control is obtained by manipulation of th
resistor and a far larger number of running points is provided than is coiv
mercially practicable with the transformer arrangement shown in Fig. 17(
The greater the counter e.m.f. supplied by B, the lower will be the spec
of the rotor of A and consequently also, of the shaft common to A and B. Th
load carried hyB is proportional to its counter e.m.f., consequently B'scontr
676
 A. C. GENERATORS AND MOTORS Sec. 7-315

bution increases as the speed decreases, with the result that the total torque
provided by the set increases as the speed decreases. The set thus yields
the same total kw. output at low speeds as at normal speed, and this is
an important characteristic of the system. It is rarely practicable or
desirable to provide for more than 30 per cent, regulation on 60-cycle sys-
tems or oO per cent, regulation on 25-cycle systems, since it is difficult to
design the auxihary motor B for good commutation except at low frequencies,
and the frequency supplied to its commutator is proportional to the slip of
the rotor of A. Greater capacities and greater speed ranges can be supplied
by these sets the lower the frequency of the system from which they are
operated.

Iw 1
B 1 Cf

Via. 170. —The Kramer system of Fig. 171. — American variation of

speed control. Kramer system.
316. The Scherbius system of speed control. The arrangement in-
dicated in Fig. 172 is known as the Scherbius system. As in the Kramer
system, the main motor A, is a simple induction motor with slip-rings. The
speed control is efTected by an auxiliary
set on an independent shaft. This
auxiliary set comprises a commutator
motor fi, driving an induction generator

-The Scherbius system

speed control.
of Fig. 173.
method
— Synchronous converter
of speed control.

^D. The auxiliary machine, instead of delivering mechanical power to the

"nain motor's shaft as in the Kramer system, returns electrical energy to the
lupply system. The amount of power transformed by the auxiliary set is
controlled by the adjustment of the position of the taps in the transformer
-'
(or rheostat if an exciter is used as described in Par. 314 and Fig. 171).
rhe greater the amount of energy absorbed by B, the lower will be the speed
'f the main motor A, just as in the case of the Kramer system. An article
>y J. D. Wright at p. 104 of Vol. XX (1917) of the Gen. Elec. Remeic, entitled
'
Speed Control of Induction Motors for Steel Mill Drive " contains a detailed
lescription of a modification of the Scherbius system as applied to induction
iiotors for steel mill main roll drives which permits the operation of the
oil motor at speeds above and below synchronism.
It may, in general, be said of the Scherbius system that the first cost is
;ss than for the Kramer system and that the operation is equally successful.

677
Sec. 7-316 A. C. GENERATORS AND MOTORS
The use of an independent high-speed set which can be readily transferred
to some other motor if subsequent conditions make the change desirable, is
also an advantage. While the Kramer system possesses some advantage
under conditions involving the full kilowatts output at the lowest speed and
high synchronous speed, this advantage often disappears where slow-speed
motors are concerned.
316. Synchronous converter method of speed control. As stated
above, the permissible range of speed regulation with either the Kramer
or Scherbius system as described, is limited by the maximum frequency which
can be successfully applied to the regulating motor without excessive commu-
tation stresses. In general this frequency should not exceed 18 to 20
cycles or approximately 30 per cent, regulation for 60-cycle systems, and
from 10 to 12§ cycles or approximately 50 per cent, regulation for 25-
cycle systems. Where greater ranges are required or with units involving a
slip energy of 1,000 kw. or more, a synchronous converter and direct-current
motor can be successfully substituted for the polyphase commutator motor.
In this case (Fig. 173) the slip energy of the main motor A, at varying fre-
(juency and voltage is transformed to direct current at proportionately vary-
ing potential by a synchronous converter B. This direct current is then
utilized to drive a separately excited shunt motor C which may be direct-
connected on the shaft of the main motor (Kramer), or (Fig. 173) may form
one unit of (CD), a two-unit motor-generator (Scherbius), the second unit
of which (jD) is a standard squirrel-cage induction motor which, driven above
synchronism, acts as an induction generator and returns to ihe system the
slip energy of the main motor, less, of course, the losses in the rotary and
motor generator. This arrangement can be used for practical y any range
of speed reduction which may be desired. It is of especial advantage on 60-
cycle systems, not only because of the freedom from difficulties encountered
with the commutator motor when subjected to higher frequencies but also
due to the fact that the limitation imposed by the minimum frequency at
which the synchronous converter will remain in synchronism is less objec-
tionable on 60-cycle than on 25-cycle equipments. With suitable electrical
and mechanical devices for controlling the speed of the synchronous con-
verter during the unstable period of minimum impressed frequency corre-
sponding to the interval between approximately 2 cycles above and below
the synchronous speed of the main motor, the speed of the main motor can
be raised above normal synchronism by an amount corresponding to the
frequency impressed on the slip-rings by the now-inverted synchronous
converter.
317. BibliographT of systems of speed control requiring auxiliary
commutating machines.
Pages 2483 to 2484 of Part III of Vol. XXX
(1911) of Trans. A. I. E. E. in
a paper by G. A. Maier entitled "Methods of Varying the Speeds of
Alternating-current Motors."
Trans. A. I. E. E., Vol. XXXI (1912) p. 2067, by F. W. Meyer and
Wilfred Sykes entitled "The Economical Speed Control ofJ Alternating-
current Motors Driving Rolling Mills."
F. B. Crosbt. —"Speed Control of Polyphase Motors." General Electric
Review for June, 1914, pages 589 to 599.

PHASE MODIFIERS
318. Definition. In order to correct for the lagging current consumed
by induction motors and other inductive apparatus, and thus improve the
power-factor of a system, apparatus known as phase modifiers (or phase
controllers), may be employed. These are of two classes, synchronous, and
non-synchronous.
319. Synchronous phase modifiers (usually [termed synchronous
condensers) are of the same general construction as synchronous motors,
except that they need not be proportioned to deliver power from the shaft
and that their fields should be proportioned for a wide range of excitation.
320. The usual method of employing synchronous condensers
consists in installing them to float on the line. They are overexcited so
as to draw a current leading the pressure by nearly 90 deg. This current
neutralizes an equal amount of lagging component due to other apparatus
on the system, such as induction motors and lightly loaded or unloaded
transformers. If designed with the necessary mechanical strength, synchro-

678
 ,

A. C. GENERATORS AND MOTORS SeC. 7-321

nous condensers may simultaneously operate as motors and it is customary

to proportion them to thus operate to the extent of a consumption of 70 per
cent, of their rated kv-a. They can, when thus operating, be so excited that
they also draw from the line, as leading wattless kv-a., 70 per cent, of their
rated capacity in kv-a. thus effecting power-factor improvement at the same
time that thej' are serving as motors to deliver mechanical energy. Synchro-
nous condensers are fitted with amortisseur windings to improve their
starting qualities and to serve in preventing surging and hunting.
321. Non-synchronous phase modifiers (or phase controllers).
Several varieties of apparatus customarily called phase advancers, have
been developed for use in connection with individual induction motors for
the purpose of improving their power-factor. Such apparatus is supplied
with very low frequency electricity from the secondary windings of the
induction motors. The frequency is that corresponding to the "slip" of the
induction motor. Such phase advancers have an inherent characteristic
which may conveniently serve to distinguish them from synchronous con-
densers (Par. 319 and 320). This characteristic is that they are not synchro-
nous machines.
Leblanc was probably earliest in drawing attention to methods of securing
phase control by the use of non-synchronous auxiliaries. His proposals
may be explained by reference to the accompanying diagrams. In Fig.
174, AC and BDrepresent two series-excited machines which, by suitable
mechanical means, are driven at some appropriate speed. The field C of
AC and the armature B of BD
are connected in series with phase N of the
quarter-phase rotor MN. Similarly, the field D ofBD and the armature
A of AC are connected in series with the other phase, M. Thus the current

c^>—
Sec. 7-322 A. c. generators and motors
has three geometric poles. The field windings are usually distributed in
slots at the inner periphery of the stator instead of being arranged on salient
poles as indicated diagraminatically in Fig. 170.
322. The Miles Walker phase advancer. In the phase advancer
developed by Prof. Miles Walker, a compensating winding is added as
shown in Fig. 178 in which E1.E2E3 arc the three exciting windings and
C1C2C3 the three compensating windings. The exciting windings E are (for
abi-polar design) usually concentrated in three large equi-distant slots in the
stator core, while the compensating windings C are distributedin many small
slots in order to neutralize (or slightly overneutralize), the m.m.f. of the
rotor winding. It is claimed for this type thatit possesses features specially
conducive to ready adjustment and good commutation.
323. Omission of stator windings in non-synchronous phase
advancers. Leblanc's original proposals showed examples of phase ad-
vancers, in which no windings were provided on the stator. Such a plan
as applied to a three-phase four-pole advancer, is shown diagrammatically
in Fig. 179. The recesses opposite the brushes are provided for improving
the commutation. Scherbius in some phase advancers built by Messrs.

Fig. 176. Fig. 177. Fig. 178.

Fig. 176. — Alternative method of diagrammatic representation of Leblanc
single-armature phase advancer.
Fig. 177. —
three phases.
Diagrammatic representation of phase advancer wound for
Fig. 178. — Miles Walker phase advancer with exciting and compensating
windings on the stator.

Brown-Boveri & Co. has employed this plan of omitting exciting windings
from the stator. But compensating windings are usually fitted on the
stator in phase advancers for large slow-speed induction motors.
324. An understanding of the underlying idea of the non-
synchronous phase advancer (Par. 321) may also be obtained by
first considering that the low-frequency currents, from the secondary
of the main motor, flow into the rotor' of the phase advancer while it
is at rest. Under these conditions the current will lag, since the rotor cir-
cuits are inductive. But if the rotor is driven in the direction of the mag-
netic field which is circulating in it and which has been occasioned by the
m.m.f. of the low-frequency currents from the secondary of the main motor,
and if the speed at which it is driven is exactly that of the rotating field, then
there is a state of relative rest between the field and the rotor, and the latter's
windings are non-inductive and occasion neither lag. nor leod._ If the rotor
is driven at higher speeds, the rotor circuits again become inductive but
introduce leading electromotive forces into the secondary circuits of the main
motor.
326. Scherbius phase advancers with entire omission of stator.
Scherbius has devised a phase advancer consisting simply in a rotor with
its windings completely embedded below the surface. Diagrammatically
such a phase advancer and its connections reduce to the simple arrange-
ment shown in Fig. 180, in which A represents the rotor of the induction

580
 A. C. GENERATORS AND MOTORS See. 7-326

motor with its windings connected to the brushes of the Scherbius phase
advancer B. The latter is usually mounted directly on the shaft of the main
motor. Thus the scheme reduces to the simple proposition of establishing
a field in the magnetic circuit of B by means of the m.m.f. of the current sup-
plied to its brushes from A. This field rotates very slowly in space since the
frequency of the rotor currents is small. But B is rotated mechanically
at the high speed of the rotor A and consequently the windings on B rotate
much faster than the magnetic field in B, and in cutting through this field
they set up an e.m.f. which, combined with the e.m.f. in the main rotor,
occasions an advance in thephaseof the currents in the rotor circuits and im-
proves the power-factor of the motor.
In a letter published in The Electrician, July 12, 1912, page 582, Scherbius
states that both theory and practice support the idea that a mere ring is

_
Fio. 179. —
Leblanc-Scher- Fia. 180. — Diagrammatic
bius phase advancer without representation of Scherbius
windings on stator. statorless phase advancer.
sufficient tocomplete the magnetic circuit and that no stator is necessary.
Consequently in a considerable number of his smaller sizes of phase advanc-
ers Scherbius has abandoned the use of a stator and has built his phase
advancers without any air space in the magnetic circuit. The consequent
reduction in the magnetic reluctance permits at small loads the generation
of an increased e.m.f. of rotation and results in a greater improvement of the
power-factor at light loads. See Ahmed, A. A., "Methods of Testing the
Scherbius Compensator," Jour. I. E. E., Vol. 53 (1915), p. 640.
326. Operating data of Scherbius phase advancers. In Fig. ISl
are given curves, showing the power-factor obtained by Scherbius on a
Leading
0.8

V
Lagging
1.0

0.8
I'l
^

0.6
©
o
°0.2

40 80 120 160 200 240 280 320 360 400H.E.

Fia. 181. —Performance curves of a 400-h.p. motor when operated re-
spectively with (upper curve) and without (lower curve) a Scherbius phase
advancer.

400-h.p. motor when operated respectively with and without a phase ad-
vancer. It is seen from the curves that at only 20 per cent, of rated load the
power-factor is improved from 0.4 to 0.8, and that beyond half load the
current is leading. The 400-h.p. motor on which the tests were made, has
24 poles and runs from a 3,300-volt, 32-cycle circuit at 160 rev. per min.
The overall dimensions of the advancer (including a small motor to drive it)
are 50 in. X22 in. X25 in., and the weight of the advancer and its driving

681
 Sec. 7-327 A. c. generators and motors
motor amounts to 0.34 metric ton. This particular phase advancer was
fitted with a stator but without any' windings. The general tendency is
toward the employment of a stator fitted with compensating windings but
without any exciting windings. At page 366 of Vol. L, of the Jour. I. E. E.
are given curves, reproduced in Fig. 182, showing the improvement effected
in a 25-h.p., 50-cycle, 450-volt, 1,000-rev. per min., three-phase induction
motor by fitting a Scherbius phase advancer on the end of the shaft of its
rotor. In the motor the stator is the secondary and its three terminals are
connected to three brushes on the commutator of the advancer. The total
weight of the motor and advancer is only 0.36 metric ton, or 14.5 kg.
per h.p.
At a steel mill in Sheffield in England, a Scherbius advancer with a sta-
'
tor fitted exclusively w'th compensafng windings is employed in the rotor
circuit of a 700-h.p. induction motor which is usually running lightly loaded.
Without the phase advancer the power-factor of the system is 0.55. With
the advancer it is increased to 0.7. The advancer is driven by a 2-h.p. in-
duction motor running at nearly 1,500 rev. per min. —
327. The Eapp vibrator. In Edairage Electrique, for August 5,
1899, Leblanc suggested that phase control could be accomplished by the
use of a device which he termed a "recuperator" and which consisted of a
copper disc through which alternating current was transmitted radially
between the centre and the periphery, and which was located in a magnetic

2 4 6 8 10
Input
Fig. 182. — Performance curves of a 25-h.p. motor when operated respec-
tively with and without a Scherbius phase advancer.

field inwhich it oscillated. The current was transmitted to and from the
disc by means of a slip-ring on the shaft and a trough of mercury in which the
disc dipped.
Dr. Gisbert Kapp has developed from this principle a commercial phase
advancer which he terms a "vibrator." Kapp has realized that success is
contingent upon employing as a vibrating element a rotor of small diameter.
He conveys the current into the rotor windings by brushes bearing on a coni-
mutator. In order that the commutator may be small and cheap, it is
desirable that the secondary of the main motor shall be wound for a fairly
high pressure and small current. The scheme is illustrated in Fig. 183
taken from an article by Kapp published in The Electrician for May 17
and, 24, 1912, pp. 222 to 272. VVV are three vibrating armatures for
improving the power-factor of a three-pha.se motor whose rotor has a three-
phase winding. A three-phase motor can, as well, have a two-phase rotor,
and this will permit of reducing the number of vibrating armatures from
three to two. A starting resistance, S, of the usual type is provided. It is
short-circuited after the motor has acquired speed. The field of the vibrator
ia shown excited from a battery, but any convenient source of direct current
may be employed. Dr. Kapp states that the power required for excitation
is only a fraction of 1 per cent, of the power of the motor, and that the loss
of power by windage and brush resistance in the armatures is of the same
 A. C. GENERATORS AND MOTORS See. 7-328

order of magnitude. A switch may be arranged to short-circuit the vibrator

while the motor is being started and thus avoid subjecting the windings of
the vibrating armatures to the high pressure established, during starting,
in the rotor of the induction motor. When it is arranged to protect the
vibrator in this way, its £»-mature need only be provided with low-voltage
insulation, since the pressure of the rotor windings during normal running is
only a small percentage of the pressure during starting.
There is no difficulty in proportioning a vibrator for good commutation.
At maximum speed the cur-
rent is zero and at maxi-
mum current the speed is
zero. Consequently at
both these limits the reac-
tance voltage is zero. The
reactance voltage passes
through its maximum value
at some intermediate value
of speed and current, but
there is no difficulty in so
proportioning the vibrator
that this maximum value
of the reactance voltage will
be low. In Vol. LI (1913)
of the Journ. I. E. E., are
given, p. 292 the curves
reproduced in Fig. 184.
Fig. 183. — Diagrammatic representation of Thesecurves were obtained
an induction motor and a Kapp vibrator type of on a 40.8-cycle, 2,650 volt,
phase advancer. 408-rev. per min., 12-pole,
90-h.p. induction motor,
when run with and without a Kapp vibrator. The natural slip of the motor
was 2.75 per cent, at full-load. The curves disclose a slightly undesirable
feature which is more or less common to all these phase advancers, namely,
that their use increases the slip. The use of a phase advancer, however,
greatly increases the instantaneous overload capacity of the induction motor
to which it is applied.

1.0
Sec. 7-329 A. c. generators and motors
factors without the vibrator, were 0.76 lagging and 0.87 lagging respectively.
The excitation loss in the fields of the vibrator was only 50 watts.
The Kapp vibrator's chief advantage over revolving types of phase ad-
vancers relates to the greater facility with which good commutation may
be obtained. A disadvantage relates to its deifendencc upon a supply of
direct current for field excitation.
 — ,

A. C. GENERATORS AND MOTORS SeC. 7-330

Dr. Kapp puts the cost of the vibrators as ranging from about $1.25 per h.p.
in favorable cases, up to S4.00 per h.p. in relatively unfavorable cases, such,
forinstance, of considerable slip or low-pressure secondary windings or both.
These are pre-war estimates.
330. Oeneral considerations in the design of phase advancers. In
order to keep down the size and cost of the commutators and the losses at the
brushes, it is desirable to wind the secondary of the main motor for fairly
high pressure, and it is also desirable that the slip shall be small. It ia
claimed by Kapp that the smaller the slip, the more favorable is the case for
employing a vibrating rather than a rotating phase advancer. The weight
and cost per h.p. decrease with decreasing slip and increasing secondary
pressure of the main motor. All of these types of phase advancer have the
valuable feature of greatly increasing the instantaneous overload capacity
of the motors with which they are employed. For a given load the primary
current is considerably decreased, and the secondary current increased.
This would lead to about the same total copper loss for a given load, were
it not for the circumstance that it is usually quite practicable to increase the
cross-section of the secondary copper. It is fair to state that the decrease in
the losses in the main motor for a given load approximately off-set the losses
in the advancer, leaving the eflBciency substantially unimpaired at rated
load. The efficiency will usually be materially improved at small loads.
The power-factor and overload capacity may be both greatly increased.
331. Bibliography of phase modifiers.
—
Walker, Miles. "The Influence of Power-factor in Alternating-current
Systems." Journ. I. E. E., Vol. XLII, 1909, page 599.
—
Kapp, Gisbbrt. "On Phase Advancers for Non-synchronous Machines."
The Electrician, Vol. LXIX, May 17 and 24, 1912, pages 222 and 272.
ScHEBBius. The Electrician, Vol. LXIX, 1912, page 582.
—
Kapp, Gisbert. "Ueber Verbesserung des Leistungsfactors." E. T. Z.,
1913, No. 33.
—
Walker Miles. "The Design of Apparatus for Improving the Power-
factor of Alternating-current Systems." Jour?i. I. E. E., Vol. L, 1913, page

Kapp, Gisbert. — "On Phase Advancing." Journ.

329.
E. I. E., Vol. LI, 1913,

Eardlet-Wilmot, G. H. — "Phase Compensation." The

page 243.
Electrician, Vol.
LXXII, Nov. —"The Brown-Boveri Phase Advancer."
1913, page 327.
28,
. The Electrical
Times, Vol. XLV, Jan.
— "Tests1914,on page
.
8, 33.
a Kapp Vibrator." Electrical Engineering,
Vol.X, Apr. 16, 1914, page 214.
Adams, L. F.— "Phase Advancers." General Electric Review, Vol. XVII,
June, 1914, page 583.

MOTOR GENERATORS
332. General flexibility of combinations. For transforming alternat-
ing electricity from one pressure or phase system to another of the same
frequency, stationary transformers usually offer advantages over rotating
apparatus. Even for such transformations, however, motor-generator sets
permit of adjusting the ratio of transformation of pressure at will and over a
wide range. This advantage of greater flexibility in the motor generator
rarely suffices to justify its use in transformations where it is not desired to
alter the frequency. For effecting all other transformations of electricity,
motor generators usually represent the most satisfactory means, if questions
of cost and efiiciency are left out of account.

333. Motor generators for frequency changing. Transformations

from alternating electricity of one frequency to alternating electricity of
another frequency are usually effected by means of synchronous motor-
generator sets. Such frequency changer sets are discussed in Par. 346 to 369.
334. Synchronous converters and motor converters. The lower
Cost and higher eflficiency of transformations from alternating to direct
current by means of synchronous converters (Sec. 9) or motor converters
(Sec. 9) justify their use for certain classes of work notwithstanding certain
less desirable features.

585
Sec. 7-335 A. c. generators and motors
336. Synchronous-motor drive for motor-generator sets. The use
of a synchronous motor-generator for transforming from alternating to
direct current permits of effecting phase control to practically any desired ex-
tent; whereas, with asynchronous converter, phase control is only practicable
within very narrow limits (Sec. 9). Moreover the direct-current generator
of a motor-generator set can be provided with all the desirable attributes of
a machine driven by a prime mover. Although the motor-generator set may
be employed in a substation many miles away from the generating station,
the direct-current generator will have as close speed regulation as the prime
movers in the generating station. Its voltage may be controlled through any
desired range and it may be provided with a compound winding for giving
'it practically any characteristics which may be desired. For operating from
60-cycle circuits and for commutator pressures above 1,200 volts, the syn-
chronous converter has a competitor in the synchronous motor-generator
set. The motor converter (Sec. 9) is also a rival for such work. For still
higher commutator pressures, the synchronous motor-generator set is ex-
clusively suitable for operation from 60-cycle circuits and it is often prefer-
able on 25-cycle circuits.
336. Induction-motor drive for motor-generator sets. While it
is usually preferable to employ a synchronous motor for a motor-generator
set, cases arise where the simplicity of the squirrel-cage induction motor
and its lower cost is considered sufficient inducement to employ it notwith-
standing its low power-factor and its slip. The induction-motor drive is
usually confined to relatively small sets and for low voltages at the motor.
It is less objectionable at 25 than at 60 cycles, since for a given size and speed
the power-factor of induction motors is higher the lower the periodicity.
337. Starting of motor-generator sets. It is at present usual to
start synchronous motor-generator sets from low-voltage taps of trans-
formers or auto-transformers by means of the torque supplied by squirrel-
cage windings fitted in the pole shoes. After the rotor has come up to
speed, the stator windings are thrown over to the full-voltage position. The
method differs in no essential respect from the "tap" starting of any syn-
chronous motor or rotary converter. Another available method which as
yet is but rarely employed in America consists in fitting a small auxiliary
induction motor on the shaft with its stator windings either in series with the
stator windings of the synchronous motor or else with its stator windings
supplied from the secondaries of a series transformer whose primaries are,
during starting, in series with the synchronous motor's stator windings.
This method is especially appropriate for large sets and is widely used in
England. The rotor often consists of a cast-iron cylinder without any slots
or windings. As a third method may be mentioned that of starting from the
commutator end by temporarily employing the direct-current generator
as a motor. Some 25 per cent, of rated full-load current is usually required
by this method of starting motor-generator sets. The method is the more
worthy of consideration, the higher the frequency of the supply circuit, since
tap starting requires more current with the higher frequencies. If the set '

is started from the commutator end, the compound winding should be i

temporarily short-circuited by a switch mounted on the frame of the machine ,,

or close to it. For this method of starting it becomes necessary to employ :j

synchronizing apparatus. When induction motor-generator sets are era- \

ployed, one of the motives usually relates to the readiness of starting from <

the induction-motor end in the same way in which any large squirrel-cage i[

induction motor is usually started up, i.e., by taps from transformers or ;

induction starters.
338. Motor-generator sets for charging storage batteries. It might
be concluded at first sight that the mercury-arc rectifier would monopolize
the function of charging storage batteries when the available supply consists
of alternating current. There is, however, a consideration which often
weighs decidedly in favor of the motor generator for such work: There is
an internal drop of some 20 to 30 volts in the mercury arc rectifier. Let us
for explanatory purposes take the drop as 25 volts. Then for supplying
electricity at a pressure of 25 volts, the efficiency cannot be greater than
125/(25 + 25) ]X 100 = 50 per cent. But for supplying energy at 250 volts,
the efficiency may bo of the order of 2.50/(2.50 -f- 25) =91 per cent.
Consequently the higher the required pressure the more appropriate is
586 I
I A. C. GENERATORS AND MOTORS Sec. 7-339

the mercury-arc rectifier, and the lower the required pressure the more
appropriate is the motor-generator. We thus see that for low-voltage stor-
age-battery charging there is an important consideration weighing in favor
of the motor generator, although its greater initial cost, the greater cost for
attendance, and the general inconvenience inherent to rotating rnachinery
may turn the balance in favor of the mercury-arc rectifier in many instances.
339. Motor-generator sets for electrolytic work. The explanations
in Par. 338 apply in greater degree to the provision of direct-current
still
for such electrolytic as requires a pressure of only a few volts.
work For
such work the required pressure is often of the order of only some 2 to 10
volts. Since the technical problems arising in connection with such sets
hinge around the abnormal proportions required for the direct- current
generator, and since the alternating-current rnotor for such sets is entirely
normal, this matter is more appropriately discussed in Sec. 8.
340. Motor-generators for main-line railway substations. In
most main-line railway electrification, direct current will be suplied to the
conductor rail or overhead trolley wire at pressures of not less than 1,200 volts
and often of from 2,400 volts, to 4,000 volts. Such pressures cannot success-
fully be provided by synchronous converters or motor converters. Con-
sequently motor-generators will be employed.
341. Ward Leonard system. The modern conception associated with
the term "Ward Leonard System" is of a system for effecting any desired
variations in the speed of a motor for all loads carried by the motor without
incurring any rheostatic losses in the main circuit. This is accomplished by
interposing a motor-generator set between the variable-speed motor in ques-
tion and the system from which it is supplied. If the system be one furnish-
ing alternating electricity it will be usual to employ for the motor-generator
set a synchronous motor coupled to a direct-current generator. It is
arranged that the excitation of the latter may be varied over a wide range by
means of a rheostat in its field circuit. The generator's armature and the
motor's armature consiitute a circuit by themselves which is not interrupted
in service. By simple and efficient manipulations of the field rheostats
and switch gear in the exciting circuits of the generator, and of the variable-
speed motor the latter's speed and direction of rotation are under perfect
control at all loads. The system is regenerative; thus, when applied to
hoisting, the descending load drives the motor, which, as a generator, re-
verses the action of the motor-generator set and returns energy to the
supply system.
342. The Ward Leonard system has been applied to a large variety
of work requiring economical operation under widely varying conditions of
speed and load. Among these applications that of operating railway trains
is of interest. In this instance Ward Leonard employed single-phase trans-
mission to a motor-generator set on the locomotive. The generator delivered
direct current to motors geared to the driven axles. The control was
effected exclusively by manipulation of the field excitation. This system of
railway electrification was formerly occasionally employed by the Oerlikon
Co.
343. Bibliography of Ward Leonard system. The system has been
described and discussed on several occasions when its inventor presented
papers before the American Institute of Electrical Engineers. The following is
a list of several papers by H. Ward Leonard relating to his system; these were
published, at the various times noted, in the Trans. A. I. E. E.
_ "A New System of Electric Propulsion (June, 1892)," Vol. IX, page 566.
"How Shall We Operate an Electric Railway Extending One Hundred
Miles from the Power Station" (Feb., 1894), Vol. XI, page 76.
"Volts vs Ohms (Speed Regulation of Electric Motors)" (Nov., 1896),
Vol. XIII, page 377.
"Multiple Unit, Voltage-speed Control for Trunk Line Service" (Nov.,
1902), Vol. XX, page 155.
344. The Ilgner system. By providing the motor-generator set with
a fly-wheel, Ilgner goes a step farther than Ward Leonard and obtains a
system for supplying electricity to a motor which shall carry sharply varying
loads at widely varying speeds without imposing any material load variations
on the supply system. When operated from a direct-current supply, both

587
Sec. 7-345 A. c. generators and motors
members of the motor-generator set are direct-current machines as indicated
at A and B in Fig. 187. The shunt motor A is supphed from the direct-
current system G, and drives the generator B and tne fly-wheel C. It is
desired that the motor, F, shall be economically operated at any speed in
either direction and with widely varying loads. For instance, F may drive
reversible rolls in a steel mill or a winder at a coal nune. (Although in the
case of such heavy work, the supply would consist in nolyphase electricity, it
is simpler first to describe the arrangement employed with a supply of con-
tinuous electricity.) It will be observed that there are no switches or
rheostats in the circuit of the armatures of the generator B, and the variable-
speed motor F. The excitation for the latter may be supp led from G, as
indicated in the diagram. The control of the speed of F is effected by control
of the field excitation of the generator B by means of the rheostat D. The
direction of F is controlled by the switch E. Assuming the case of winding
a load up out of a shaft, let us take the moment when the load is at rest at
the bottom. Switch E will be open at this moment and F will be at rest.
To wind up the load the switch E is closed in the right direction and the field
of B is rapidly strengthened by cutting out the rheostat D, point by point.
This accelerates the motor F
to its full speed.
Theload thusimposed on
the fly-wheel motor-genera-
tor set is largely provided
from the energy stored up in
the fly-wheel C. By the time
the wind is completed, the
motor generator's speed has
decreased a few per cent.
During the descent, the mo-
tor A is still loaded, since it
is accelerating the fly-wheel
to its full speed and storing
energy in it. The descending
load may contribute to the
process by regeneration.
346. Field of application
of the Ilgner system. The
Ilgner system has been exten-
sively used andi nstances are
on record of reversing rolling
millsin whichload variations
of enormous amount occur-
ring many times per min. are
so effectively equalized as to
occasion practically constant
load on the supply system.
See Sec. 15. However, for
heavy work of this character, Fia. 187.— Ilgner system
the supply consists of poly-
phase energy, and an induction motor replaces the direct-current motor
A of the motor-generator set. But the generator /} and the variable-speed
motor F remain direct-current motors, and the operation is quite as ex-
plained above. It is, however, necessary to provide an exciter for the field
winding of F. Furthermore, certain details are introduced relating to the
automatic insertion of resistance! n the secondary windings of the induction
motor of the motor generator, in order to control the rate and extent of deliv-
erance of the kinetic energy of the fly-wheel.

FREQUENCY CHANGERS
346. Field of application of the frequency changer. With the
rapidly extending employment of electricity as a means of transmitting
energy to a distance, it has come about that most civilized regions of the world
are now provided with enormous networks of transmission conductors.
Various networks in neighboring localities are often the outgrowth of small
undertakings which were originally in competition with one another, and they
differ as regards pressure, phase system, and frequency. At the present
588
 A. C. GENERATORS AND MOTORS SeC. 7-347

stage of development it is becoming important to interconnect these systems.

The difference in pressure and phase system are readily reconciled by means
of stationary transformers, Sec. 6. But the different frequencies can only be
dealt with commercially in the linking-up process by means of rotating ma-
chinery termed "frequency changers." Such machines are also required
when, for a portion of the load on a system, a different frequency is appro-
priate from that required for the bulk of the load. Thus single-phase rail-
ways are less unsatisfactory the lower the frequency employed. Consequently
when a large 60-cycIe power-supply undertaking contracts to supply a
single-phase railway, frequency changers must be employed to provide
electricity of a frequency of 25 or preferably 15 cycles per sec. In Europe a
periodicity of 16.66 cycles per sec. has been standardized for single-phase
railways, and 50 cycles for general power and hghting purposes. Without
devoting more space to a specific discussion of the occasions for frequency
changers, we may briefly subdivide these occasions into two groups relating,
respectively: first, to the case of the exclusive supply of electricity through a
subsidiary system with no other source of power, at a frequency differing
from that of the main system, and, secondly, to the linking up of two systems
of different frequencies, each system also having its own independent
generating plant. While the first case is relatively simple, a number of
important considerations involving attention to complex details arise in
connection with the second case.
347. Frequency changers for the exclusive supply of subsidiary
networks. Let us now deal with the first case and base our explanations
on the example of a circuit for which 25-cycle energy is required, the fre-
quency of the main system being 60-cycles. The simplest plan, and the one
almost always adopted, consists in employing a synchronous motor-generator
set, the motor of which is designed to run at 60-cycles while the generator is
designed with such a number of poles that, when driven by the motor, its
frequency will be 25 cycles per sec. The smallest number of poles for
these two combinations are 24 for the motor and 10 for the generator, since
24/2 = 12, and 10/2 = 5 are the smallest whole numbers bearing to one another
the ratio of 60 to 25. A 24-pole motor on a 60-cycle circuit runs at (60 X
60)/12 = 300 rev. per min. It is usually desirable to select the smallest
practicable number of poles, since this corresponds to the highest speed and
consequently to the smallest and cheapest motor-generator set. The
synchronous motor of such a set may be designed with an appropriate
squirrel-cage (amortisseur) pole^face winding to enable it to run up to speed
as an induction motor. In this case it will be started from low-pressure
taps of a transformer or induction starter as described in Par. 337. As an
alternative, it may be started by means of an induction motor in series as
also mentioned in Par. 337, and will be self-synchronizing. In other instances
it may be preferred to employ an auxiliary direct-current motor to bring
the set up to speed. After the set is in synchronism, the 25-cycle load may
be supplied from the generator. Synchronous frequency changers have the
good feature that by overexciting the synchronous motors, they can be made
to also act as synchronous condensers to improve the power-factor of the
system as described in Par. 319 and 320.
348. Induction motor versus synchronous motor as primarjt
member of a frequency changer set. Except for this last feature (Pa^
347), it may occasionally be preferable in such a case to employ a motor of
the non-synchronous type and with a squirrel-cage rotor. But by such a
plan a lagging load will be imposed upon the main system and this will
usually be so objectionable that it will more than offset the advantage of
simpHcity possessed by the squirrel-cage induction motor. Furthermore, it
will not permit us to dispense with a supply of direct-current for excitation,
since this will be required in any case for providing the excitation for the
generator member of the motor-generator set. In exceptional cases it might
be a good plan to let the motor be of the induction type and arrange to operate
It at unity or leading power-factor by the employment of
a phase advancer
of one of the types discussed in Par. 321 to 331. The Brooklyn Edison Co.
has 1,000-kw. and 500-kw. induction-motor-driven frequency-changer sets
(which have been supplied by different manufacturers) operating in parallel.
349. The parallel operation of two or more frequency changers.
If two or more frequency changers of the synchronous motor-generator
type mentioned in Par. 333 and 347 are required to operate in parallel in

589
Sec. 7-350 A. c. generators and motors
supplying a load, certain complications arise due to the necessity for synchro-
nizing the frequency changers at both ends, and due to the requirement that
the internal reactance and shifting of magnetic axes in the machines (with
loads varying as regards amount or phase) shall not be such as to cause
inappropriate division of the load among the different machines in parallel.
These matters have been carefully considered by J. B. Taylor in a paper
entitled "Some Features Affecting the Parallel Operation of Synchronous
Motor-generator Sets," published in Proceedings of the American Institute
Electrical Engineers, Vol. XXV (1906), p. 113 and by N. E. Funk in a
paper entitled "Operation of Frequency Changers" at p. 1579 of the July,
1913, issue of the Proceedings American Institute Electrical Engineers. The
relations involved are too complicated to be satisfactorily abstracted. Let
us. however, consider the matter briefly by reference to the case of supplying
40 cycles from a 60-cycle system through two sets, each consisting of a 6-pole
1,200-rev. per min. synchronous motor, direct-connected to a 4-pole synchro-
nous generator. Let us assume that the relative angular positions of the
generator and motor fields are as shown in Fig. 188, see I and //. Set /
is in service and it is desired to place set // in parallel with it. The large
letters A^ and S relate to the North and South poles of the 6-pole motors and
the small letters n and s to the poles of the 4-pole generators. It is not only
necessary that the North poles of the motors of II shall occupy the same
angular positions as the North poles of the motors of I, but it is furthermore

53 5i

*a *i
I
 -

A. C. GENERATORS AND MOTORS SeC. 7-352

reference has already been made, describes interesting arrangements for

synchronizing frequency-changer sets when operating in parallel.
362. Refinements of construction necessary to permit of parallel
operation. From the above discussion it will be evident that in order to
obtain an appropriate division of the load between two frequency changer
sets operated in parallel, great exactness in construction and adjustments
is necessary. It is desirable to be able to effect a final mechanical adjust-
ment of the stators with relation to one another. This is often arranged by
providing a cradle construction. The stator of one machine is bolted to a
cradle fastened to the base. By "slacking off" the bolts, a small angular
adjustment of the stator may be effected, and the bolts afterward tightened.
353. Efficiency of a motor-grenerator frequency changer. By using
a motor-generator set as a frequency changer, each of the two machines has to
be proportioned for the entire load to be delivered to the changed-frequency
circuit, and the set is consequently large and expensive. Furthermore, if
each machine has an efficiency of, say, 95 per cent., the combined efficiency
is only 91 per cent, since 0.95X0.95 = 0.91.
354. Induction-type frequency changer. We shall now consider
means by which better results, in these respects, may sometimes be
obtained. These means rest fundamentally upon the circumstance that,
in an ordinary polyphase induction motor, the frequency of the current in
the rotor winding depends upon the speed of the rotor. Let us consider a
60-cycle three-phase induction motor with a three-phase rotor and three
slip-rings. If the stator windings are connected to a 60-cycle circuit, then
if the rotor is restrained from moving, the frequency in the rotor windings
will also be 60-cycles per sec. If, on the contrary, the rotor's speed is the
same as that of the revolving magnetic field in the stator, and in the same
direction, then the frequency in the rotor winding will be zero. Thus if the
60-cycle induction motor has fgur poles, the magnetic field will travel around
the stator at a speed of: (60X60) -=-(4/2) = 1,800 rev. per min.
If the rotor's speed is also 1,800-rev. per min. and in the same direction,
then the frequency in the rotor windings will be zero. If, however, the rotor's
speed is only 1,200 rev. per min. the frequency will be [(1,800— 1,200)/ 1,8001 X
60 = 20 cycles per sec. If the rotor's speed is only 300 rev. per min., the fre-
quency will be [(l,800-300)/l,800]X60 = 50 cycles per sec. If the rotor is
restrained from running, the frequency will be [(1,800 — 0)/l,800]X60 = 60
cycles per sec. If the rotor is driven at a speed of 300 rev. per min. in a
direction opposite to that of the magnetic field in the stator, the frequency
will be [(1,800 + 300V1,800]X60 = 70 cycles per sec.
In our case we wish a frequency of 25 cycles per sec. Consequently, if
we denote by R the speed at which we shall drive the rotor we may have
either ((K- 1,800)/1,800]X60 = 25 or [ri,800-«)/l,800]X60 = 25 and
18 = 2,550 or i2 = 1,050.

355. Direct-current motor drive for induction-type frequency

ehanger. Let us select the former case and drive the rotor at a speed of
2,550 rev. per min., by another motor. We can only do this if we have a
source of supply of continuous electricity and employ a 2,550 rev. per min.,
continuous-electricity motor. We could not employ a 60-cycle induction
motor to drive the rotor since this would run at only 1,800 rev. per min.,
if wound with 4 poles and at 3,600 rev. per min., if wound with 2 poles, and
we require it to run at 2,550 rev. per min. 1

356. Alternating-current motor drive for induction-type fre-'

quency changers. If there is no source of continuous electricity supply,
thus limiting us to the use of a 60-cycle motor to drive the rotor of the fre-
quency changer, then we shall have to abandon the plan of employing a
4-pole frequency changer and we shall be obliged to employ one with more
'poles which, consequently, will be heavier and more expensive. We can
determine upon a suitable combination by consulting the table in Par. 367.
357. Selection of proper speed and number of poles in induction
iype frequency changers. In the table given in Par. 358, the smallest
lumber of poles which, in column 7 V, corresponds to the synchronous speed of
I 60-cycle motor, is 14, corresponding to a rotor speed of 300-rev. per min.
3ur frequency changing outfit thus consists of a 14-pole induction motor
vith its rotor driven by a 300-rev. per min., 60-cycle synchronous motor
vhioh will, consequently, have 2X[(60X60)/300] = 24 poles. But, for so
691 ,
Sec. 7-358 A. C. GENERATORS AND MOTORS
slow a speed, the outfit will be heavy and expensiye. Examining column
V of the table we see that for an 8-pole frequency changer in which the rotor
is driven at a speed greater than that of the stator field, the required speed
is 1,275 rev. per min. Since a 6-pole, 60-cycIe synchronous motor runs at a
speed of only 1,200 rev. per min., the frequency will be only (1,200/1,275) X
25 = 23.5 cycles per sec.
It has been assumed that the frequency changer is required for supplying
an independent circuit which has no other source of supply. In such a case, a
periodicity of 23.5 cycles would usually be nearly as appropriate as 25 cycles.
If, on the other hand, we were to elect to employ a 6-pole frequency changer,
the rotor speed required for 25 cycles would, as seen from column V, be
1,700 rev. per min., and if we arranged to drive it by a 4-pole synchronous
motor, the speed would be 1,800 rev. per min., giving' (1,800/1,700) X 25 =
26.5 cycles per sec. If, in the latter case, we were to employ a squirrel-
cage induction motor to drive the rotor, instead of employing a synchronous
motor, and if we were to design the induction motor for a full-load slip of
5.5 per cent., then the periodicity would vary from 26.5 cycles, at no-load]
to 26.5 X 0.945 = 25. 0-cycles, at full-load. Enough has been said to indicate
that the circumstances of each proposed installation will largely govern the
suitable design.

358. Table of relativespeeds for induction-type

frequency changers

Number of
poles of
stator of
frequency
changer
 A. C. GENERATORS AND MOTORS SeC. 7-361

we may employ a 4-pole frequency changer and drive its rotor at 300 rev.
per min. in opposition to the 1,500 rev. per min. of the stator field. If the
output dehvered from the frequency changer is 1,000 kw., then (300/1,800) X
1,000= 167 kw. is provided by the driving motor and (1,500/1,800) X 1,000 =
833 kw. is provided by the frequency changer itself in_».it8 transformer
capacity, and at high efficiency.
Obviously the less the required alteration in frequency, the greater is
the appropriateness of the induction-type of frequency changer as compared
with the motor-generator type.
361. Relative merits of various kinds of motors for driving the
rotor of an induction-type frequency changer. Whether or no it
may be practicable to employ an induction motor to drive the rotor, depends
to a considerable extent upon the importance or otherwise of supplying
absolutely constant frequency at all loads. When it is permissible that the
frequency may decrease 1 or 2 per cent, or more from no-load to full-load,
an induction motor may provide the most satisfactory solution, since it
elirninates the necessity for having a supply of continuous electricity for
excitation.
In some instances instead of employing a squirrel-cage induction motor
and then having a slip necessarily proportional to the load, it becomes
appropriate to drive the frequency changer's rotor by a slip-ring induction
motor and regulate its slip, and consequently the frequency supplied, by
regulating the resistance in its rotor circuits. This becomes the more expedi-
ent, the smaller the proportion of the total energy which is supplied by the
driving motor. For instance, in the example in Par. 360, only (300/1,800) X
100=16.7 per cent, of the total output, is provided by the driving motor,
and a considerable rheostatio loss in its rotor circuits would not seriously
affect the efficiency of the complete outfit. It should again be emphasized
that induction-type frequency changers are not used in commercial practice.
Synchronous motor-generator sets are practically always employed.
362. Frequency changers for connecting two systems, each of
which has its own generating machinery of fixed frequency. We
now come to the problem encountered when frequency changers are employed
between two systems each of which has a definite frequency imposed upon it
by its own generating plant. Synchronous motor-generator sets have
nearly always been employed for this class of work. Thus, in order to link
up two systems with frequencies of 60 and 25 cycles per sec, respectively, two
synchronous machines of 24 and 10 poles respectively are coupled together.
It is necessary for the frequencies of the two systems to be exactly identical
;in order to successfiilly operate such plant. Furthermore, there are the
various complicated relations necessarily observed in synchronizing such
apparatus, as already discussed in Par. 349.
Indeed, there is the further consideration that when sets for parallel
operation are so proportioned and adjusted that they share the load in ap-
propriate proportions when delivering power from, let us say, a 2.5-cycle
ystem to a 60-cycle system, the division of the load will be altered when it ia
desired to reverse the sets and deliver power from the 60-cycle set to the
25-cycle system. Notwithstanding the niceties imposed by the relative-
frequency conditions, synchronous motor-generator sets constitute the
usual means employed.
When synchronous sets are employed to link two large systems, the
slightest alteration in the relative frequencies of the two systems occasions
jnormous fluctuations in the load carried by the frequency changers. This
lifficulty is less the greater the size of the frequency changers as compared
mth the size of the systems connected. Unless the frequency changers are
)f large size as compared with the size of the systems which they connect,
;ney will be pulled out of step if there is any slight change in the ratio of the
requencies of the two systems. Consequently, when the frequency changers
be of relatively great size, it would be preferable to employ sets in
*i?°u*
'Vhichan induction machine constitutes the motor member.
Induction-motor drive for non-reversible frequency changers-
J^'- the
Vhere object is to deliver energy always in the same direction, the em-
''°ynient of an induction machine with a shp-ring rotor as motor element,
no the control of its precise speed by the adjustment of a rheostat in its
otor circuits provides freedom from the necessity for maintaining
at exactly
ne same value the ratio of the frequencies of the
inter-connected systems.
Sec. 7-364 A. c. generators and motors
Indeed any slight change in the ratio of the frequencies is automatically
accompanied by an appropriate alteration in the slip of the induction motor
and this alteration is of such a nature as to reduce the accompanying load
variation to a moderate amount.
364. The use of an induction machine in a reversible frequency
changer. It has even been suggested that by the adoption of suitable
pole numbers and by providing sufficient range of slip-control by the resist-
ances in the rotor circuits, such a set could be employed reversibly. In
such a case the induction machine would function as a generator to an extent
which may be controlled by adjustment of the resistances in the rotor circuits.
365. Frequency changring by two induction machines. Both
machines could be of the induction type, the one operating as a motor and the
other as a generator. This arrangement, if required to be reversible, would,
however, only be possible for connecting two systems each of which is pro-
vided with synchronous apparatus, since the generator member would be
dependent upon such apparatus for its excitation. Each machine would have
a slip-ring rotor and the amount and direction of the load would be controlled
by adjustment of the amount of resistance in the rotor circuits.
366. Position of shaft in frequency changers (horizontal or ver-
tical). While frequency changers are usually built with horizontal shafts,
the vertical type offers the advantage in large sets that an economy in floor
space is effected. The construction may also permit of reduced friction
losses.
367. Number of bearings in frequency changers. Where floor space
is restricted, setswith only two bearings are occasionally employed. Three-
bearing designs are, however, to be preferred. They afford better oppor-
tunity for circulation of air through the machine, since the shaft may be
smaller. Such designs also provide for more ready access to all parts.
368. Pairs of rotary converters as frequency changers. It has
been proposed to accomplish frequency transformation by the employ-
ment of two rotary converters arranged with their alternating-current ends
connected to the circuits of the two frequencies and with the commutators
in parallel. This plan of transforming from alternating electricity of one
frequency into continuous electricity and then into alternating electricity
of another frequency avoids the difficulties of speed inflexibility of synchron-
ous motor generators while retaining their desirable feature as regards
power-factor control.
369. Literature relating to frequency changers is rather meagre.
The most important contributions are: J. B. Taylor's paper entitled,
"Some Features Affecting the Parallel Operation of Synchronous Motor-
generator Sets," Proc. A. I. E. E., Vol. XXV (1906), p. 113, N. E. Funk's
paper entitled, "Operation of Frequency Changers," Proc. A. I. E. E.,
July, 1913, p. 1579, and R. Townend's paper entitled "Frequency Changers,"
Journ. I. E. E. (1917), Vol. 5,5, p. 197. . , .^ „ „ ,

In the Ehctrician, Sept. 27, 1912, page 1021, is an article by C. TurnbuU,

entitled, "Frequency Changers." In the General Electric Review, August,
1913, page 609, are some notes on "Frequency-changer Sets." In th(; Gen-
eral Electric Review, Dec, 1913, page 941, is an excellent article by Gordon
Harris andL. B. Bonnett entitled, " Frequency Changers," which covers the
main considerations thoroughly. See also 'Parallel Operation of Frequency
'

Changers," by G. H. Rettew at p. 836 oi Gen. Elec. Review for August, 1915.

BIBLIOORAPH7
870. Selected lists of reference literature concerning the .subjects
treated in Sec. 7, will be found in Par. 16, 43, HI, 113, 117, 129, 147, 209,
242, 313(a), 317, 331, 343 and 369.
The following books will be found of advantage:
—
Steinmetz, C. p. "Alternating Current Phenomena." McGraw-Hill
Book Company, Inc., New York, 1908.
—
Arnold, E. "Die Wechselstromtechnik." Julius Springer, Beriin, 1910.
—
.

Jackson, D. C. and J. P. "Alternating Currents and Alternating-cur-

rent Machinery." The Macmillan Co., New York, 1913.
—
Grat, a. "Electrical Machine Design." McGraw-Hill Book Company,
Inc., New York, 1913.

594
 A. C. GENERATORS AND MOTORS ScC. 7-370

HoBART, H. M. — "Electric Motors." Whittaker and Co., London, 1910.

HoBABT, H. M. — "Design of Polyphase Generators and Motors." Mc-
Graw-Hill Book Company, New York, 1913.
— "The Magnetic Inc.,
Kabapetoff, V. Circuit." McGraw-Hill Book Com-
New York, 1911.
Blowdel, a. — "Synchronous Motors and Converters." McGraw-Hill
pany, Inc.,

Book Company, New York, 1903.

McAllisteb, a. — "Alternating-current Motors." McGraw-Hill Book
Inc.,
S.
Company, New
PuNGA, F. — "Single-phase Commutator Motors." Whittaker and Co.,
Inc., York, 1909.

London, 1906.
Niethammeb, — " Wechselstrom-Kommutatormotoren; " Zurich, 1905.
Hawkins and Wallace. — "The Dynamo." Macmillan Company, New
F.

Creedy, — "Single-phase Commutator Motors." D. Van Nostrand Co.,

York, 1909.
F.
New York, 1913.
Fynn, V. A. — "Classification Alternating-current Motors." Electrician
of
Printing & Publishing Co., Ltd., London, 1909.
Walker, Miles. — "Specfications and Design Dynamo Electric Machi-
of
nery." Longmans & Co. 1915.
Still, Alfred. — "Principles Electrical Design."
of McGraw-Hill Book
Co., 1916.
L.^WRENCE, R. R.
— ' Alternating Current Machinery."
'Principles of
McGraw-Hill Book Co., 1916.
Lamme, B. G. — ' Engineering Papers." Westinghouse Elec. and
'Electrical
Mfg. Co., 1919.

606
>
 SECTION 8

DIRECT-CURRENT GENERATORS
AND MOTORS
BY ALEXANDER GRAY, M. S., Whit. Sch.
Prof of Electrical Engineering, Cornell University, Member
.

American Institute of Electrical Engineers, Author of

" Principles and Practice of Electrical Engineering"
and of " Electrical Machine Design"

CONTENTS
(.Numbers refer to Paragraphs)

"eneral Principles 1 Weights and Costs 177

lassification of Types 10 Standard Constant-potential
rmature Windings 13 Generators 181
rmature Reactions 30 Three-wire Constant-potential
ommutation 36 Generators 190
rmature Design. 59 Standard Constant-potential
.eld Design 73 Motors 200
eneral Design and Construc- Standard Constant-current
tion 90 Generators 206
isulation 103 Thury System 216
X)ling and Ventilation 116 Motor-generator Sets 222
95ciency and Losses 133 Homopolar Machines 226
snerator Characteristics and Operation of Generators and
Regulation 144 Motors. 236
otor Characteristics and Testing 257
Regulation 157 Bibliography 277

.910tOfr

687
 SECTION 8

DIRECT -CURRENT GENERATORS AND MOTORS

OENE&AL PBINCIPLES
1. Lines of magnetic flux. A magnetic field may be represented by-
continuous lines, called lines of flux, whose direction at any point in the field
is that of the force acting on a north pole placed at the given point; they
therefore emerge from a north pole and enter a south pole (Sec. 2).
2. Electromagnetic induction. When the total magnetic flux thread-
ing a coil undergoes a change, an electromotive force (e.m.f.) is generated
or induced in the coil. This e.m.f. is proportional to the time rate of change
of flux. One volt is generated in a coil of one turn when the rate of change
of flux threading the coil is 10' lines per sec.
5. Magnitude of induced e.m.f. In Fig. 1,N and S are respectively the
north and south poles of a magnet and ^ represents the direction of the
magnetic flux passing from the north to the south
pole. When coil A is moved from position 1 where
the flux threading the coil is <t>,to position 2 where
the flux threading the coil is zero, in t sec, the average
e.m.f. generated in the coil is £= (i^/t) 10~* volts.

4. The direction of the generated e.m.f. may be

found by Fleming's right-hand rule, which states
that if the thumb, forefinger, and middle finger of the
right hand be placed at right angles to one another
so as to represent three coordinates in space, with the
thumb pointed in the direction of motion of the con-
ductor relative to the field, and the forefinger in the
direction of the lines of flux, then the middle finger
will point in the direction of the induced e.m.f.
(Sec. 2). The direction of the e.m.f., found by
Fleming's rule, is shown by the arrow in Fig. 1,
and it may be seen (Sec. 2), that the magnetic
effect of the current produced tends to prevent
the flux threading the coil from decreasing or, as
•'
stated by Lenz's law (Sec. 2), the generated e.m.f.
Fig. 1. —
Direction of always tends to send an electric current in such a
generated e.m.f. direction as to oppose the change of flux which pro-
duces it.

Force on a conductor in a magnetic field. A conductor L cm.

6.
long, carrying a current of / amp. perpendicular to a magnetic field of (B
lines per sq. cm., is acted on by a force of (BL//10 dynes in a direction found
by Fleming's left-hand rule, which states thatif the thumb, the forefinger
and the middle finger of the left hand be placed at right angles to one another
so as to represent three coordinates in space, with the thumb pointed in the
direction of the force on the conductor and the forefinger in the direction of
the lines of flux, then the middle finger will point in the direction of the
current.
6. Identity of generator and motor structure. Diagrani A, Fig. 2,
shows a generator under load; the direction of rotation is determined by the
prime mover, while the direction of the current in the conductors may be
found by the right-hand rule (Par. 4). A force is exerted on the con-
ductors, inasmuch as they are carrying current in a magnetic field; the
direction of this force is found by the left-hand rule (Par. 6) and is opposed tojj

598 'I
I
D. C. GENERATORS AND MOTORS SeC. 8-7

the direction of motion of the armature. The

driving force must be large enough to over-
come this retarding force and also to overcome
the friction of the machine.
Diagram B shows the same machine acting
as a motor. In this case the direction of the m - o««r»««r
current is determined by the polarity of the iV ||®^ |e||s
connected line, while the direction of motion
is that of the force on the conductors and may
be found by the left-hand rule (Par. 6). Since
the motor armature revolves in a magnetic
field, an e.m.f. will be generated in the conduct-
ors. The direction of this e.m.f., found by
_ A
the right-hand rule, is opposed to the direc- Right hand rule
tion of the current. The applied e.m.f. must ^^
be large enough to overcome this counter „ „, .,'".„
e.m.f. and also to send the current through ^°"''°8" Lto-rfnox
Middle Finga- e.m.f.
the resistance of the armature.
7. Armature circuits. Armature con-
ductors must be connected together in such .

a way that a desired resultant e.m.f. may be

maintained between two terminals connected
to the external circuit. Fig. 3 represents a
type of connection known as the Gramme
ring winding in which all the conductors are o. j,„t„, a o i r
1 1

connected in series. Each conductor is marked iV 1® a k all c>1

with a dot (within the circle) when the direc-

tion of the e.m.f. is toward the reader and by
a cross (within the circle) when the direction ia
from the reader. Between the lowermost and
the uppermost conductors, represented as cross-
ing the neutral axis, there are two conduct- -S
ive paths through the winding, but inasmuch Left hand rule
as the e.m.fs. generated in these paths are Thumb Fane on Condaotw
equal and opposite, no current can flow until Fort Finger Lmeiofnoz
the brushes B are placed on the commutator C. Middle Finger Ciursat
By the latter means the equal and opposite Fiq. 2.— Direction of current
e^m.fs. of the two halves of the armature wind- j^ generator and motor,
ing are connected in parallel with respect to
the external circuit. The commutator consists of a number of copper blocks
connected to various points of the winding, but insulated from one another.
8. Commutator and brushes. As the armature in Fig. 3 revolves, the
coil ]
passes from M
one side of the neu-
tral line to the other,
i
'^'^
y y-~L,''A ^^^ ^^^ direction of
\L-V— —
4 r ^V- \
tlie current in this
coil is shown at three
successive instants in
diagrams A, B and C.
jg-^^^ As the armature
•
moves from A to C
N I -.i_n ^
l®=rtfl I ftJ-^^l I S '-^
\—T I — » [
r~~~iis.B
/ ^-^
*'i<i *^6
changes contact from
brush
—J-.
1

,/ ^m segment 2 to seg-
// I ^^ ment 1, the current
,

^ _^^
^'"^^
in coil M automat-
is
ically reversed. For
a short period the
I
"^"^ f T'^^y'^"^
brush is in contact
a;„„i„_ „;„„! ^-"^IIZIZ^T-C. with both segments,
r^J^^l gramme ring
r^entrant
'"naing
^^ T ^
-TT^-'^ and during this inter-
^^l ^^^ J^
-^ ^j^^^
circuited; it should
•
Stages in
commutation therefore be in such a
Fio. 3. position that no
699
Sec. 8-9 D. C. GENERATORS AND MOTORS

e.m.f. is being generated in it, that is, it should be midway between the polei
or in the neutral position.
Field excitation. The m.m.f. necessary to establish the flux in th(
9,
magnetic circuit is obtained by means of field coils which are wound upon th(
poles of the machine. The exciting current for the field coils may be suppliec
m various ways. When a generator supplies its own exciting current it ia saic
to be self -excited ; when the exciting current is supplied from some externa
source, such as an exciter, the machine is said to be separately excited
The different connections used are shown diagrammatically in Fig. 4.
Diagram A shows a separately excited machine. Diagram B shows i

shunt machine, in which the field coils form a shunt across the armatun
terminals and have many turns of small wire carrying a current which is pro
portional to the terminal voltage of the machine. This field current seldon
exceeds 5 per cent, of the armature current under full-load conditions. Dia _

gram C shows a series machine, in which the field coils are in series with th(

C- Series ZJ-Oompound
E - Compound
Short Shunt
Long Shunt
Fia. 4. —Methods of excitation.

armature and have fewer turns than the coils of a shunt winding, but emploj
a larger size of wire because they carry the whole or a fixed proportion of th(
total current. Diagram D shows a compound machine in which there i
connected to the terminals a shunt winding which carries an exciting curren
proportional to the terminal voltage; and also a series winding which carriei
a current proportional to the armature current. This method of connectioi
is known as the "long shunt." Diagram E shows a compound machin(
connected in another manner. The connection in this case is known as thi
"short shunt" ; that is, the shunt coil is connected to the terminals of th(
armature. Small machines using permanent magnets for field poles an
called magnetos.
CLASSIFICATION OF TYPES
10. Classification according to the number of poles, as follows:
(a) Bipolar machines (Fig. 4) have only two poles.
(b) Multipolar machines (Fig. 46) have more than two poles; th«
number of polos is always a multiple of two.
(c) Homopolar niachines (Fig. 89) have two poles, but the conductors
always cut lines of unidirectional flux. The resultmg e.m.f. is continuous ir
one direction and therefore no commutator is required.
11. Classificationaccording to the method of drive, as follows:
(a) Belted-type motors and generators are self-contained. This typ<
of machine includes bearings, shaft extended for a pulley and a shdini:
base with belt-tightening doviro. An outboard bearing is usually proviucc
with machines of larger capacity than 200 kw. at 600 rev. per min.
(b) The engine-type generator has its armature mounted on a continua-
tion of the crank shaft of the engine, and slow-speed units are generallj
 D. C. GENERATORS AND MOTORS Sec. 8-12

supplied without base, bearings, or shaft, these being furnished by the engine
builder.
(c) The direct-connected turbo-generator has its armature shaft
coupled directly to that of a steam turbine. In this type the construction of
the generator is special on account of the high speed.
(d) The geared turbo-generator has its armature shaft connected to
the shaft of a steam turbine through a reduction gear, so that a generator of
moderate speed and simple construction may be used.
(e) The water-wheel type generator has its armature shaft coupled
directly to that of a water wheel. Such a generator may be of either the
_

horizontal or the vertical type and is generally supplied complete with base,
bearings, shaft and coupling.
(f) The back-geared type motor embraces a speed-reduction gear as an
element of the machine. The slow-speed shaft is supported in bearings
attached to the frame.
12. Classification according to special features of construction, as
follows:
(a) Interpole machines (Fig. 24) have small auxiliary poles which carry
series windings and improve commutation.
(b) Compensated machines (Fig. 27) have series windings on the pole
faces to neutralize armature reaction. Such machines may also have inter-
poles.
(c) Miscellaneous. Under this class may be included mill motors,
used in rolling mills; flame-proof motors for mine service; variable-speed
generators, for train lighting; etc. (Par. 183 to 216).
ARMATURE WINDINGS
13. The Gramme ring winding is almost obsolete; examples of it
are shown in Figs. 3, 5, and 6 merely to present clearly the meaning of the
terms used in describing the various types of winding.
14. A re-entrant winding closes or re-enters on itself. A singly re-
entrant winding closes on itself only after including all of the conductors;
see Figs. 3 and 6. A doubly re-entrant winding closes on itself after
including half of the conductors; see Fig. 5.

Fio. 5. —'Doubly re-entrant duplex Fig. 6.- -Singly re-entrant duplex

winding. winding.

16. A simplex winding has only two paths through the armature from
jach brush; see Fig. 3. A
duplex winding has twice as many, or four paths,
through the armature from each brush. In this winding each brush should
iover at least two commutator segments; see Figs. 5 and 6. Although it is
jossible to use multiplex and multiply re-entrant windings, they are
tddom found in modern machines. Even duplex windings are rarely used
)xcept for machines of very large current capacity.'
16. The drum winding has coils shaped as shown in Fig. 7. At any
nstant, two sides of each coil are under adjacent poles. Since the number of
^ionductors in each coil miist be a multiple of two, the total number of conduct-
>r« must be even. A winding made with coils of this shape must lie in two
ayers and is called a double-layer winding.
17. Representation of drum windings. Fig. 8 shows a double-layer
601
Sec. 8-18 D. C. GENERATORS AND MOTORS
drum winding corresponding to the Gramme ring winding in Fig. 3. It has
the same number of conductors and the same number of paths through the
armature, but only half the number of commutator segments. Conductors
in the upper layer are represented by full lines and those in the bottom layer
by dotted lines. The radial lines represent face conductors; the connecting
lines on the inside represent the connections
at the commutator end, and those on the out-
side represent the connections at the opposite
end. For convenience the brushes are shown
inside the commutator.

Fig. 7.— Coil group for double Fig. 8.- -Simplex singly re-entrant
drum winding.
layer winding with two turns per
coil and eight conductors per slot.

18. Multiple winding. Fig. 9 shows a six-pole drum winding with six
paths in parallel between the positive and the negative terminals. The three
positive brushes are connected together outside of the machine by a copper
ring T+, and the three negative brushes are connected by a similar ring T _.
This winding is of the multiple type, that is, the number of armature circuita
between terminals is a multiple of the number of poles.

Fig. 9. . Fia. 10.

Figs. 9 and 10. —
Simplex, singly re-entrant, full-pitch multiple
with equalizers.
.
wmding

19. Squalizers. Fig. 10 shows a multiple-wound armature which is not

central with the poles. The flux density in the air gaps A is greater than that
in the air gaps B, and the voltage generated in a circuit under poles A
is

greater than that in a circuit under poles B, so that the generated voUiiEC
between c and d is greater than that between / and g\ hence a Circulating
current will flow through the winding and brushes, causing sparking, addi-
tional loss and additional heating. This circulating current may be mim-
careful centering during erection, while the sparking may
be pre-
niized by
602
 D. <7. GENERATORS AND MOTORS Sec. 8-20

vented by providing a low-resistance path of copper between c and /, and also

one between d and g (shown outside of the brush circle), so that the circulating
current will flow through this path rather than through the brushes. These
equalizer connections, as the low-resistance paths are called, do not eliminate
the circulating current, but merely prevent it from passing through the
brushes.
An armature is completely equalized by connecting together all commu-
tator segments which should be at the same potential. However, it is usual to
provide about 30 per cent, of the maximum number of equalizer connections
and make their cross-section equal to half the cross-section of the armature
conductor. The equalizer connections shown in Fig. 9 are located behind
the commutator. In this position it is difficult to reach them for repair;
consequently it is usual to connect the equalizers to the windings at the rear
end of the machine.
20. The number of slots and the number of conamutator seg-
ments, in amultiple-wound armature supplied with equalizers, should, for
a simplex winding, be a multiple of p/2, the number of pairs of poles.
21. Pitch of winding. The winding shown in Fig. 9 is a full-pitch
winding or one in which the width of the coil exactly equals the pole pitch.
Fig. 1 1 shows part of a short-pitch winding or one in which the width of the
coil is less than the pole pitch.

Fia. 11. —Simplex singly re-entrant Fig. 12. —Two-circuit

winding.
progressive
short-pitch multiple winding.

22. Two-circuit or series winding. Fig. 12 shows a six-pole drum

winding w ith only two paths between the positive and the negative terminals.
Only two sets of brushes are required and each brush short-circuits p/2 coils
in series. Since the points a, b, and c are all at the same potential, and also
the points d, e, and/, it is possible to place brushes on the commutator at each
' of these points, so that the current may be collected from three sets of
brushes instead of from one, and a shorter commutator may be used. A
machine with a two-circuit winding has generally as many brush sets as there
are poles.
23. The number of commutator segments in a two-circuit winding
must not be a multiple of the number of pairs of poles, for otherwise the
winding, after it had passed once around the armature, would close upon
itself. To be singly re-entrant, the winding must progress or retrogress by
one commutator segment each time it passes around the armature, the con-
dition for which is that the number of commutator segments must equal
i{kp/2)±l, where k is a whole number and p is the number of poles.
24. Application of two-circuit winding. Each circuit of a two-
circuit winding is made up of conductors passing under all the poles, so that
no equalizers are required. Because of this, and also because only two sets
" 603 '•
Sec. 8-25 D. C. GENERATORS AND MOTORS
of brushes are required, this type of winding is well suited for direct-current
railway motors, inasmuch as the two sets of brushes for a four-pole motor
are placed 90 deg. apart so that they may easily be inspected from the car.
25. Lap windings and wave windings. A multiple-wound armature
is sometimes said to have a lap winding and an armature with a two-circuit
winding is said to have a wave winding.
26. Dead coils. There are generally more coils than there are slots, and
each coil may have more than one turn. A coil in this case is defined as the
shortest winding element between two commutator segments. It ia
not always possible to put a proper two-circuit winding into a given
armature. A 110-volt, four-pole machine, with forty-nine slots, forty-nine
coils, and two conductors per slot, may have a two-circuit winding because
it fulfills the condition that 49 = (24 p/2)-f-l; when wound for 220 volts,
however, four conductors per slot are required, and the number of coils is
98= (49 p/2) +0, which will not give a two-circuit winding. In such a case,
one coil, called a dead coil, is not connected into the winding, its two ends
being taped so as to completely insulate the coil. The machine, there-
fore, may have a two-circuit winding with ninety-seven active coila and
ninety-seven commutator segments.
27. Turbo-generator windings. In turbo-generators the conductors
are long and move at high speed, so that the voltage between adjacent com-
mutator segments is often higher than desirable. For such machines it has
been proposed to use the type of winding shown in Fig. 13, the voltage
between adjacent commutator segments being that generated in one con-
ductor. To keep the inductance of the return conductors low, it is desirable
to group together return conductors in which the currents at any instant are
in opposite directions.

Fia. 13. —turn

Winding with
coil.
half- Fig. 14. —
Connection of equalizer
between parallel windings.

28. Equalizer connections for turbo-generator windings. The

normal multiple-circuit doubly re-entrant duplex or multiplex windings
can only be used to their full advantage when the voltage between
the segments belonging to the different parallel windings is equally dis-
tributed, that is to say, the potential between segments 1 and 2 should
be exactly half of the potential between segments 1 and 3; but without
special means of bringing about this condition it is rather dangerous to use
these windings. It may happen that the potential is very unevenly distrib-
uted between the segments, and this gives rise to very great equalizing losses
over the brushes. The winding shown in Fig. 14 is a multiple-circuit doubly
re-entrant duplex winding; the thin lines in the diagram indicate one of the
parallel windings, the thick the other. The thin lines at the bottom of the
diagram indicate the normal equalizer connections for the winding shown in
thin lines, and the thick lines at the top indicate the normal equalizer con-
nections for the winding shown in thick lines. The corresponding equalizer
rings of the two parallel windings are connected through the equalizers indi-
cated on the left of the diagram, and by means of these connections equal
604
 D. C. GENERATORS AND MOTORS Sec. 8-29

division of potential between adjacent segments is ensured. In the diagram,

the point which should be of the same potential as segment 3 is shown con-
nected through two equalizer rings and the connection o. The potential
of point e lies midway between the potential of segments 2 and 4, the poten-
tial of segment 3 will therefore also be midway between 2 and 4. The
complete equalizing connection is denoted by the letters a, b, o, c, d, e.
This winding ia especially useful for turbo-machines.
29. Shop instructions to the winding department are generally
given in the following form: For a winding such as that in Fig. 9, slot pitch
1-5, commutator pitch 1-2; which means that the two sides of the first coil
shall be put in slots 1 and 5 and the commutator leads of that coil shall be
connected to segments 1 and 2, where the position of segment 1 relative to
that of slot 1 is fixed by the shape of the end of the coil. For a winding such
as that in Fig. 12, slot pitch 1-5, and commutator pitch 1-9.*
ARMATURE REACTIONS
30. Cross-magnetizing effect. Diagram A, Fig. 15, represents the
magnetic field produced in the air-gap of a two-pole machine by the m.m.f.

A
Main Field Armature Field Load Coudltlona
Fig. 15. — Flux distribution.

of the main exciting coils and B represents the magnetic field produced by
the m.m.f. of the armature acting alone. If each of the Z armature con-
ductors carries /e amperes, then the m.m.f. between a and h, due to the
armature, is equal to ZIc/p ampere-turns, and that between c and d is equal
to \j/ZIc/p ampere-turns, where is the ratio of pole arc to pole pitch.
i/- As-
suming that all reluctance is in the ^^
air-gap, half of the m.m.f. between c
and d acts across the path ce and the
other half across fd, so that the cross-
magnetizing effect at each pole tip is
i'ZIe
—z
2p
— (ampere-turns) (1)

for any number of poles.

31. Field distortion. Diagram C
(Fig. 15) shows. the resultant magnetic &®9
field when both armature and main ex-
citing m.m.fs. exist together; the flux
density is increased at pole tips d and ii^I,
g and is decreased at tips c and h.
Flux reduction due to cross-
32.
magnetization. Fig. 16 shows part
I

I
of a large machine with -p poles.
Curve D shows the flux distribution in
Fig. 16. Flux distribution.—
[the air-gap due to the main exciting m.m.f. acting alone, flux density being
fjriotted vertically. Curve G shows the distribution of the armature m.m.f.
rand curve F shows the resultant flux distribution when both the armature
•For further information regarding windings see: Arnold, "Die Gleich-
tstrommaschine," Vol. I and II; S. P. Thompson, "Dynamo-electric Machin-
^fPf'" Vol. I; Hobart and Ellis "Armature Construction;" D. H. Braymer,
\
Armature Winding and Motor Repair," McGraw-Hill Book Co.
605
Sec. 8-33 D. C. GENERATORS AND MOTORS
and the main exciting m.m.fs. exist together. Since the armature teeth are
saturated at normal flux densities, the increase in flux density at / is less than
the decrease at e, so that the total flux per pole is diminished by the cross-
magnetizing effect of the armature.
33. Demagnetizing effect. Fig. 17 shows the magnetic field produced
by the m.m.f. of the armature when the brushes are shifted through an angle

Fig. 17. Fig. 18.

Figs. 17 —
and 18. Demagnetizing and cross magnetizing effect.
e so as to improve commutation (Par. 47). The armature field is no longer
at right angles to the main field, but may be considered as the resultant of
two components, one in the direction OY, called the cross-magnetizing com-
ponent, the effect ofwhich is discussed in the last paragraph, and the other
in the direction OX, which is called the demagnetizing component because
opposed to the main field. Fig. 18 shows the armature divided
it is directly
so as to produce these two components, and it may be seen that the demag-
netizing ampere-turns per pair of poles are
(ampere-turns)
\ p ; ^ 180
(2)

where 2fl/180 is generally

about 0.2. Therefore the
demagnetizing ampere-turns
per pole are

0.1 f —— ^ (ampere-turns) (3)

34. No-load and full-

load saturation curves.
Curve 1, Fig. 19, shows the
no-load saturation curve of.i
a direct-current generator. ;
"

When load is put on the

full
generator there is a decrease
in flux and therefore a drop
in voltage ab due to the arma-
ture cross-magnetizing effect
(Par. 32). A further voltage
drop due to the armature
19 iiyin3 demagnetizing effect is
4 6 8 10 li itxiu
2 counter-balanced by an in-
Ampere Turns per Pole crease in excitation of bc =
y iQ 0.1 (Z/c)/p; also a portion
cd of the generated e.m.f. is
required in overcoming the internal resistance of the machine. With an ex-
citation of 10,000 ampere-turns, the voltage at no load and normal speed
equals 240 volts. At full load, with the same excitation, the terminal
voltage equals 196 volts. In order that the full-load voltage may be the
same as that at no load, the number of ampere-turns per pole which must
be supplied by the series field is (13,400-10,000) =3,400 ampere-turns.
 D. C. GENERATORS AND MOTORS Sec. 8-35

S6. Relative
strength of main ex-
citing and armature
magneto - motive
forces. Inspection of
Fig. 16 will show that,
if the armature current
have such a value that
the cross ampere-turns
at the pole tips, namely
^ZIc/2p, becomes
equal to the exciting
ampere-turns for tooth
and gap, then the flux
density will be zero un-
der the pole tip toward
which the brushes have
been shifted (Par. 31).
The quantity ZIc/2p is
the number of arma-
ture ampere-turns per
pole. The exciting
ampere-turns per pole
for tooth and gap are
seldom less than 1.2
times the armature
ampere-turns per pole
for a machine which
must operate without
sparking up to 25 per
cent, overload, and
which has a series field
to counteract the de-
magnetizing effect of
armature reaction. For
a machine such as a
shunt motor, which has
no series field, the ex-
citing ampere-turns for
gap and tooth should
not be less than 1.5
times the armature
ampere-turns per pole.

COMMUTATION
S6. Resistance com-
mutation. Fig. 20
shows part of a ma-
chine with a full-pitch
double-layer multiple
winding, two conduct-
ors per slot, and with
coils M
undergoing
commutation. The
current in coils
reversed as the
M is
arma-
ture moves
and the
brushes change from
segments 1 and 5 to
segments 2 and 6. If
the brush contact re-
sistance is large com-
pared with the resist-
ance and self induction
of coil M then, in dia-
gram B, the current 21 e Fig. 20. — Stages in commutation.
607
 1

Sec. 8-37 D. C. GENERATORS AND MOTORS

divides into two parts which are proportional to the areas of contact between
the brush and segments 5 and 6 respectively, and the current density is uni-
form across the brush surface. In diagram C the two contact areas are equal;
there is no tendency for current to pass round coil M, and the current density
is again uniform across the brush surface. In diagram D the contact area
between the brush and segment 5 is small while that between the brush and
segment 6 is large; the larger part of the current therefore enters at segment
6 and the current in coil M is reversed, while the current 2Ie again divides
into two parts which are proportional to the contact areas between the brush
and the two commutator segments, and the current density is still uniform
across the brush surface.
37. Perfect commutation is defined as such a change of current in the
coil being commutated that the current density over the brush contact
surface is constant and uniform.
38. The brush contact resistance depends on the brush material andt
for carbon brushes, it decreases with increase of current density as shown
in Fig. 21. The contact resistance with current flowing from commuta-
tor to brush is somewhat higher than with current flowing from brush to
commutator.
39. Change of contact resistance with temperature. If the current
density in a brush contact be suddenly increased, the contact resistance
does not immediately decrease to
1.0 the value given in Fig. 21, but
gradually decreases as the temper-
ature of the contact increases, and
reaches a constant value after
about 20 min. This explains why
a machine will carry a considerable
overload for a short time without
sparking, whereas, if the overload
be maintained, the machine will
begin to spark as the brush tem-
perature increases and the contact
resistance decreases.
40. Current density in tha |

brushes. For sparkless com-

mutation, (1) the current density i

in the brush tip must not b^ i

come infinite, and (2) the aver-

age amount of energy expended!
at the brush contact must be lim-
ited. For machines required tai
operate without sparking up to 25 per cent, overload, a rate of energy dissi-
Fiation of 35 watts per sq. in. (5.5 watts per sq. cm.) may be allowed at
ull-load, so that the permissible current density depends upon the voltaeO
drop across the brush contact. The better the commutation, the more nearly!
uniform is the current density in the brush contact, and the higher thtj
average density which may be allowed.
41. Current density in the brush tip. The efTect of coil resistanq
may generally be neglected, but that of self-induction must be considere
The e.m.f. of self-induction and mutual induction of coil M (Fig. 20) oppo^
the change of current in that coil, so that, in diagram C, at the end of nalfj
the period of commutation, the current in the coils M has not become zej
When it does become zero, some time later, and the currents entering r
ments 5 and 6 are equal, the contact area with segment 5 is smaller than
segment 6 and the current density in the brush tip .S is greater than norr
It may be shown theoretically that the tip density at the end of commutati||
becomes infinite* when RTc/(L + M) is less than unity,
where R is the resistance of the brush contact in ohms,
Tc is the time of commutation in seconds,
L is the coefficient of self-induction in henrys of one coil M,
and M is the coefficient of mutual induction in henrys between coil ^^
and coils Mi and Mi.

• Reid, on " Direct-current Commutation," Trans. A. I. E E., Vol. XXiMj

60S
 D. C. GENERATORS AND MOTORS Sec. 8-42

42. Copper leaf brushes can carry 150 amp. per sq. in. (23 amp. per
sq. cm.) with a drop of 0.3 volt at the contact.
Carbon brushes can carry 35 watts per sq. in. (5.5 watts per sq. cm.).
Par. 40, for example 35 amp. per sq. in. (5.5 amp. per sq. cm.) with a drop
of 1.0 volts at the contact.
43. Average reactance voltage. The criterion for sparkless commu-
tation is, then (Par. 41), that RTc/i.L + M) shall be greater than unity, or
that
2IcR>^^{L + M) (4)

where 21 e the current entering the brush (Fig. 20). The latter quantity is
is
called the average reactance voltage and the former is the voltage drop across
one brush contact. It will
be found that the higher
M
the contact resistance and
the lower the reactance
voltage, the better is the
commutation.
Fig. 22 shows the mag-
netic field encircling the
short-circuited coils of a
full-pitch multiple wind-
ing. The reluctance of the
magnetic path may readily
be calculated from which
the value of the flux per
unit current and L+M,
the coefficient of self and
mutual induction, are ob- Fig. 22.
tained. Deep slots de-
crease the reluctance of the magnetic path (for the same cross-section of
conductor) and increase the reactance voltage, therefore they should be
avoided if possible.
44. Effect of type of winding on reactance voltage. In the short-
pitch winding shown in Fig. 11, the conductors undergoing commutation
lie in different slots, and the reluctance of the magnetic path around the
coils is_ greater, and the coefficient of mutual induction smaller, than in a
r tuU-pitch winding. The use of a short-pitch winding therefore lowers
the reactance voltage and improves commutation, but, as shown in Fig. 11,
t it also reduces the effective interpolar space by the angle d.
In the two-circuit winding with one set of positive and one set of
negative brushes, shown in Fig. 12, each brush short-circuits p/2 coils in
!• series, so that the reactance voltage is p/2 times that of a multiple winding.
1 When, however, the number of brush sets is the same as the number of poles,
:» there is a short commutation path around one coil and the commutation is
improved.
46. Reactance voltage formula. Approximate results may be obtained
by use of the following formula for the average reactance voltage. *

Er = kS{T.x>.ra.)IcLeTi T^^VO"' (volts) (5)

Vpaths/
where S is the number of commutator segments,
r.p.m. is the speed of the machine in rev. per min.,
Ic is the current in each armature conductor,
Lc is the frame length in inches (see Fig. 38),
T is the number of turns per coil between segments,
(poles \
= 1 for mxiltiple windings and p/2 for two-circuit windings,
paths/
A; = 1.6 for two-circuit windings and for full-pitch multiple windings,
and
A = 0.93 for short-pitch multiple windings.
Deep slots increase the reactance voltage above this value.

•Gray. "Electrical Machine Design," p. 84.

39 609
 Sec. 8-46 D. C. GENERATORS AND MOTORS
46. Eflect of brush arc. An increase in the brush arc has no eSect on
the reactance voltage because, while it increases the number of coils in series
at short circuit, it decreases the time of commutation in the same ratio, and
the reactance voltage remains unchanged. On the other hand, a wide arc
may cause sparking by starting commutation in the coils before they are in
a reversing field, or by keeping them short-circuited until they are in too
strong a field. To minimize this trouble make the proportions such that,
pole pitch\ /commutator diameter-^
brush arc <(- )^ \ armature diameter (6)
12
where all dimensions are in inches. Furthermore, the brush should not
cover more than three commutator segments except in machines of low
reactance voltage, otherwise there will be large circulating currents in the
brush face.
47. Shifting of brushes. To improve commutation, the brushes are
shifted from the neutral position, so that the short-circuited coils are in a
magnetic field and an e.m.f. {E,) is generated in them which opposes the
reactance voltage and improves commutation. As the current in the machine
increases, the reactance voltage increases with it. To have perfect commu-
tation at all loads, the voltage E, must maintain an unvarying ratio to the
current. This is only possible when the distance by which the brushes are
moved from the neutral position increases as the cur-
rent increases. Modern machines must operate from
no load to 25 per cent, overload without sparking and
.without shifting of the brushes during operation. In
these machines the brushes are permanently shifted
(at the time of erection) from the neutral position
until the voltage E, is so large that sparking takes
place at no load.
48. Number of slots per pole. Fig. 23 shows
three of the stages in the commutation of a machine
with six coil sides i>er slot. The commutator segments
are evenly spaced while the coils, being in slots, are
not. Between the instant when the brush breaks con-
tact with coil A, and the instant it breaks with coil C,
the slot has moved through a distance x, so that if the
magnetic field in which the coils are commutated is
suitable for coil yl, it is too strong for coil C, and the
latter will therefore be badly commutated, every third
commutator segment being blackened. The distance
X is equal to the slot pitch minus the width of one
commutator segment. To minimize this trouble, a
machine should have more than twelve slots per pole.
Large machines have generally more than fourteen
slots per pole.
49. Limits of reactance voltage. Experience
shows that when the following conditions are fulfilled,
Fig. 23. —
Commu-
tation with several
namely:
(1) Number of slots per pole is greater than twelve,;
coils per slot. (2) Brush arc is less than one-twelfth of the pole
pitch measured at the commutator surface,
(3) Pole arc is less than seven-tenths of the pole pitch, and
(4) Ampere-turns for air-gap and teeth are greater than 1.2 to 1.5 times
the armature ampere-turns per pole (Par. 36): then the reactance voltage'
calculated by Eq. 5 (Par. 46) should be
(1) Less than seven-tenths of the voltage drop per pair of brushes, with
brushes in neutral position, and
(2) Less than the full voltage drop per pair of brushes, with the brushes
shifted to improve commutation. _
,

A machine with a two-circuit winding will commutate about 20 per centi

better than would be indicated by the value of reactance voltage obtaineo
from Eq. 5 (Par. 46), while the commutation of a machine with a short'
pitch winding will be about 30 per cent, wor.se than indicated, because of tht
, reduction of the effective interpolar space (Par. 44).
60. Shunt, compound and series machines. Due to armature reactiow
the flux at the pole tip toward which the brushes are shifted decreases witt
 D. C. GENERATORS AND MOTORS Sec. 8-51

increase of armature current (Par. 31). This decrease is kept within reason-
able limits by the use of a strong exciting field (Par. 36) and is less in a com-
pound machine than in a shunt machine operating on constant excitation.
In the series machine the main exciting m.m.f. and the armature m.m.f.
increase together, and the flux at the commutating pole tip may increase or
decrease, depending on the relative strength
and armature.
of field
61. Interpoles. An interpole genera-
tor shown diagrammatically in Fig. 24,
is
where n and s are auxiliary poles which
have a series winding so connected that their
strength increases with the armature cur-
rent. To improve commutation in a non-
interpole generator, the brushes are shifte'd
forward in the direction of motion, so that
B+ would come under the tip of the pole N
and B_ under the tip of the S^pole. In the
interpole machine the auxiliary pole n is
placed opposite the brush B+ and the auxili-
ary pole s opposite the brush B_.
62. Interpole excitation. The inter-
pole must have a m.m.f. equal and opposite
to that of the cross-magnetizing effect of
Fio. 24. — Magnetic
interpole generator.
circuit of

the armature, namely, j^7<;/2p ampere-turns

per pole (Par. 30) and, in addition, a m.m.f. which can send across the gap
a flux large enough to generate in the short-circuited coil an e.m.f. equal
and opposite to the reactance voltage. In order that the interpole flux
may be always proportional to the current, the interpole magnetic circuit
must not be allowed to become saturated.
63. The efiFective interpole arc is represented by the expression Wip+2s
(see Fig. 25) and should be of such proportions that while the current in a
conductor is being commutated, the slot
^\
"V L^n>] 3 ^^
carrying that conductor is in the interpole
J _ L Tk- _C__ field.
64. The reluctance of the interpole air-
gap should vary as little as possible for differ-
Fig. 25. —
Interpole width.
ent positions of the armature, otherwise the
interpole field will be pulsating. The effect-
ive interpole arc should therefore be a
multiple of the slot pitch; it is generally made about 15 per cent, of the pole
pitch and, to minimize the interpole leakage flux, the main pole arc is not
more than about 65 per cent, of the pole pitch.
66. The axial length of the interpole in inches is given by the formula, •
-. _24 X core length in inches X amp. cond. per in.
interpole gap density in fines per sq. in.
The ampere-conductors per in. (Par. 69) seldom exceed 900, and, with an
interpole gap density of 45,000 lines per sq. in. (7,000 lines per sq. cm.),
I
the interpole circuit will not be saturated up to 50 per cent, overload; the
interpole length, therefore, need not exceed half the frame length, if there
are as many interpoles as there are main poles and if the overloads do not
exceed 50 per cent.
66. The interpole ampere-turns per pole for a newly designed machine
are usually made equal to 1.4 times the armature ampere-turns per pole
(Par. 6a)._ This is generally too large, so adjustment must be made after
jthe machine is erected.
67. Flashing over t is generally caused by a sudden change of load. Fig.
26 shows a representation of the armature cross-field in a loaded machine-
lA sudden change of load alters the value of the cross-flux, and a voltage

•Gray. "Electrical Machine Design," p. 94.

t Lamme, "Physical Limitations in Commutating Machinery," Trans.
A. I. E. E., Vol. 34, pp. 1559-1614, Aug., 1915, andLinebaugh and Burnham,
'Protection from Flashing for D. C. Apparatus," Proc. A. I. E. E., Vol. 37,
^pp. 617-628, June, 1918.

611
Sec. 8-58 D. C. GENERATORS AND MOTORS
proportional to the rate of change of flux is generated in coil a. This may
increase the voltage that already exists between adjacent segments to such a
value that arcing starts, and then the machine flashes over from brush to
brush, particularly if the commutator is dirty. Machines with badly
distorted fields and a high average voltage between commutator segments
are especially likely to flash over.
88. Compensating windings. For such service as the operation of
reversing rolling mills, the current in the motors may change suddenly from
full-load value in one direction to three times full-load value in the opposite
direction. For such machines the average voltage between adjacent
commutator segments, which is equal to the terminal voltage divided
by the number of commutator segments per pole, should not exceed

Fig. 26. Fia. 27.

Figs. 26 and 27. — Armature field with and without compensating windings.

about 15, otherwise compensating windings will be required to prevent

flashing over. The compensating winding is carried by the pole face, and
isin series with and has the same number of ampere-turns per pole as
the armature. However, the current passes in the opposite direction to
that in the armature and thus, as shown in Fig. 27, the armature field is
completely neutralized. For further discussion of the subject of commu-
tation see the references below. *

ARMATURE DESIQN
89. Output equation. The output of a machine is proportional to the
armature volume, and the output equation is
_, ,^ watts X 60.8X10' , ^ /v^
Da^Lc'= C7;5-^7^^T (cu. m.) (h)
r.p.m.XfflffXgX*
where Da is the armature diameter in inches,
Lc is the frame length in inches (Fig. 38),
(Bo is the apparent gap density in lines per sq. in.,
* is the per cent,
enclosure ( = pole arc pole -i- pitch) , and
g is the ampere-conductors per in. (== Zle/vDa)-
60. The e.m.f. equation for all types of direct-current generators is:

(-•-> («>
^=-^K"^r)(pSi)^«-'
where E is the generated voltage between terminals,
Z isthe total number of face conductors,
0a the flux per pole which crosses the air-gap and is cut by the arina-
is
.j ture conductors,
.>, r. p.m. is the armature speed in revolutions per min.
"paths" refer to the number of parallel circuits (electric) through the
armature.

"Die Gleichstrommaschine," Vol. I and II; Hawkins and

•Arnold,
Wallis, "The Dynamo," Vol. II; Baily and Cleghorne, Journal of Inst, of
Elec. Eng.; Vol. XXXVIII; Gray, "Klectrical Machine Design;" Hobart,
" Dynamo Design," Lamme, Trans. A. I. E. E., Vol. XXX, p. 2369.
 D. C. GENERATORS AND MOTORS Sec. 8-61

61. Another output equation, readily obtained from the e.m.f. equa-
tion, is given by
watts / Zla \, , ^ , V 1
(10)
r.p.m.
where (Z7o/paths), called the electric loading:, is the total number of am-
pere-conductors on the armature periphery. The larger the electric loading,
the more copper and the less iron there is in the machine. The magrnetic
loading, as the quantity (0a X poles) is termed, ia the total flux entering the
armature. The larger the magnetic loading, the more iron and the less cop-
per there is in the machine.
62. The gap density ((B,) is limited by the density at the bottom of the
teeth; the greater the diameter, the less the tooth taper, and the higher the
gap density for a given tooth density at the root. The relation between
©5 and Da is given in Fig. 28.

70 * 10'
Sec. 8-66 D. C. GENERATORS AND MOTORS
66. The armature aznpere-turns per pole seldom exceed 7,500 in
non-interpole machines. A larger number requires a long pole pitch, long
end connections, a large number of exciting ampere-turns per pole, long
poles, and a yoke of large diameter. For interpole machines, the main
field need not be so strong relatively to the armature field as in non-inter-
pole machines, and a reasonable limit for the armature ampere-turns per pole
is 10,000.
67. A simple procedure for arm.ature desigrn is given in the follow-
ing:
ZIc, the number of ampere-conductors, is obtained from Fig. 30.
q = ZIc/irDa, the number of ampere-conductors per in., is obtained
from Fig. 29.
Da, the armature diameter, is next determined.
(Bo is obtained from Fig. 28.
Lc is found by substitution in Eq. 8, Par. 69.
p, the number of poles, is so chosen that the pole pitch divided
by Lc equals 1.1 to 1.7.
4>, the flux per pole = 0.7 (pole pitch) XicXCBj, assuming the pole
enclosure =0.7.
Z, the number of armature conductors, is found from Eq. 9, Par. 60.

C B A
KlO
 D. C. GENERATORS AND MOTORS SeC. 8^71

p, poles, = 10
T, pole pitch, =18.2 in.
0, flux per pole, = 8 8 X 10«
.

Z, total face conductors, =164 =820 =820

Winding, 1-turn ser. 2-turn mult. 1-turn mult.
short pitch short pitch
<S,commutator segments, =82 =205 =410
RF, reactance voltage, =13 =3.1 =1.5
Dc, commutator diameter, =35 in.
Brush arc, =0.91 in.
Volts per pair of brushes, =2
Amp. per sq. in. brush contact, = 35
Brush length, =10.5 in.
F, commutator face, = 13 in.
the winding were series, or two-turn multiple, the reactance voltage
If
would be too high and interpoles would be required.
Comparative designs should be worked out with both larger and smaller
armature diameters and with different numbers of poles; then a choice
should be made, and the design completed as below.
The final or detailed design is worked out in the following order. The
probable number of total face conductors is 820, from the preliminary design.
The number of slots per pole should be greater than fourteen and the total
number of slots greater than 140; the nearest number of slots that will give
an even number of conductors per slot is 200. Therefore
Slots = 200
Conductors per slot =4
Coils = 400
Commutator segments = 400
Winding 1-turn multiple
Ampere-conductors per in. = 167 X 800/«- X 58 = 730
Ampere-conductors per in. , „ , „ , ,, „. „ .

7=n
7-. =1.3 for 40 deg. cent, nse, from Fig. 31.
Cir. mils per amp.
Cir. mils per amp. = 560
Amp. per conductor at full load =167
Section of conductor =93,000 cir. mils = 0.073
sq. in.
Slot opening = 0.47 X (slot pitch) in large machines
= 0.52 X (slot pitch) in small machines
For a first approximation, therefore
Slot pitch =0.91 in.
Slot opening = 0.43 in.
0.064 width of slot insulation (Fig. 47)
0.04 clearance between coil and core
0.326 available space for copper and conductor insulation.
Use flat strip, as in Fig. 47, with two conductors in the width of the slot;
make the strip 0.14 in. wide and insulate it with half-lapped cotton tape.
Depth of conductor = 0.073/0. 14 = 0.52 in.; increase this to 0.55 in. to
allow for rounding of the corners.
Slot depth is found as follows:
0.55 = depth of each conductor
0.024 = insulation of each conductor
0.084 = depth of slot insulation (Fig. 47)
0.658 = depth of each insulated coil
2 = number of coils in depth of slot
1.316 = depth of coil space
0.2 = thickness of stick at top of slot
1.516 = necessary slot depth; make it 1.6 in.
The tooth flux density should now be checked to make
sure that it is not
too high, see Par. 123, and the internal diameter of the armature made such
that the flux density in the armature core shall not exceed 85,000 lines per
8q. in.
71. Effect of interpoles. When interpoles are used, the reactance vol-
tage is no longer a limiting factor in the design, so that deep slots may be
used and a large amount of copper put on each inch of the periphery. For
interpole machines, the value of q, the ampere-conductors per in., will
Sec. 8-72 D. C. GENERATORS AND MOTORS
generally be 20 per cent, greater than given in Fig. 29. The commutating
fringe under the pole tip is not used, so that the ratio of the exciting ampere-
turns per pole for gap and teeth to the armature ampere-turns per pole, which
is seldom less than 1.2 for non-interpole machines, is generally made about
0.8 for similar machines with interpoles. There
is therefore a large saving in field copper, and
- in pole and yoke material.
72. Speed limitations in design. * If the
peripheral velocity of a machine is fixed, the
output can be increased only by increasing the
^ l60o[ I W-f^^
J I I I
frame length, the number of conductors, or the
I I

current per conductor, all of which increase the

reactance voltage; so that, after a certain out-
put has been reached, interpoles must be sup-
plied or the peripheral velocity increased, t Fig.
32 shows the maximum output that can be ob-
tained for a given speed, the peripheral velocity
being taken as 6,000 ft. per min. (1,830 m. per
min.) for machines of ordinary construction, and
Fig. 32. — Maximum
curves,
output 15,000 ft. per min. (4,600 m. per min.) for turbo-
machines. The high-speed turbo-machine is
not too satisfactory as regards efficiency, com-
mutation, and heating and the tendency is to gear a high-speed turbine to a
moderate speed generator through a reduction goar.
FIELD DESIGN
73. The magnetic circuit is well shown in general in Fig. 38, where the
closed dot-and-dash line indicates the complete path through one pair of
poles, two air-gaps, the armature and the yoke, all in series. There are as
many paths similar to this one, in a multipolar machine, as there are poles.
This path, of course, is the path of the useful flux, and does not take into
consideration the leakage flux.
 I

D. C. GENERATORS AND MOTORS Sec. 8-75

There is a small amount of fringing at the pole tips which tends to increase
the air-gap area, but this effect is counterbalanced by the effect of the in-
crease in the air-gap clearance near the pole tips. The fringing constant
for the vent ducts may be found in the same way as for the slots, but is so
nearly equal to unity that the calculation is seldom made.
76. The magnetic areas: In Fig. 38, let
Ag = the yoke area;
Ap = the pole area=TFpLp for solid rectangular poles and = 0.95 WpLp for
^
poles built of laminations;
At =the tooth area per pole= (^iV/p)<Ln where Ln, the net length of the
core equals 0.9 (Lo — the space taken by the ducts), \^ is the ratio pole
arc/pole pitch, and N is the total number of teeth.
Ac = the armature core area = dai„;
Ag =the apparent gap area per pole = ^7-Lc;
Aag = the actual gap area per pole = Ag/C', where C is a constant greater
than unity, which takes
into account the effect of
the slots in reducing the 0.48 J,

gap area.
These areas are determin-
able, in the first instance, by
dividing the total flux in a
ft
0.43-U4—
,;? Slots SCCaiSx 1.6
given portion of the magnetic '
OoU«400
circuit, by the allowable flux Winding 1 Turn
density. Mull.

76. Flux density in the Polu 10

air-gap. The apparent gap K.W.400
density which may be allowed Telti no lo*d 240
Volta fuU load 240
for an armature of specified B.P.M. 200
diameter is shown by the curve 5 0.3 In.
in Fig. 28. It will be noted
=
that (Zg <j>a/Ag, where Ag is Fig. 35. —
Fringing constant study.
the apparent gap area per pole.
The apparent gap area is connected with the actual gap area by the relation
Ag = CAag, where C (fringing constant) is greater than unity. Conversely,
the apparent gap density is connected with the actual gap density by the
same constant, and Bag = CBg.
77. Flux densities in the iron are given below. These are average
values found in standard machines designed for continuous duty.
Sec. 8-80 D. C. GENERATORS AND MOTORS

110 X
 {

D. C. GENERATORS AND MOTORS Sec. 8-81

where
L,h,
01 = lSk(_nI)g+i (14)
irW.
4,2=19k(,nl),^, A. logio (l+ ""^^'
) (15)

(16)
(I

.^4 = 9.5/fc(n/)„+, hp logic (l+ ^^^^) (17)

Fia. 38. — The paths of the main and the leakage fluxes.

and k equal to unity for inch units and to 1/2.54 = 0.3937 for centimeter
is
units. For a given value of <t>a, the flux crossing the air-gap, the value of
{nl)g+i, the necessary ampere-turns per pole for gap and teeth, may be found;
and, substituting this value in the above formulas, the corresponding value
of <t>4 may be found. The leakage factor = l-t-i^e/<^ a.
81. Calculation of field
ampere-turns per pole. Yoke
The total ampere-turns per
pole required to establish the
necessary flux in the mag-
netic circuit may be analyzed
into a series of components.
The natural subdivision fol-
lows the several different —
members or elements which
go to make up the complete
circuit. These would in-
clude the yokes, the field
arma-
cores, the air-gaps, the
ture teeth and the armature
core. Since the field poles
are structurally duplicates of
each other, except where in-
terpoles are used, it is nat-
ural to confine the calcula-
tions of required ampere-
turns to a single field pole.
Fig. 40 shows the unit mag- The leakage paths.
netic circuit for a multipolar
machine, or that part of the total magnetic structure which corresponds to
one field pole and simply needs repeated application to build up the whole
structure, This unit magnetic circuit comprises one complete field core, one
complete air-gap, one complete group of armature teeth under a single pole
 Sec. 8-82 D. C. GENERATORS AND MOTORS
face, two half-yokes and two half-armature cores in parallel.
in parallel
The total number ampere-turns, at no load, may be expressed as
of
n/=(n7)„ + (nJ).-Kn7)p-f-(n7), + (n7), (18)
where the several quantities in the formula are as follows:
(n7)j, represents the number of ampere-turns required to establish the
flux 0m/2 through a length of yoke equal
r to l„ in Fig. 38; this length is one-half the
total length of the yoke circuit from pole
to pole. In a single-yoke machine, such
as the horse-shoe bipolar type, with two
field coils, the full value of flux, or tpm,
should be assumed instead of <j>m/2.
(.nl)e represents the number of am-
pere-turns required to establish the flux
4>a/2 through a length of armature core
equal to h in Fig. 38.
(n7)p represents the number of am-
pere-turns required to establish the flux
<t>m through the field core, which has a
length of Tp as shown in Fig. 38.
Fia. 40. — .... (m7)i represents the number of am-
Unit magnetic circuit of pere-turns required to establish the flux
multipolar machine. ^^ through one set of armature teeth
under one pole face.
{nl)g represents the number of ampere-turns required to establish the
flux a through one air-gap.
The calculation of ampere-turns in each case, except for the air-gap, is
carried out by taking different values of flux density (B and obtaining the
proper -value of ampere-turns per in. from the curves in Fig. 37; the latter
is then multiplied in each instance by the length of the corresponding por-
tion of the magnetic circuit, in inches.
The required number of ampere-turns for the air-gap, in terms of inch
units, is given by . ,,..„.... •„
(«J)«=|;~^ (19)

and in terms of centimeter

units, by

The quantity C is the fringing

constant (Par. 75). .9120

82. Excitation for tapered |

teeth. When the armature «j
teeth are tapered, the flux " tjoo
> density is not uniform through-
out the total depth of the
tooth. The tooth length must
therefore be divided into a
number of short lengths, the
flux density and the corre-
sponding ampere-turns per in.
length found in each case, and
the average value multiplied
by. the tooth length to give
(n7)(. This process can be Fig. 41.-
shortened by use of the series
of curves shown in Fig. 41; if
 D. C. GENERATORS AND MOTORS SeC. 8-84

Ap = the pole area = 0.95X 10.5X 11.5= 114 aq. in.

200
Ai = the minimum tooth area per pole = 0.7 X-j^X 0.43X9.45 = 57 sq. in.
Ac = the core area = 5.-65X 9.45 = 53.5 sq. in.
A, = the apparent gap area = 12.7X12 = 153 sq. in.
C =the fringing constant = 1.12 from Par. 74.
,,^
<t,a = the useful flux per pole
,
240X60X10X108
= ~^00X200X l0~ *""
„ „
= 9X10«
The leakage factor = 1.16 from Par. 79.
0„ = the total flux per pole =10.5X10«
(B„ = the yoke density = 39,000 lines per sq. in.
{Bi, = the pole density = 93,000 lines per sq. in.
(B( =the apparent tooth density = 158,000 lines per sq. in.
The actual tooth density (Fig. 36) = 150,000 lines per sq. in.
(Be =the core density = 84,000 lines per sq. in.
(Sig =the apparent gap density = 59,000 lines per sq. in.
nJ, = for a cast-iron yoke = 75 X 13= 980 ampere-turns.
nlp = for steelpunchings = 40 X 15 = 600 ampere-turns.
nl, =» = 1300X 1.6 = 2080 ampere-turns, from Fig. 41.
nlc= = 20X6.5 =130 ampere-turns
1.12X59,000X0.3
5~ „„„
=6,200 ampere-turns.
nlg=
The total ampere-turns per pole at 240 volts = 9,990. Three more points
are worked out in the same way and then plotted in curve 1, Fig. 19.
84. The full-load saturation curve is shown in curve 2, Fig. 19. The
drop in voltage ab is due to the decrease in flux caused by the cross-mag-
netizing effect of the armature. Par. 32- the ampere-turns be are required to
overcome the demagnetizing effect of the armature and are equal to
O.lZIc/p, from Par. 33; the voltage cd is that required to send full-load
current through the resistance of the armature winding, the brushes and
the series field coils.
85. Calculation of cross-magnetizing effect. The method of cal-
culating the decrease of flux due to the armature cross-magnetizing effect is
complicated and will be found in several standard texts.* The decrease in
flux is directly proportional to the armature ampere-turns per pole; it also
depends on the tooth density and on the ratio of the armature ampere-turns
per pole to the exciting ampere-turns per pole for tooth and gap (Par. 38).
For a first approximation on standard machines, allowance may be made
by making the distance /c. Fig. 19, equal to 0.3 times the armature ampere-
turns per pole. In the machine shown in Fig. 35,
1 800
The armature ampere-turns per pole = -^ X -y^ X 167 = 6,700
The demagnetizing ampere-turns per pole = 0.2 X 6,700 = 1,340
The equivalent cross-magnetizing ampere-
turns per pole =670
The resistance of armature and series field coils =0.0037 ohms
The volts drop in armature and series field coils =6.2
The volts drop per pair of brushes =2.0
86. The size of wire for field coils is given by the formula

cir. mils = ^^-^-^ (21)

where 7/ the current in each field coil,

is
nr is the number of turns per field coil,
M
is the length of mean turn in inches,
Ef is the voltage drop across each field coil.
Thus, for a given machine, the size of wire for the field coils is fixed as soon
as the number of ampere-turns per pole and the voltage per coil have been
determined.

•Gray "Electrical Machine Design," p. 56; Hobart, " Dynamo Design,"

p. 75; Karapetoff, "The
Magnetic Circuit," p. 166; Thompson, "Dynamo-
electric Machinery," Vol. I, Chap. 17.

621
Sec. 8-87 D. C. GENERATORS AND MOTORS
87. The minimum length of field coil to give the necessary radiating
surface for cooling is given by the formula*
length of mean turn
" (22)

where Lf
' 1,000

is
4 external periphery X watts
the length of the field coU in inches, Fig. 42,
per aq. in. Xd/ Xs/Xl.27

df is the depth of the field coil in inches,

s/ is the space factor of the winding and may be found from Fig. 43.
Q The allowable watts per sq. in. of surface B, Fig. 42,
•J-
may be found from Fig. 44.
88. The weight of field coil for a given machine
'^ is equal to \/(i/ multiplied by a constant. The
'"'
larger the value of df, the shorter the length £</, the
A smaller the radiating surface and the lower the per-
missible loss in the coil. Since the section of the
field coil wire is fixed (because it depends only on
the ampere-turns and the voltage per coil. Par. 86),
Fig. 42. —
Field coil a lower permissible loss can be obtained only by the
length, use of a smaller current i/, a larger number of
turns n/, and therefore a more expensive coil. It must not be overlooked,
however, that when d/ becomes smaller and the field coil becomes cheaper,
the value of Lf increases and therefore the cost of the poles and the yoke
increases. The most economical value for d/ must be determined by trial;
an average value is 2 in.
89. Example of field system design. The armature of a ten-pole,
240-volt no-load, 240-volt full-load, 1,670 amp., 200 r.p.m. generator is
shown drawn to scale in Fig. 35; it is required to design the field system,
which isnot supposed to be given.
The following data are taken from Par. 83.
0m - 10.5X10*
0. -9X10«
nil = 2,080
(Bj = 59,000 lines per sq. in.
 D. C. GENERATORS AND MOTORS SeC. 8-90

(b) Calculation of approximate dimensions for the magnetic

circuit.
Assume the no-load excitation= 1.25[(n7)j + (nJ)(]
= 10,100 ampere-turns per pole.
Next find L/ for the shunt coil from eq. 22 (Par. 87),
where d/ is assumed to be 2 in.; sf is assumed to be 0.6, from Fig. 43; the
allowable watts per sq. in. =0.6 from Fig. 44; the external periphery of the
field coil equals 1.2 times the length of the mean turn, approximately; there-
fore L/= 10 in., approximately; the latter should be increased 30 per cent, to
allow for the series coil.
The pole area = «m/(Bp = 10.5 X 10»/95,000= 112 sq. in.
The yoke area = 0m/2(B„ = 10.5 X 10«/2 X 40,000 = 132 sq. in.
(c) Saturation curves. From these dimensions the magnetic circuit
is drawn to scale and the no-load and the fufl-load saturation curves are
determined and plotted. For the machine in question, the curves are given
in Fig. 19.
(d) Design of the shunt coils. The details are as follows:
The no-load excitation = 9,990 ampere-turns per pole. Fig. 19, or Par. 82.
Ef, the volts per coil, equals 0.8X240/10 = 19 volts; this leaves 20 per cent,
of the terminal voltage to be absorbed by the field rheostat.
M, the mean turn, equals 53 in. The external periphery equals 61 in.
The size of wire equals 9,990X53/19, from Par. 85, or 28,000 cir. mils. The
proper size of wire is No. 5.5 A.W.G., a special size between Nos. 5 and 6,
which has a section of 29,500 cir. mils and a diameter when insulated with
double cotton of 0.19 in. When such odd sizes are not available, the coil
can be made with the proper number of turns of No. 5 wire in series with
the propernumber of turns of No. 6, so as to have a field coil of the proper
resistance.
The number of layers of wire in a 2-in. depth equals 2/0.19 = 10.
The number of turns per layer in a 10-in. length equals 10/0.19 = 53.
71/, the number of turns per coil, equals 530.
If, the shunt current, equals 9,990/530 = 18.8 amp.
The current density equals 29,500/18.8=1,570 cir. mils per amp.
(e) Design of the series coils. The details are as follows:
Excitation at full load and normal voltage = 13,400 ampere-turns. Fig. 19.
Shunt excitation at normal load = 9,990 ampere-turns.
Series ampere-turns per pole at full load = 3,410
Series turns per pole =2.5
Series current = 3,410/2.5 = 1,370 amp.
Current in series shunt = 300 amp.
The current density is taken 20 per cent, greater than in shunt coils because
the series coils are better ventilated.
Current density = 1,300 cir. mils per amp.
Size of wire = 1,300X 1,370 = 1,780,000 cir. mils= 1.4 sq. in.
Resistance of 2.5 turns = 7.4 XIO"' ohms.
Loss in one series coil = 1 ,370=X7.4 X
lO'' = 140 watts.
The permissible watts per sq. in. is taken 20 per cent, greater than in shunt
coils.
Watts per sq. in. = 0.72
Necessary radiating surface = 140/0.72 = 195 sq. in.
Length Lf of series coil = 195/61 = 3.2 in.
Depth of wire = wire section/!,/ _
= 0.45 in.
Size of wire = 3 strips (3.2 in. X0.15 in.).

GENERAL DESIGN AND CONSTRUCTION

90. Type of construction for small machines. Fig. 45 shows the
type of construction generally adopted for machines up to 100 h.p. at 600
rev. per min.
91. The armature core (Af in Fig. 45) is built of laminations of sheet
steel 14 mils (0.35 mm.) thick, which are separated from one another by layers
of varnish and have slots F punched to carry the armature coils G.
92. A marking notch is punched at one side of the key-way (Fig. 45) K
and these notches must line up when the punchings are assembled, to ensure
that the burrs at the edges all lie in the same direction.

623
Sec. 8-93 D. C. GENERATORS AND MOTORS

93. Brass vent segments (P in Fig. 45), about | in. (1 cm.) wide,
separate the core into sections about 3 in. (7.5 cm.) wide. The core and the
vent segments are clamped between end heads N which carry coil supports
L attached by arms shaped like fans. The coils are held in place against
centrifugal force by steel band wires.
94. The poles (B in Fig. 45), are of circular cross-section in order to give
the required area for the magnetic flux with the minimum length of mean
turn of field coil A. They are made of forged steel and have laminated pole
faces E made of sheet steel 25 mils (0.63 mm.) thick.
96. End play is provided for by making the axial length of the pole face
i in. (1 cm.) shorter than that of the
armature core. This enables the
revolving part of the machine to oscillate^ axially and so prevent the journals,
bearings and commutator from wearing in grooves.

Fig. 45. — Small direct-current motor.

96. The yoke (C in Fig. 45) carries the bearing housings D which stiffen
the whole machine. The housings can be rotated with respect to the yoke
through 90 deg. or 180 deg., so that the machine may be mounted either on
a wall or a ceiling. This rotation of the bearings is necessary because the
machine is lubricated by oil rings and the oil wells must always be below
the shaft.
97. The commutator segments (J in Fig. 45) are of hard-drawn copper
and have a wearing depth of from 0.5 in. (1.25 cm.) on a 5-in. (12.5-cm.)
commutator to 1.0 in. (2.5 cm.) on a 50-in. (125-cm.) commutator. The
commutator shell, as the clamps and their supports are called, is provided
with air passages R which help to keep the machine cool.
98. The bearing construction is shown in detail in Fig. 45. The
projection T on the oil-hole cover keeps the oil ring from rising and resting
on the bushing; the oil slingers prevent the oil from creeping along the shaft.
The liner of special bearing metal is given a snug fit in the bearing shell, and
can be removed when worn and another put in its place. A small overflow
at U makes it impossible to fill the bearing too full.
99. The brushes are carried on studs which are insulated from the rocker
arm V. The rocker arm is carried on a turned seat on the bearing and can
be clamped in a definite position.
100. Type of construction for large engine-type generators. For
large direct-connected engine-typo units the type of construction shown in
Fig. 46 is generally adopted. The armature core is built of segments
carried
by dovetails on the spider. The segments of alternate layers overlap so as to
break joints and give a solid core. The poles are of rectangular cross-section

624
 "

D. C. GENERATORS AND MOTORS See. 8-101

and are built of laminations 25 mils (0.63 mm.) thick, of the shape shown at
P, and assembled so that the rounded pole tips point in opposite directions
and a saturated tip is produced which helps commutation. The shaft,
base and bearings are generally supplied by the engine builder, so that the
commutator must be sup-
ported from the armature
spider; the brush rigging
must also be supported by
the machine.
Mechanical design. *
101.
The yoke should be heavy
and, in engine-type units, is
often made with a large sec-
tion of cast iron rather than a
smaller section of cast steel;
it must be stiff enough to
prevent undue sagging even
when there is a large unbal-
anced magnetic pull. The
shaft should be stiff enough
to limit the deflection to 5
per cent, of the air-gap clear-
ance and, along with the
spider, should have a factor
of safety of 12 to take care
of short-circuits.
Fig. 46. —Large engine-type generator.

102. Unbalanced magnetic puU.t the armature of a machine is x

If
cm. out of centre, the flux density under the poles where the gaps are smallest
will be greater than under the poles where the gaps are largest, and the pull
on one side of the machine will be greater than on the other by an amount

kS(&^'r (23)

where the effective gap density,

(B is
S = Tr DaLc, the total armature-core surface,
a; = armature displacement,

S = length of air-gap,

k = - if inch units are used and the pull is in pounds,

k = if centimeter units are used and the pull is in kilograms.

The above formula holds for a two-circuit winding; if a multiple winding is

used, the e.m.fs. in the different paths will be unequal, and circulating
currents will flow tending to keep the flux densities under the poles equal.
INSULATION
103. General requirements. A good insulator
for electrical machinery
must have high dielectric strength and high electrical resistance, should be
tough and flexible, and should not be affected by heat, vibration, or other
operating conditions.
104. The insulating materials generally used for revolving machinery
are as follows:
(a) Micanite, which is easily bruised and should be protected by a
tougher material.
(b) Varnished cloth, which must be carefully handled to prevent
cracking or scraping of the varnish film.
(c) Paper, which is chosen for its toughness and should be baked dry
•when tested.

•Livingstone, "Mechanical Design and Construction of Commutators;"

Livingstone, "Mechanical Design and Construction of Generators;" Haw-
kins and Wallis, 'The Dynamo ;" Hobart and Ellis, Armature Construction.
'
' '

t Behrend, B. A. Trans. A. I. E. E., Vol. XVII, p. 617; and Rosenberg,

: "Magnetic Pull in Electrical Machines," Proc. A. I. E. E., Vol. 37, p. 1069.
40 625
Sec. 8-105 D. C. GENERATORS AND MOTORS
(d) Cotton tape, which is used to insulate copper strip of large section.
(e) Cotton covering is used in one, two or three layers, and has the thick-
ness given in Sec. 5, when applied to round wire. Small strip copper is
generally double-cotton-covered, and the total thickness of insulation (two
sides) varies from about 14 mils on the smaller sizes to about 20 mils on
sizes more than i in. thick.
(f) Impregnating compound must be used at a temperature lower than
120 deg. cent., which is the breakdown temperature of cotton. It should have
as little chemical action as possible on copper, iron and insulating materials.
(g) Elastic finishing Tarnish should have a hard skin when dry and
should be proof against oil, water, acids, and alkalies.
106. The limiting temperature* for cellulose materials is about 120
deg. cent., but the operating temperature should not exceed about 90 deg.
cent. When subjected to higher temperatures for long periods, the material
becomes dry and brittle, and pulverizes under vibration. When mica,
asbestos, enamels and special gums can be prepared in such a manner that
they are tough and flexible
and do not become brittle
at high temperatures, then
the operating temperature
limit may be increased.
106. Insulation of ad-
jacent conductors in a
slot. The voltage between
adjacent commutator seg-
ments seldom exceeds 20
volts, so that cotton tape
is sufficient insulation be-
tween adjacent coils in a
slot. When the individual
coils are made of a number
Fia. 47. Fia. 48. of turns of round double-
Figs. 47 and 48.- -Armature slot insulation. cotton-covered wire, it is
advisable to- put extra in-
Bulation between them as shown in Fig. 48, because the cotton covering may
become damaged when the coils are squeezed together to get them into a slot.
107. Example of 240-volt armature insulation. The winding is to
be of the double-layer multiple type with two turns per coil and four coils
or eight conductors per slot. The conductors are to be of strip copper
wound on edge. A section through the slot and insulation is shown in Fig.
47, and the various operations are as follows:
(a) After the copper has been bent to shape, tape over with one layer
it all
of half-lapped cotton tape 6 mils (0.15 mm.) thick. This forms the insula-
tion between adjacent conductors in the same slot.
(6) Tape together the two coils that form one group,
with one layer of
half-lapped cotton tape 6 mils (0.15 mm.) thick. This forms the end-
connection insulation and also part of the slot insulation.
(c) Bake the coil in a vacuum tank at 100 deg. cent, so as to
expel all mois-
ture, then dip it in a tank of impregnating compound at 120 deg. cent, and
leave it there long enough to become saturated with compound.
(d) Place one turn of empire cloth 10 mils (0.25 mm.) thick
on the slot
portion of the coil and lap it over as shown at d. This empire cloth cell
should project 0.75 in. (2 cm.) from each end of the core. -
,
,

(e) Place one turn of paper 10 mils (0.25 mm.) thick on

the slot portion
of the coil and lap it over as shown at e. This paper also should project
0.75 in. (2 cm.) beyond the core at each end. It is not placed on the coil for
insulating purposes, but to protect the other insulation which is likely other-
wise to become damaged when the coils are being placed in the slots.
(/) Heat the coil to 100 deg. cent, and then
press the slot portion to shape
while hot. The heat softens the compound and the pressure forces out th» .

excess of compound. The coil is allowed to cool under pressure and comes
out of the press with such a shape and size that it slips easily into the slot.
varnish.
Co) Dip the ends of the coil into elastic finishing

•Rayner. Journtil of Inst, of Elec. Eng., Vol. XXXIV, p. 613.

626
 D. C. GENERATORS AND MOTORS Sec. 8-108

108. Example of S50-volt insulation for a railway motor armature.

The winding is of the double-layer, two-circuit type with four turns per coil
of double-cotton-covered wire and six coils or twenty-four conductors per
slot. cross-section through the slot and insulation ia shown in Fig. 48.
A
The various operations are as follows:
(o) The cotton-covered wire is treated with enamel to increase its heat-
resisting properties and is then bent to shape.
(6) A group of three coils are placed together and a wrapping of mica cloth,
made of 5-mil (0.13-mm.) mica and 5-mil (0.13-mm.) cloth is placed on the
slot portion of the coil to form the insulation between coils and also between
the coil group and the sides of the slot.
(c) The end leads of each coil have to pass all the other turns of the coil
and are insulated with a stocking of cotton, different colors being used for
the three coils in a group so that the position of each coil may be easily
determined when the winding is being connected to the commutator.
Id) The group of three coils is taped on the ends with half-lapped cotton
tape 6 mils (0.15 mm.) thick, which tape is allowed to overlap the slot in-
sulation for 0.5 in. (1.3 cm.) so as to bind it in place.
(e) The group of coils is completely taped with one layer of half-lapped
cotton tape 6 mils (0.15 mm.) thick.
If) The top and the bottom layers of the
winding are separated from one
another at the ends by a layer of canvas 30 mils (0.75 mm.) thick and in the
slot by a layer of fibre 30 mils (0.75 mm.) thick.
(g) After being wound, the armature is impregnated with compound and is
finally painted with elastic finishing varnish.

Fig. 49. — Field coil insulation.

109. Field coil insulation. Three examples are shown in Fig. 49. The
coils, after being wound and taped, are baked in a vacuum tank and then
impregnated with compound. This compound is a better insulator than the
air which it replaces; it is also a better conductor of heat.
110. Ventilated field coils, as shown at C in Fig. 49, are insulated with
wooden spacing pieces about 0.5 in. (1.3 cm.) thick. The coils are made
self-supporting by being impregnated with sohd compound at about 120 deg.
cent. The insulation on the individual turns of the series coil consists of one
layer of half -lapped cotton tape 6 mils (0.15 mm.) tiiick.
111. Fire-proof field coils for railway motors have been made with
strip copper wound on edge, with asbestos insulation between layers. The
coils arebrought to a red heat to expel the binding material in the asbestos
fabric and then placed in a metal case lined with asbestos and sheet mica.
112. Commutator segments are insulated from one another by mican-
ite about 30 mils (0.75 mm.) thick, strips of uniform thickness being used
and the copper segments tapered to suit. The mica must be one of the soft
Irarieties (Sec. 4) so that it will wear equally with the copper segments.

(527
Sec. 8-113 D. C. GENERATORS AND MOTORS
The segments of copper and mica are assembled together in an external
press ring, are next heated to soften the binding material in the micanite, and
are then drawn tightly together. The F-grooves shown in Fig. 45 are then
turned and the segments clamped tightly by the F-cones, from which they
are insulated by mica cones ^in. (1.6 mm.) thick.

lis. Potential stresses due to switching. A conductor conveying a

current is surrounded by a magnetic field. If the circuit be suddenly opened,
the flux decreases rapidly and an e.m.f. is induced in the circuit. In the case
of shunt field coils with many turns, this e.m.f. may be excessive and must
be provided against as described in Par. 245 and 249. This flux due to the
field coils also threads the armature, and the sudden change of flux may
increase the e.m.f. per coil enough to cause flashing over between segments
or to break down the insulation between adjacent coils in the same slot.
This latter trouble may also be caused by a sudden change of load (see
Par. 67).
114. If, due to switching, any point in a coil be suddenly raised by a poten-
tial of E volts, the potential of the whole winding will gradually rise; but,
as this requires a definite though very short interval, the potential difference
across the first few turns of the coil is approximately equal to E and may be
large enough to break down the insulation between adjacent turns near
the terminals.
116. Puncture test. To make sure that there is enough insulation be-
tween the conductors and the core, and that this insulation has not been
damaged in handling, all new machines are subjected to a puncture test be-
fore they are shipped, that is, a high voltage is applied between the conductors
and the core for 1 min. If the insulation does not break down, it is as-
sumed to be ample. The values of puncture voltage recommended by the
Standards Committee of the American Institute of Electrical Engineers may
*
be found in Sec. 24. For further information on insulation see footnote.
COOLINQ AND VENTILATION
116. Heat transfers. The losses in an electrical machine are transformed
into heat, causing a rise of temperature at the source of loss. Heat is trans-
mitted in general by three methods, namely, conduction, convection and
radiation. In order that a flow of heat may take place, there must be a
difference of temperature, and heat flows in the direction of diminishing
temperature. Thus the highest temperature, or "hot spot," in an electrical
machine, is at the seat of loss; the temperature falls in the direction in which
the heat flows, and becomes a minimum at the point or points where the heat
leaves the machine. The temperature becomes stationary when the rate at
which heat is generated is equal to the rate at which it is conducted away.
117. Heating and cooling curves. The rate at which heat is dissipated
depends on the difference between the temperature of the machine and that
of the surrounding air. During a brief interval after starting under load,
this temperature difference is small, very little heat is dissipated, and the
temperature rises rapidly. As the temperature increases, more of the heat
is dissipated, and the temperature rises more slowly. _ The heating and cool-
ing curves of a continuous-current motor are given in Fig. 60, the cooling
curve being the reciprocal of the heating curve.
118. Qeneral effect of densities and speed. The lower the flux and
the current densities, the larger will be the mass of material in the machine
for a given loss, and the longer the time taken to reach the final temperature.
Slow-speed machines are poorly ventilated, have low current densities, and
require a long time to reach the final temperature; field coils require longer
than armature coils because they are stationary and the current density in
the wire is very low.
119. Permissible temperature rise. Cotton insulation should not be
operated continuously at temperatures greater than about 90 deg. cent.
This permits a temperature rise of 50 deg. cent, with an air temperature of
40 deg. cent.
* Fleming and Johnson, Journal of Inst, of Elec. Eng., Vol. XLVII, p. 530;
Hobart and Turner, "Insulation of Electric Machines; " Rayner, /oumo/
of Inst, of Elec. Eng., Vol. XXXIV, p. 613; Vol. XLIX, p. 3.

628
 D. C. GENERATORS AND MOTORS SeC. 8-120

120. Intermittent ratings. Suppose that a machine is operating on a

continuous cycle, x min. loaded and y min. without load. The temperature
of the machine will vary during each cycle between the values dx and By
(Fig. 50), where the temperature increase in the interval x is equal to the
temperature decrease in the interval y. Under these service conditions,
Sx, the highest operating temperature, is less than Bm, the maximum tem-
perature that would be obtained on continuous operation under load. For
this service, therefore, a machine may be designed with higher coppier and
iron densities than otherwise it would have if designed for the same load but
for continuous operation. It must be noted that, if the machine is stationary
during the period of no load, the drop in temperature_ is small, and the
rating of the machine cannot be made much greater than if it were operating
on continuous load.
su
 Sec. 8-123 D. C. GENERATORS AND MOTORS
The core length being the longer the pole pitch the greater will be
fixed,
the flux per pole and the deeper the core required to carry thia flux. When
the peripheral velocity is high, the core is therefore deep and the vent ducts
have a large surface and are very effective, so that the ventilation is good.
The loss, however, is large since much iron is used in the core. When the
peripheral velocity is low, the core is shallow and the vent ducts are not very
effective because of their small surface, and the ventilation is poor; the loss,
however, is small because there is not much iron in the core. It is found
that, for a given frequency, the same flux densities can be used for all pe-
ripheral velocities.
123. Tooth and core densities. For frequencies up to 60 cycles per
sec. and for a temperature rise of less than 50 deg. cent., the following flux
densities may be used:
Actual maximum tooth density
•' ( ^^2'^?,^ ]\^^^ P^'' ^^-
^"•
23,000 lines per sq. cm.
1

Average core density "^^ ^^^ ^"^^ '"•

I
f^-j^22 v
13,000 hues per sq. cm.
I
Higher densities may be used for frequencies lower than 60 cycles, as far aa
heating is concerned; but, with a greater density than the above, the core
becomes saturated and the cost of the extra field copper required to send
the flux through a saturated core ia greater than the cost of the extra iron
required to keep the flux density below the saturation point. There is no
such objection to high tooth densities, because a machine with saturated
teeth and a short air-gap ia just as effective in preventing field distortion as a
machine with unsaturated teeth and a long air-gap. With tooth densities
greater than the above, it is difficult to predetermine the ampere-turns for
the teeth with sufficient accuracy to ensure enough field margin to give
normal voltage at full load, because the permeability of the iron used may
be lower than was expected.
124. Heating of armature windings. The heating of the end con-
nections must be considered separately from the heating of the core, because
the kind of radiating surface is different, and also the manner in which it is
cooled. The temperature rise is proportional to
ampere-conductora per in. of periphery
cir. mils per amp.
and may be obtained from Fig. 52. For a given loss per unit area of radiating
surface, a large machine operates at a lower temperature than a small one
because its windings are not so crowded
on the ends, and free passage of air into the
machine is not restricted by the bearing
housings.
126. Overload temperatures. Due to
the fact that the heat loss in the copper
> has to pass through the insulation or be
dissipated from the end connections, the
maximum rise in temperature of a machine
willbe more nearly proportional to the
copper loss than to the total loss in arma-
ture core and copper. A large number of
tests on standard machines have shown
• X 10^ that the temperature rise of an armature
P«ripher»i Veiooitjofthe AnMtnreiiiFi. perMiiuiB approximately proportional
to the sum
Fig. 52.— Temperature rise of °^ ^^'^ armature copper loss plus 30 per
armature coils. '^^Sl. m "'°'^ ^2^^'
^, . j.t.
126. Temperature gradient in the
j.

conductors.* The hottest part of the winding is at e. Fig. 51. If it be

assumed that all the heat is conducted along the copper and dissipated from
the ends, then the difference in temperature between e and a in deg. cent, is
given by the formula, t

• Goldschmidt, Eledrotechnische Zeitschrift, Vol. XXIX, p. 886; Gray,

"Electrical Machine Design;" Symons and Walker, Jo«moi of Inst, of Elec.
Eng., Vol. XLVIII, p. C74.
t Gray. "Electrical Machine Design," p. 110.

630
 D. C. GENERATORS AND MOTORS SeC. 8-127

5.7 X 10* X (length ae in inchea)*

(deg. cent.) (26)
(cir. mils per amp.)*
If a« is 10 in., and the number of cir. mils per amp. is 500, then this tempera-
ture difference is 23 deg. cent.
Much of the heat, however, is conducted through the insulation and,
assuming that all the heat travels in this direction, the temperature difference
between the copper and the surrounding iron, in deg. C-, is given by the
formula
1 / ampere-conductors per slot) \ / thickness of i nsul.
-) (26)
0.003 \ cir. mils per amp. / \ 2d + s
In the machine shown in Fig. 35, the design data is as follows:
Ampere-conductors per in. = 730
Slot pitch =0.91 in.
Ampere-conductors per slot =670
Cir. mils per amp. = 560
2d+s =3.63 in.. Fig. 51
Thickness of insulation =0.06 in. including clearance
Temperature difference =6.5 deg. cent.
127. Commutator heatingr. The direction of the air circulation in a
commutator with open necks is shown in Fig. 63, and the temperature rise
may be obtained from the heating curve. The radiating surface is taken as
vDcF. The effect of the necks
has not yet been determined
experimentally. Part of the
neck from a to 6 can be closed
up w-ithout affecting the venti-
lation or the temperature rise
to any great extent. The losses
are assumed to be brush fric-
tion and contact resistance
losses; hence if the commuta-
tion is poor and the brushes
chatter badly the temperature
rise may be higher than that
obtained from the curve.
128. Field coil heating.
The temperature rise of the
coil surface is proportional to
the loss per unit area of ex-
ternal surface and may be ob-
tained from Fig. 44 if B, Fig.
42, is taken as the radiating
8.6 « 10*
surface. The effect of arma-
_ jPeilpbenl Vtlocitj of the Oommuutat in Ft, pa Mia.
ture fanning can readily be un-
derstood; a short coil is more Fig. 53.- -Temperature rise of commutators.
effective than a long one be-
cause of the larger per cent, of the loss that is dissipated from the ends of the
coil. Ventilating openings, as shown in C, Fig. 49, allow the loss per unit area
of external surface to be 50 per cent, greater than for an unventilated coil.
129. The maximum
temperature* of the coil is that which limits the
current it can carry, but this temperature cannot readily be determined
experimentally. The external surface temperature may be measured
by a thermometer and the mean temperature can be found by the increase
in resistance of the coil. The resistance at any temperature t is approxi-
mately Rt = Ro(.l +0-004:1) , where Ro is the resistance at deg. cent., and (
is expressed in deg. cent. The ratio between the maximum and the mean
temperatures seldom exceeds 1.2, but the ratio between the mean and the
external surface temperatures may have any value from 1.4 to 3 depending
on the thickness of the coil and the amount of insulation used, an average
value for coils 2 in. thick, made of double-cotton-covered wire and impreg-
nated, is 1.5 when no external protecting covering is used.

* Lister. Journal of Inst, of Elec. Eng., Vol. XXXVIII, p. 399.

631
 Sec. 8-130 D. C. GENERATORS AND MOTORS

130. Semi-enclosed machines have the frame openings screened with

perforated sheet metal. This prevents free circulation of air through the
machine and causes the temperature to rise, on an average, about 20 per cent,
higher than if operating as an open machine.
131. In totally enclosed machines, the temperature rise of the core and
the coils is proportional to the
total loss in the machine (neg-
lecting bearing friction) it is ;

independent of the distribution

of this loss and may be found
from Fig. 54. The rating as
an enclosed machine will be
considerably lower than that
as an open machine. A casing
around the machine makes it
equivalent to an enclosed ma-
chine with an extra large radi-
ating surface; the casing should
be of heat-conducting material
such as sheet metal and should
not be of wood. Fans on the
armature help in the cooling of
enclosed machines by blowing
Anuatnre Peripheral Velocity in Ft per Mia.
the hot air against the casing.
-Temperature rise of enclosed motors 132. Forced ventilation,*
whereby air is blown through
a machine by an external fan or by a fan attached to the armature, allows
the machine to have the same rating as it would have when operating as an
open machine; 100 cu. ft. (2.8 cu. m.) of air per kw. loss should be supplied
for a temperature rise of the windings and the core of 40 deg. cent.

EFFICIENCY AND LOSSES

133. The iron lossest consist of hysteresis and eddy-current losses in the
armature teeth and core; „ „„ „j
o,.i«i^yi ,

these may be kept small by

10 16 29 86 80 4o 60 co so loo
the use of special grades of
iron (Sec. 4) and by the use !**• 0^ /
of thin and well-varnished jjg
laminations. There are
losses also in the end heads ^^
and spider due to leakage
flux losses due to filing of the ^
;

slots which short-circuits the ^

laminations; losses due to the "
> fact that the core flux takes 8.*"
the shortest path and crowds |
*"
in behind the teeth, so that -j
the core density is not uni-
form; and pole-face lossesj 20
due to the movement of the
armature teeth past the faces
of. the poles. In order to WtuprLb.
minimize the pole-face losses,
—
the pole faces should be lam- Fig. 55. Iron-Foss curves for direct-current
machines,
inated if the slot opening is
greater than twice the air-gap clearance.
134. The iron losses increase with the load if the flu x per pole ia
kept

*Gray. "Heating of Pipe-ventilated Machines," London Electrician,

Jan. 16, 1914. . . ^
, „ , . .

"Distribution of Magnetic Induction in Armatures, Journal

, 7

t Thornton.
of Inst, of Elec. Eng., Vol. XXXVII, p. 125. ,
, ^ , -n,, r. v i
Journal of Inst, of Elec. t-ng., vol.
t Wall and Smith. "Pole-face losses,"
XL, p. 577.

032
 D. C. GENERATORS AND MOTORS SeC. 8-135

constant, because of field distortion, as the densities are then very high under
alternate pole tips.
135. The individual iron losses cannot be calculated separately, and
curves such as those in Fig. 55, obtained by tests on completed machines,
must be used as follows:
Taking the machine shown in Fig. 35:
Actual maximum tooth density = 150,000 linea per sq. in.
Average core density = 84,000 lines per sq. in.
Weight of armature teeth = 385 lb.
Weight of armature core = 2,300 lb.
Frequency = pXr.p.m./120 = 16.6 cycles per sec.
Tooth loss per lb. = 6 watts, from Fig. 55.
Core-loss per lb. = 1.8 watts.
Total iron loss = (385 X 6) + (2,300 X 1.8 = 6,450 watts.
136. The armature copper loss is given by the formula
^^^^^ (watts) (27)
cm.
where Z is the number
of conductors, L
is the length of one conductor in
in. (Fig. 56), Ic is the current in each conductor, or the total current divided
by the number of armature -„
paths, and cm. is the cross- a
section of each conductor in S S,in
cir. mils.
137. The shunt excitation
loss equals EJ/ watts, where
Et is the terminal voltage and ID-
If the shunt current. In a
generator, about 20 per cent,
of this loss will be in the shunt- CO
a> <s
10
field rheostat.
138. The series excitation
5 10 15 20 25
loss equals la^R, watts, where
la is the total current in the Pole Pitch In Inches
machine and R, is the com-
bined parallel resistance of the
Fig. 56. — Dimensions of coils.
series field coils and the series shunt.
139. The brush contact resistance loss has been discussed in Par.
38 and equals Ebia watts, where Eb is the voltage drop per pair of brushes
and la is the total current of the machine.
140. The bearing friction loss for moderate-speed bearings with ring
lubrication and light machine oil is given by the*formula

0.8dZ(^)t (watts) (28)

where d is the bearing diameter in inches, I is the bearing length in inches,

and V is the rubbing velocity in feet per min.
141. The brush friction loss, assuming the coefficient of friction to be
0.28 and the brush pressure to be 2 lb. per sq. in., is given by the formula

1.25 Ay^ (watts) (29)

where A is the total brush rubbing surface in square inches, atad V is the
rubbing velocity in feet per min. The brush pressure is generally less
than 2 lb. per sq. in. (0.14 kg. per sq. cm.) except for railway motors, where
tit may be twice as large in order to keep the contact firm in spite of the vibra-
i
tion of the machine.
142. The windage loss cannot be accurately calculated and, with periph-
eral velocities less than 6,000 ft. per min., is so small that it may be
neglected.
143. The efficiency of a generator is given by the expression

Eff, -^'1^
output + losses
(30)

633
 -

Sec. 8-144 D. C. GENERATORS AND MOTORS

The efficiency of a motor is expressed

input
£;//m=- (31)
input
When the copper losses only are taken, the result is the electrical efficiency.
The commercial efficiency, which is the important one, is obtained by
substituting the total losses in the above equations. For values see Figs. 66
and 67.

OENERATOE CHARACTERISTICS AND REGULATION

144. External characteristics of separately excited generators.
Fig. 57 shows some of the saturation curves of a continuous current genera-
tor. Given a constant excitation of 18 amp., the terminal voltage at no
load is 320, at full load is 292, and at twice full load is 262 volts. The rela-
tion between Ei, the terminal voltage, and la, the load current, is given in
curve 1, Fig. 58, the excitation and the speed being constant. This curve is
called the external characteristic of the machine. The voltage drop.s as the
load increases because the cross-magnetizing and the demagnetizing effects
of armature reaction reduce the' flux per pole, while part of the generated
voltage is required to send the armature current through the armat re and
brushes. The demagnetizing ampere-turns per pole are directly propor-
tional to the armature current, but their effect in reducing the flux increases
as the flux density decreases.

faoo

tl60
 D. C. GENERATORS AND MOTORS Sec. 8-147

ance is reduced below this value, the machine becomes completely demag-
netized (except for the residual magnetism), and the terminal voltage and
the armature current both become practically zero.
147. When a shunt generator is short-circuited the machine is de-
magnetized and the current becomes negligible (Fig. 59). At the instant
of short-circuit, however, the flux in the pole cannot reduce suddenly to
zero, and the voltage due to this flux will send a large current through the
circuit; at the end of a few seconds, however, the current will have become
zero.
148. Instability of unsaturated shunt generators. If the no-load,
normal voltage point on the saturation curve la a. Fig. 60, below the point
of saturation, then the overload capacity of the machine will be small, and
the change of voltage with load will be large. Furthermore, a slight decrease
in speed will cause a decrease in the generated voltage, which will decrease
the shunt field current and cause the voltage to drop still further. If ac is
tangent to the saturation curve at point a, then the ratio of voltage change
to the change of speed producing it, is ab/oc.

S
600 rj 160

I
Sec. 8-153 D. C. GENERATORS AND MOTORS
characteristic curves for compound generators. The compounding of a
machine may be reduced by shunting the series field coils with a resistance;
this resistance is called a "series shunt."
153. Series generators. Curve 1, Fig. 61, shows the relation between
voltage and current if there is no armature resistance or armature reaction.
This is really the no-load saturation curve of the machine and is determined
by separately exciting the field coils so that no current flows in the armature.
Curve 2 shows the actual relation between terminal voltage and load current.

330

ISO
 D. C. GENERATORS AND MOTORS SeC. 8-158

e.m.f.and also to send the armature current la through Rm, the resistance of
the armature winding, the brushes and the series field coils; or
Ea^Ei+IaRm (volts) (32)
where Ea is the applied e.m.f. and Eb, the counter e.m.f., is given by Eq. 9,
Par. 60.
158. Shifting of the brushes. It may be seen from Fig. 2 that, while the
brushes of a generator are shifted forward in the direction of motion to help
commutation, those of a motor have to be shifted backward. In each case,
however, the armature reaction reduces the flux per pole.
169. The torque equation. The torque of a motor is proportional to
the number of conductors on the armature, to the current per conductor
and to the total flux in the machine. The formula for the torque is
torque = 0.1175 Z ^Ia(^~^J IQ'^ (lb. at 1 ft. rad.) (33)

where Z the total number of armature conductors,

is is the total flux per
pole, and la is the armature current taken from the line.
160. The speed equation is
E. = Ea-IaR.^Z,C-:^) (ggjlO-« (volts) (34)

or

For a given motor the number of armature conductors Z, the number of poles,
and the number of armature paths, are constant. The torque can therefore
be expressed as
torque = a constant X 0Jo (36)
and the speed, likewise, is expressed

r.p.m. = a constant X (— — -
)
(37)

161. Shunt-motor speed and torque. In this case Ea, Rm and <t> are
constant, and the speed and torque curves are shown in curves 1, Fig. 64; the
effective torque is less than that generated, by the torque required for the
windage and the bearing and brush friction. The drop in speed from no
load to full. load seldom exceeds 5 per cent.; indeed, since <p, the flux per pole,
decreases with increase of load, due to armature reaction, the speed may
remain approximately constant up to full load.
162. Effect of field-coil heating on speed. The field-coil resistance
increases and the exciting current decreases about 20 per cent, as the field
coils increase in temperature. The flux per pole is therefore less and the
speed greater when the machine is hot than when cold, unless a field rheostat
is manipulated to keep the exciting current constant. The effect of change
of exciting current on speed is minimized by having the magnetic circuit
well saturated, so that a large change in current will produce only a small
change in flux.
163. Variable-speed operation of shunt motors can best be investi-
gated by means of Eq. 37, Par. 160. In order to increase the speed, must
be reduced by inserting a resistance in series with the field coils. In order
to decrease the speed below the value which it has with full field, the quantity
{Ea — IaRm) must be decreased by placing a resistance in series with the
armature. The latter resistance must be able to carry the armature current,
i
but the starting resistance must not be used for this purpose since it is de-
, ngned for starting duty only, and would burn out if allowed to carry full-
load current for more than a few minutes.
164. Speed control of shunt motors by armature resistance is not
very satisfactory, since the speed regulation is bad. If a motor is operating
with full-load current at half speed, about 50 per cent, of the applied voltage
ia consumed in the resistance, but if the load were decreased, so that only
half of full-load current was required, then only 25 per cent, of the applied
voltage would be consumed in the same external resistance, and the motor
peed would increase to 75 per cent, of normal speed, unless the external
637
 Sec. 8-165 D. C. GENERATORS AND MOTORS
control resistance were automatically increased with decrease of load. Due
to the large voltage drop across the external resistance, the efficiency of the
system is low.
165. When
the speed of shunt motors is controlled by field resist-
ance, the speed regulation and the efficiency are both good, but the commu-
tation is generally poor becauae, at high speeds, the main field is weaker than
normal while the armature field is unchanged, so that the field distortion is
excessive and the commutating field under the pole tip consequently dis-
appears (Par. 36). The reactance voltage also is increased (Par. 46). With
standard shunt motors without interpoles, it is generally impossible to in-
crease the speed more than 60 per cent, by field weakening without having
trouble due to sparking, the output of the machine being the normal full
load.
166. Speed changes of shunt motors under rapidly fluctuating
loads. * When the load on a shunt motor increases slowly, the flux per pole
decreases due to armature reaction,
mo and the speed (Eq. 37, Par. 160) re-
mains approximately constant. If,
1100 however, the load changes rapidly,
the flux per pole cannot cihange
rapidly due to the self-induction of
„„.
1000 - ,^ .^ the field coils; the machine then
A [sf^A, VtP operates for thj instant as a con-
^ jj^ _52^o, Y?^..
stant-flux machine, and the speed
900
drops rapidly to allow the counter
e.m.f. to decrease and the necessary
800
current to flow.
M n^^^^::d~~~/J 167. Speed and torque of series
motors. The speed equation (Eq.
700
37, Par. 160) and the torque equa-
tion (Eq. 33, Par. 159) apply to
600 motors of all continuous-current
,yrr types. In the case of series motors
S /j^. the flux increases with the arma-
<t>

SO ture current la', the torque would be

(g J^ d' proportional to la^ were it not that

.^^ ^y
tS tn <^ the magnetic circuit becomes satu-
^ 40 I I
"^
I cP
I I
rated with increase of current. Since
I

<p increases with load, the speed drops

' 30 as the load increases. The speed
and torque characteristics are shown
in curves 3, Fig. 64.
20
168. Excessive speeds of series
motors on small loads. If the
) 10 load on a series motor becomes small,
the speed becomes very high, so that
a series motor should always be
geared or direct-connected to the
load. If it were belted, and the belt
broke, the motor would run away
and would probably burst.
169. Speed adjustment of series motors. For a given load, and there-
fore for a given current, the speed of a series motor can be increased by
shunting the series winding or by short-circuiting some of the .series turns,
so as to reduce the flux. The speed can be decreased by inserting resistance
in series with the armature.
170. The compound motor is a compromise between the shunt and the
series motor. which assists the shunt winding,
Becau.se of the series winding,
that the torque increases more
the flux per pole increases with the load, so
rapidly and the speed decreases more rapidly than if the series winding was
not connected, but the motor cannot run away on light loads, because of the
 D. C. GENERATORS AND MOTORS SeC. 8-171

shunt excitation. The speed and torque characteristics for such a machine
are shown in curves 2, Fig. 64. The speed of a compound motor can be
adjusted by armature and field rheostats, just as in the shunt machine
(Par. 163).
171. Automatic speed regulation. To keep the speed constant under
all conditions of load some kind of centrifugal governor may be used to operate
on the shunt-field rheostat. A piece of apparatus of this kind now on the
market* is an adaptation of the Tirrill voltage regulator, in which a cen-
trifugal control device mounted on the motor shaft performs the functions
of the main control magnet in the standard regulator. The regulator period-
ically short-circuits pax-t of the shunt-field rheostat by means of light vibrat-
ing contacts of small inertia. The time during which the rheostat is short-
_

circuited, or is active, determines the average field current and the flux per
pole, and therefore the speed of the machine. When the speed is too high,
the centrifugal device short-circuits the rheostat for a long period and allows
the flux per pole to increase and the speed to decrease.
172. The differential motor is a compound-wound machine with the
series winding opposing the shunt winding, so that the flux will decrease as
the load increases and the speed be constant from no load to full load, or
actually increase with increase of load. The series winding of such a motor
should be short-circuited when starting the machine, so that the starting cur-
rent will not be excessive. Differential motors are rarely used, because the
speed of the shunt inotor is so nearly constant from no load to full load that
the extra complication of the differential winding is rarely necessary. Dif-
ferential windings are used to some extent for small motors, in order to
secure constant speed with variable load.
173. Unstable operation with rising-speed characteristic. Upon
suddenly increasing the load torque on a differential motor, designed for a
rising-speed characteristic, the speed for a brief instant decreases. This
results in a momentary drop of counter e.m.f., which admits a larger armature
current, in turn weakening the resultant field strength and further reducing
the counter e.m.f. The attendant increase in armature current increases
the armature torque, and the reactions are such that the latter continues
to increase until it exceeds the load torque and commences to accelerate
the armature. The increase in speed continues until the rising counter
e.m.f. finally limits the armature current to a value at which. the armature
torque equals the load torq^ie, and the speed becomes constant. These re-
actions, with change of load, occur quite rapidly; if, however, the field
cores are large and massive, changes in flux attendant upon sudden changes
in m.m.f. will lag by an appreciable time interval, on account of eddy
currents in the cores. The presence of an appreciable flux lag, with very
rapidly changing loads, results in unstable operation; for example, when the
load is suddenly increased, the speed will drop appreciably before it com-
mences to accelerate, and when the load is suddenly removed, the speed
will rise appreciably before it commences to decrease. The effect of the
armature inertia will accentuate these defects in speed regulation. Such
defects are not found in motors whose speed decreases with increasing
load, i.e., which have a drooping speed characteristic.
174. Interpole motors have a commutating field which increases with
the current and is not affected by armature reaction (Par. 62). Motors
which are subjected to excessive overloads, and adjustable-speed motors
operating at high speeds with a weak main field, give little trouble due to
sparking if supplied with interpoles. Huntingf takes place in interpole
machines which have a rising-speed characteristic. Such a character-
istic may be obtained by working with a weak main field and with
a short
air-gap under the main poles, so that the field distortion under load is large
and the flux per pole decreases with increase of load due to the cross-mag-
netizing effect of the armature (Par. 32).
Such a characteristic may also be obtained by making the interpoles too
^^ commutation is perfect, the current in the short-circuited coil
'**''i?u^'
will be zero when that coil is in the geometrical neutral position.
If, however,

* General Electric Company's Bulletin on "Automatic Voltage Regulators,"

t Rosenberg, Electrician, Aug. 4, 1911.

 Sec. 8-17.5 D. C. GENERATORS AND MOTORS
the commutating field is too strong, the reversal of this current will be ad-
vanced, so that the true neutral will be shifted backward. The flux per pole
will therefore decrease with increase of load, due to the demagnetizing effect
produced, and the speed will increase with load.
Due to saturation of the interpole core, the interpole field will be too strong
at light loads, if of the proper strength at full load. Hunting is therefore
likely to occur at light loads, particularly if the main field is so weak that the
effect of the brush currents in demagnetizing the machine is proportionately
large.
175. Non-inductive shunts should not bo used with interpole
windings if the load fluctuates rapidly, because then the current, which is
rapidly changing, will pass through the shunt rather than through the inter-
pole coils, since the latter have considerable inductance, and the commutation
will therefore be poor. To make the shunt take its proper share of the cur-
rent under all conditions of load, it should be made inductive by winding it
on an iron core, and the ratio of the shunt reactance to the interpole-coil
reactance should be equal to the ratio of the shunt resistance to the interpole-
coil resistance.
176. Reversal of direction of motion. In order to reverse a motor
necessary to reverse the current in the field coils, or in the armature, but
it is
not in both. In an interpole machine, the interpole winding must be
considered as part of the armature and not as part of the field system.
WEIQHTS AND COSTS
177. Weights and costs. The cost figures given by different manufac-
turers on a large generator may vary as much as 50 per cent. One manu-
facturer may build an entirely new machine and charge part of the cost of
development to the order; another may offer a standard machine of larger
capacity, with a lower rating for the particular case; while still another
manufacturer may increase the rating of a machine of smaller capacity,
adding fans if necessary to keep the machine cool.

>

1000 20C0 3000

BeTs.per Uin.

Fia. 65. — Cost of small direct-current motors without base or pulley.

The depends largely on the cost of material, while that
cost of large units
of small motors depends largely on the cost of labor. These costs are con-
tinually changing, so that it is impossible to give figures which are always
reliable. The curves in Figs. 65, 66 and 67 are average figures for standard
machines.
178. Short-time ratings. The effect of time on the rating may be
seen from the following. A given frame will have a rating of 12 h.p. at 500
r.p.m. as an enclosed machine on continuous duly; or 19 h.p. at 500 r.p.in.
as an open machine on continuous duty; or 31 h.p. at 500 r.p.m. with a 1-hr.
rating; or 40 h.p. at 500 r.p.m. with a half-hour rating. The temperature rise
on full load is 40 dog. cent, as an open machine, and .50 deg. cent, us an en-
closed machine. The horse-power is proportional to the speed over a range
U40
 D. C. GENERATORS AND MOTORS Sec. 8-178

IGOO

2400 1200 1200

10 20 30
Horee Power
Fio. 66.— Weight and cost of standard 220-volt direct-current motors
witliout base or pulley.

020,000 21,000 1200

100,000 20,000 1000

-^80,000 516.000 . 800

S Q 5
- ^ ^

60.0001-12,000 " 600

40,000 8000 400

20,000 4000 200

Sec. 8-179 D. C. GENERATORS AND MOTORS
of 30 per cent, above or below the rated speed. The maximum permissible
speed IS the highest that can be used for variable-speed operation with the
particular line of machines on which data is given.
179. ESect of voltage on weight, cost and efficiency. If two machines
are built on like frames for the same output and speed but for different vol-
tages, the number of commutator segments will be proportional to the voltage
and the commutator length will be proportional to the current. The low-
voltage machine will be the heavier because of the long commutator, but,
for moderate outputs, there will not be much difference in cost between a
120-volt and a 000-volt machine; the cost of the extra copper on the low-
voltage machine is compensated for by the cost of the extra labor on the high-
voltage commutator.
The losses will be afTected in the following way: The windage, bearing
friction, excitation and iron losses will be unchanged; the brush friction loss
will be the smaller in the machine with the higher voltage; the contact
resistance loss will be the smaller in the machine with the higher voltage
because the contact drop is the same in each case and the loss is therefore
proportional to the current. The armature copper loss will be unchanged
if the same amount of armature copper is used in each machine, because,
since the number of conductors is directly proportional to the voltage, the
section of each conductor will be proportional to the current and the current
density will be the same in each machine. If, however, due to the space taken
by the insulation on the large number of conductors, the total amount of
copper is the smaller in the machine with the higher voltage, then the copper
loss will increase with the voltage and, for the same copper less in each
machine, the output of the high-voltage machine will be less than that of the
low-voltage machine.
180. Effect of speed on weight, cost and efficiency. The output of a
machine equals the product of (volts per conductor) X (current per con-
ductor) X (number of conductors). For a given frame, the volts per con-
ductor is directly proportional to the speed, and the product of (the current
per conductor) X (number of conductors) is constant for a constant current
density and a constant weight of armature copper. The output is therefore
directly proportional to the speed. As a matter of fact the flux density
must decrease as the speed and the frequency increase, in order to keep down
the iron loss; but the current density may increase with speed due to better
ventilation. However, the output is directly proportional to the speed, over
a considerable range. The higher the speed, the larger the output, and there-
fore the longer the commutator and the heavier the machine.
At very low speeds the number of conductors becomes large and, on account
of the amount of insulation required, the total amount of copper is less than
normal; the rating of such machines must therefore be reduced in faster ratio
than the speed is reduced.
The total armature loss for a given frame and a given temperature rise is
equal to A:(^-^BXr.p.^l.) (see Fig. 52) so that while the output is directly
proportional to the speed, the losses do not increase so rapidly; and, until
turbo-speeds are reached, at which the windage losses become excessive, the
efficiency increases with the speed.

STANDABD CONSTANT-POTENTIAL GENERATORS

181. Oenerators for power and lighting service are usually wound
for 125 volts or250 volts and are either flat-compounded or slightly over-
compounded, so that the voltage at the lamps varies but little with change of
load. The efficiency, weight, cost and speed may be obtained from Figs. 66
and 67. The regulation should be less than 2 per cent.
182. Oenerators for railway service are subject to rapidly fluctuating
loads and to sudden and excessive overloads. The engine speed will drop
considerably on an excessive overload imless a large flywheel is suppliea.
The machines are generally wound for 550 volts at no load and 000 volts at
full load for city service, 1,200 volts for interurban service and 3,000 volts
for trunk line electrification. In order to secure proper commutation under
all load conditions, interpolc machines are generally employed.

183. Generators for electrolytic work arc usually low-voltage machines

of large current capacity. When the terminal voltaae is very low, the excit-
ing current will be large if the machine is shunt wound, and the field rheostat

042
 ,

D. C. GENERATORS AND MOTORS SeC. 8-184

will be relatively expensive; therefore such machines are often separately

excited from a source of higher voltage. For electric smelting and otner work
where the machine is likely to be subjected to short circuits, shunt excitation
is desirable, since a shunt generator will not maintain a large current through
a short circuit (Par. 147). Because of the large currents to be collected, these
machines have low-resistance brushes, a high current density in the brush
contact and a wide brush arc. These conditions are bad for commutation
so that iuterpoles are often used. Since each armature circuit has compara-
tively few conductors in series^ and these conductors are of large section, there
will be large circulating currents unless equalizers (Par. 19) of large cross-
section are used. Windings such as that shown in Fig. 14 are particularly
suited for generators of this type. Electrolytic generators cost and weigh
more than standard ooO-volt machines, because of the large amount of com-
mutator copper required. Accurate cost figures cannot be given since the
design is generally special.
184. Boosters are used in constant-potential systems to compensate for
feeder-drop or to aid in charging storage batteries, etc. Boosters carry large
currents at low voltages and have long commutators in proportion to their
output. In order that the flux may be proportional to the exciting current,
the magnetic circuit must not be saturated; for this reason the machine is
heavier than a machine of normal voltage and of the same output. Boosters
often carry large currents in a weak magnetic field, so that they must be
liberally designed for commutation. Reversible boosters often have lami-
nated field systems. When reversing a machine with a solid field system,
eddy currents set up in-the solid masses by the change of flux prevent this
change from being very rapid.
185. Exciters are generally flat-compounaed for 120 volts or 240 volts if
the excited machine is operated without an automatic regulator. When
operated with an automatic regulator, the exciter must be capable of supply-
ing a voltage about 40 per cent, more than normal. The magnetic circuit
should not be highly saturated,
in order that the necessary in-
crease in excitation for a given
j

I
——
^ i
irr:±:::i
' r~
increase in voltage of the ex-
cited machine may not be too
large. Machines with solid
poles are quite satisfactory, as
very rapid changes of voltage
are not desirable. The weight,
cost and efficiency of such ma-
chines may be obtained from
Fig. CC.
186. Variable-speed gen-
erators* used for the lighting Speed
of vehicles are required to give
constant voltage over a wide
range of speed. "Many patents
have been taken out on ma- Fig. G8.- -Rosenberg car lighting genei^
chines for this purpose. In one ator.
type the armature is moved
axially out of the field by a governor, as the speed increases. In another
type the brushes are shifted automatically as the speed changes. Other
machines are driven by slipping belts or slipping clutches.
187. The Rosenberg variable-speed generatorf is self-regulating and is
shown diagrammatically in Fig. G8. The battery voltage is approximately
constant and the shunt field sends across the air-gaps a flux 0i, which is ap-
proximately constant. The armature cuts this fl\ix and an e.m.f. is generated
between brushes hb, but none between brushes BB. The former brushes are
short-circuited, so that a current flows in the armature and sets up an arma-
ture field <j)2. Since the armature cuts this latter field, there is an e.m.f.

'Morgan. "Dynamos for Motor Road Vehicles," Journal of Inst, of

Elec. Eng., Vol. XLVIII, p. 749.
t Hall. "The Rosenberg Generator," General Electric Review, Vol. XIII,
37.

I 643
Sec. 8-188 D. C. GENERATORS AND MOTORS
between brushes BB and a current I in the external circuit. This current 1
Bets up a flux 03, which opposes 0i, but can never exceed 0i, so that / cannot
exceed that value at which the armature ampere-turns per pole equal the
shunt-field ampere-turns per pole. The relationship between current and
speed for different shunt excitations is given in Fig. 68. The direction of the
current I is independent of the direction of rotation of the machine.
188. Third-brush generators. • This type of machine is shown
diagrammatically in Fig. 69. At no load the exciter voltage ab is half the
terminal voltage ac, but armature
a reaction weakens the leading pole
tip so that as the armature cur-
rent increases, the exciter voltage
ab decreases and thereby limits
the current.
Another type of thiid brush gene-

189.
-Oj
Fia. 69.
A
—
Third brush generator.
angles.
rator t gives constant voltage over
a wide range in speed and without
the use of a battery. The ma-
chine has a 2-pole armature and a
4-pole field system excited so as to
give two magnetic fields at right

system of car lighting by a shunt generator driven from

the car axle is shown diagrammatically in Fig. 70. The diagram shows the
conditions at standstill the switch S is open, the generator is cut out and the
;

battery supplies the lamps. As the car speeds up, the generator voltage
increases and, when the value is reached for which solenoid f was set, the pull
of the magnet closes the switch and connects the generator in parallel with
the battery. The generator then delivers current to the battery and to the
lamps, which current, flowing througli coil H, helps to keep the switch closed.
As the speed increases, the voltage of the generator and the battery current
bothincrease,but
'^° '^'"', when full-load
•t . battery current is
reached, the pull
of coil Dacts to
1essen the pres-
sure on the car-
bon pile B and the
generator voltage
decreases; coil D
therefore limits
thebatterycharg-
ing current.
Car-lighting system. When the bat-
tery reaches full
charge, its voltage rises to the maximum value and then the pull of coil B
acts to lessen the pressure on the carbon pile, preventing further rise of volt-
age and permitting the generator to supply only the current for the lamps.
When the speed drops below a certain value, the battery voltage is higher
than that of the generator; current then flows back through the coil H,
thus releasing the switch S and disconnecting the generator from the circuit.
Since the generator current should always bo in the same direction no mat-
ter what the direction of motion of the car, a pole changer A is supplifd this ;

consists of a double-throw switch operated by means of a mechanism on the

shaft, which mechanism reverses the switch when the rotation of the genera-
tor reverses.

THREE-WIRE CONSTANT-POTENTIAL GENERATORS

190. The early three-wire systems were operated with two similar
generator units connected in series and the neutral connected to the centre
• Langsdorf. ' 'Principles of Direct Current Machinery," 2d e<l., p. 434.

t S. R. Bergman. "D. C. Generator for Constant Potential at Variable

Speed," Proc. A. I. E. E., Vol. XXXVII
(Aug., 1918), pp. 1011-1018.

644
 D. C. GENERATORS AND MOTORS Sec. 8-191

point as shown in Fig. 71. In this system the voltages Ea and Ei can be
regulated independently of one another.
191. The earliest type of three-wire generator was a machine which
had two armature windings on the same core, revolving in the same magnetic
field, with a separate commutator for each winding. This machine was
connected as shown in Fig. 72. Since the armature reaction affects each

FiQ. 71. Fig. 72. FiG. 73.

Figs. 71, 72 and 73.- -Three-wire systems.

winding equally, it has no effect on the division of voltage, so that Ea differs

from Eb only by the armature resistance drops in the two windings. These
voltages cannot be regulated independently of one another by means of
field rheostats.
192. The Dettmar and Rothert machine is of the split-pole type
and is shown diagrammatically in Fig. 73 for the case of a two-pole armature
revolving in a field system with four pole-pieces. Even on balanced load,
the armature reaction strengthens the upper S pole and weakens the lower
S pole, so that Ea increases and ^6 decreases with increase of balanced load.
To neutralize this effect, the weakened poles are compounded cumulatively
and the strengthened poles are differentially compounded. If the shunt

i^H^^hi,
Fio. 74. Fig. 75.
Figs. 74 and 75. — Unbalanced currents in three-wire generators.
coils 2 and 4 are connected across Ea, and the coils 1 and 3 across Eb, the
balancing will be better than if all four coils were connected in series across
E. The voltages Ea and Ei, can be regulated independently, by hand, when
the excitation is thus divided.
193. The Dobrowolsky machine is that generally used for three-wire
operation. It is shown diagrammatically in Fig. 74 and consists of a stand-
ard two-wire machine with a coil of high reactance and low resistance con-

64.^
Sec. 8-194 D. C. GENERATORS AND MOTORS
nected permanently across diametrically opposite points on the armature.
The voltage between o and b is alternating and, even at no load, or when
the load is perfectly balanced, an alternating current flows in this reactance
coil. This current, however, is extremely small because the reactance is
large. The center o of the coil is always midway in potential between the
brushes c and d, and ia connected to the neutral of the system. When the
loads on the two sides of the systena differ, the difference between the cur-
rents in the outside lines flows in the neutral wire and through the reactance
coil, which offers only a small resistance to direct current.
194. The current distribution in the Dobrowolsky machine* may
be considered as that due to the average current (ti + J2)/2 and a super-
imposed unbalanced current — ii)/2, as shown in Fig. 75. The former
(,i\

of these currents flows in the outside lines, but does not pa.ss through the
neutral line, and so does not affect the potential of the point o. The un-
balanced current is that which affects the voltages on the two sides of the
system and this current is shown separately in Fig. 76.

Fia. 77.
Figs. 76 and 77. — Unbalanced currents in three-wire generators.

If Ra is the resistance of the armature from brush to brush, then the resist-
ance from a to c varies from O to '2Ra and, in the position shown in Fig. 76,
equal to Ra. If Rb is the resistance of each of the two legs of the balance
it is
coil,the voltage drop from o to a ia equal to (ii — i2)Rb/2; the drop from o to c
equals ieRc and is alternating, with an average value of (ii — i2)iJii/6. The
average drop from o to c is expressed by
{i\-i-i) /Ra r> N
,

(volts) (38)

195. The unbalanced current (u — ii) ia generally limited to 2.5 per cent,
of the full-load current in the out-side lines and, since the armature drop at
full load equals tho product of full-load current and Ra, and seldom exceeds
3 per cent, of E, it follows that the average voltage from o to c seldom
exceeds 0.25 per cent, of Ea for 25 per cent, unbalanced current. Therefore
the regulation of each side of the system is determined principally by the
drop in the balance coil and can readily be kept within 2 per cent.
196. The use of two balance coils connected as shown in Fig. 77 results
in a slight improvement in tho machine. The average voltage drop from
o to c in this case is .

(il^^l(^^J? +i?b) approx. (volts) (39)

and is apparently loss would be with only one coil. But when two
than it
coils are used, as in Fig. 77, each one carries half of the current carried by
the single coil in Fig. 7(); therefore the wire used has half the section and each
of the coils in Fig. 77 has twice the resistance of the coil in Fig. 76,_ and the
drop from o to a is the same in each case. The drop from o to c is less in"
Fig. 77 than in Fig. 70, but the difference is so small that it has little effect on
* Hawkins. Journal of Inst, of Elec. Eng., Vol. XLV, p. 704.
Fergu.son. "Characteristics of the Th-eo-wire Generator,' Electrical
WoTld, Vol. 64, pp. 1199-1204. Dec. 10, 1914.
 D. C. GENERATORS AND MOTORS Sec. 8-197

the regulation; it does, however, reduce the heating, because the unbalanced
current has the shorter distance to travel in the armature when two balance
coils are used, so that for the same armature temperature rise, the machine
with the single balance coil requires slightly larger copper for the armature
conductors than that with two balance coils.
197. The rating
of the balance coil. The voltage between o and 6
and has a maximum value equal to E and an
(Fig. 74 to Fig. 76) is alternating
effective value equal to E/y/l. The current in each half of the balance coil
—
equals (ii J2)/2, neglecting the small exciting current, so that the volt-
ampere capacity of the balance coil equals JS(n — t2)/2-v/2. The normal out-
put of the generator on balanced load equals El volt-amperes, so that for
25 per cent, unbalanced cur-
rent, the transformer rating in
volt-amperes is only 9 per cent.
of that of the generator.
198. Compound-w o u n d :j=j.
three-wire generators have 1
all the series coils on the N
poles placed on one side of the
'It
circuit and all the series coils
on the S poles placed on the
other side of the circuit, so that
J L J L
the compounding is independ-
ent of the unbalancing of the
load. The compounding has
no effect on the voltage unbal-
ancing.
199. Parallel operation*
(Par. 239) is possible if two
equalizers are used, one for
each set of series field coils.
The diagram of connections is
w ^ WW
shown in Fig. 78; six leads per Fig. 78. Parallel connection of three-wire
machine are required because generators.
W
the circuit-breakers on the
switchboard must be in the armature circuit and not in the equalizer circuit.

STANDARD CONSTANT-POTENTIAL MOTORS

200. Motors
for general industrial service should be of the open type
whenever possible. The totally enclosed type should not be used unless
absolutely necessary. For crane service, a totally enclosed series motor is
used with a half-hour rating. For elevator service, an open compound
motor is used, and for freight hoists, an open series motor each with a 1-hr.
rating.
201. Motors for railway service are generally wound for 550 volts-
They are series wound, and so constructed that they may be easily opened for
repair. The steel frame is of the split-box type, so arranged that the complete
armature may be easily removed. The armature core and commutator shell
are mounted on a cast-steel spider, in order that a damaged shaft may readily
be removed. Railway motors have undercut mica (commutator insulation)
and abrasive brushes, but the tendency is to use interpoles in order to mini-
mize sparking and flashing-over and to allow high speeds to be obtained for
suburban service by field weakening. Since the load fluctuates between wide
limits, interpole shunts should not be supplied (Par. 176).
Railway motors may be built for 1,200 volts, but the weight, size, and cost
are increased for a given rating. A 100-h.p. 600-volt motor can be rebuilt
to develop 75 h.p. at 1,200 volts; the larger the output the less will be the
difference in rating between the high-voltage and the low-voltage machine.
The 1,200-voIt machine has the shorter commutator and therefore the longer
core and the larger flux per pole, but has less copper in the slots due to the
extra insulation required for the large number of conductors and the high
voltage. A four-pole machine with an average of 20 volts between segments

• Bulletin on " I. T. E. Circuit Breakers..

1 647
See. 8-202 D. c. generators and motors
will have 240 segments and, with, a minimum segment and mica of 0.2 in.
(0.5 cm ) thickness will have a commutator diameter of about 15 in. (38 cm.).
For further information see Sec. 16.
202. Mill motors for rolling-mill work are built like street railway motors
set on feet, and are constructed in a similar manner in order that they may be
readily repaired. The shafts are made stiffer than usual, which results in
greater bearing friction and smaller efficiency than in standard motors.
These motors weigh and cost about 20 per cent, more than standard motors
of thesame rating.
203. Mine motors are designed to operate in a damp atmosphere and
must therefore be specially impregnated with waterproof compound.
204. Flame-proof motors, * for operation in explosive atmospheres, must
have the current-carrying parts completely enclosed in flame-tight enclosures
of non-infiarnmable material of sufficient strength so as not to be endangered
by an explosion in the motor interior. The housings of such motors should
never be opened in service except when the motor is completely discon-
nected from the supply circuit.
It is impossible to construct motors which are gas-tight. When the
machine becomes heated, any gas which is in the case expands and some of it
is forced out along the shaft. When the motor cools again, a fresh supply of
gas will be drawn into the case. Flame-tight motors, wherein the trans-
mission of an inside explosion to the outside is prevented, have proved feas-
ible. There are two types: (a) Totally enclosed machines, constructed to
withstand a pressure of 110 lb. per sq. in. (7.7 kg. per sq. cm.), are built in
capacities up to about 25 h.p., but become large and expensive for greater
outputs, (b) Plate-protected motors have openings which are filled with
plates about 0.02 in. (0.5 mm.) apart so as to form a labyrinth passage for
the gases; the function of this labyrinth is to cool the products of combustion.
205. Adjustable-speed motors are efficient only when operated by field
control (Par. 164). For a wide range in speed, interpoles are required (Par.
166). The size and cost of the machine depend on the minimum speed at
which it is necessary to supply the rated output, and the maximum speed is
that at which the peripheral velocity reaches a safe limit. By the use of
interpoles, deep slots may be employed, and the output for a given weight
increased 10 per cent, over that for a non-interpole machine, but the cost per
horse power is not reduced. The following table gives a list of ratings that
may be obtained from a given frame, suitable windings being supplied; a
speed range of 3 to 1 is ample for most purposes:
46 h.p. at 800 to 1,200 rev. per min.
40 h.p. at 700 to 1,200 rev. per min.
34 h.p. at 600 to 1,200 rev. per min.
29 h.p. at 500 to 1,200 rev. per min.
20 h.p. at 3.50 to 1,050 rev. per min.
17 h.p. at 300 to 900 rev. per min.
14 h.p. at 250 to 750 rev. per min.
11 h.p. at 200 to 600 rev. per min.

STANDARD CONSTANT-CURRENT GENERATORS

206. Open-circuit windings. Fig. 79 shows an armature with two open
coils and four commutator segments. The voltage between A and B varies
as shown in Fig. 80; the current is pulsating and only half of the armature
is in use at any given instant.
207. In the Brush arc machine the commutator segments are made to -

overlap as shown diagrammatically in Fig. 81 and the brushes are wide enough
to cover two overlapping segments. During the first one-eighth rev., coil C
alone is active and the e.m.f. in that coil passes through its maximum value.
During the next one-eighth rev., coils C and D are in parallel; the e.m.f. in C
is decreasing and that in D
is increasing. During the next one-eighth rev.,
coil C is cut out and coil D alone is active. When two coils are in parallel
the higher e.m.f. in one coil tends to reverse the current in the coil of lower

• Baum. " Fire Damp-proof Apparatus," General Electric Review, Vol.

XIII, p. 402.

648
 D. C. GENERATORS AND MOTORS SeC. 8-208

e.m.f. and, when the latter current is zero, the contact between the corre-
sponding coil and the brush may be broken without sparking. Thus by rocking
the brushes, a position of minimum sparking may be found.
208. Ratings of Brush arc generators. A 6,250-volt, 9.6-amp., 500-
rev. per min. Brush machine weighs 9,590 lb. (4,350 kg.), occupies a floor
space of 84 in. by 56 in. (2.1 by 1.4 m.) and requires 91 h.p. to drive it.

Open coil armature. Fig. 80. — Voltage between A B.

209. The Brush regulator in its simplestform is shown in Fig. 63.
A more recent type consists of two electromagnets rotated in opposite direc-
tions on a common axis by means of belts from the main shaft; between the
magnets is a piece of iron which, when clutched by either electromagnet,
causes the contact arm to move over the face of a rheostat which shunts the
field windings. The excitation of the clutch magnets is controlled by a sole-
noid in the line circuit, so adjusted as to close the circuit of one magnet, or the
other, according as the value of the line current is too great or too small.

Fig. 81. — Brush type.

Arc light
FiQ. 82. — Thomson-Houston type.
generators.

210. The Thomson-Houston machine has three open coils spaced 120
electrical degrees apart, joined together at their inner ends, and connected to
a three-part commutator at the outer ends, as shown diagrammatically in
Fig. 82. At the position shown in Fig. 82, the e.m.f. in coil C is increasing,
that in D is decreasing, and that in A is zero; coil A is therefore out of cir-
cuit at the instant. As the armature revolves, the e.m.f. in A increases and
that in Ddecreases, until finally the brush disconnects the coil D
and connects
A in series with C. This cannot be done suddenly, however, or bad sparking
would result; therefore the extra set of brushes (shown by dotted lines) is
added and coils A and D
are connected in parallel until the increasing voltage
in A is able to reduce the current in D
to zero, and thereupon the latter coil
can be disconnected from the brush. The voltage regulation in this machine
* For tables of ratings of arc-lighting generators see Houston and Ken-
nelly, " Recent types of Dynamo-electric Machinery," pub. 1898.

649
Sec. 8-211 D. C. GENERATORS AND MOTORS
is obtained by shifting the brushes. When
the brushes are in the position
shown in Fig. 82, large e.m.fs. are being generated in the coila connected in
series; when the brushes are shifted through 90 deg. these coils are generating
low e.m.fs. and the terminal voltage is a minimum. The mechanism which
shifts the brushes also varies the angle d between brushes so as to secure
good commutation with all brush positions.
211. Bating of Thomson-Houston arc machines.* A 2,500-volt,
10-amp., 829 rev. per min. Thomson-Houston machine weighs 5,975 lb.
(2,700 kg.), occupies a floor space of 64 in. by 52 in. (1.6 X 1.3 m.) and re-
quires 38 h.p. to drive it.
212. The Thomson-Houston regulator is shown diagrammatically
in Fig. 83. The electromagnet M
is short-circuited through the contact S.
When the line current is too strong, contact S is opened by the magnet and N
the main current passes through M, which raises a lever and increases the

Thomson-Houston regulator.

brush arc. At the same time the brushes are shifted from the position of
maximum e.m.f. The arcing at the commutator is suppressed by a mechan-
ically-operated blower, and the arcing at the switch iS is minimized by the
discharge resistance R.
213. The Wood arc machine has a Gramme-ring winding with a large
number of commutator segments. The current is kept constant by shifting
the brushes, the voltage being a maximum when the brushes are in the neutral
position and zero when the brushes are under the centres of the poles.
The regulator is operated by an electromagnet which lifts a lever against the
pull of a spring; when the line current is too large, the magnet pulls the lever
in such a manner as to engage reduction gearing with the revolving armature
and cause the brushes to move to a position of lower voltage; if the current is
too small, the spring pulls the lever in the opposite direction and the gearing
then moves the brushes to a position of higher e.m.f.
As in the Thomson-Houston machine, the brushes of the Wood arc machine
are split into two parts separated by an angle (Fig. 82). As the brushes
move under the poles, for the purpose of reducing the terminal voltage, the
e.m.f. generated in the short-circuited coils increases, and nmst be counter-
balanced by a higher reactance voltage; this is readily obtained in a Gramme
winding by reducing the brush arc so as to decrease the time of commutation.
For sparkless operation, the brush angle 6 should decrease as the brushes move
under the poles; this is accomplished automatically by the brush-rocking
device.
214. Rating of Wood arc machines. * A 6,250-volt, 9.6-amp., 500 rev.
per min. Wood arc machine weighs 14,600 lb. (6,600 kg.), occupies a floor
space of 82 in. by 80 in. (2.1 m. by 2 m.) and requires 90 h.p. to drive it.
216. Constant-current generators for series arc lighting are nearly
obsolete, although the Rosenberg machine (Par. 187), is coming into use for
the operation of searchlight arcs. Direct-current series lighting systems are
now in use, but in most cases are supplied frqm rectifiers (Sec. 6).

Houston and Kennelly, " Recent Types of Dynamo-electric Machinery,

1898.
650
 D. C. GENERATORS AND MOTORS
Sec. 8-216

216 Th« r. .
THUEY SYSTEM

designing^thfmachfnf thirthe "" ^"k"^^

P°«'«°'^^ i« 'nade possible h

machine must be inli f ^i^ f ^"""d only f or 5

driven through ^'°'» ^''^ ground
and
oK ^^ ^l^^^y
^^^^^
'^°^*'-
high,
^ach
house floor is also h.l±ltt
an
made of '°''^^*'°« ^he power- ^^-^m^
protection of the hliSa^fn:,"^-
material for the
operators (^ \j
Fif 84 fe'Sd^f
tern. To g^a^^^orr''""^
DlacP „!of'k-
"^^ --^-es.
connections of the svo
. .
^^"^f
brought
nAoZe'^rtr^ii^fZTT-
in the local circuit,

To take a machine
'' '^ fi-'
current flows
the switch
position to place thpmr,!^- SJ^t^^"^
*'^''.°^'i to the
-^
proper J
Oh/
r^^^ J
^ ^
. i
i
I
o,^^^ '"^ ?^"^«
the linl
brought slowlv to +l?o °^ operation, the brushes ar^ r.T.
^"^th r^
Connection FuTrT
^f— \^
'^'"'' generators.
fwitch S is manipulated' ^°^''^°^' '^^^ the ''^
to J>?'*^^"-
«^°-^-— t the machine and disconnect
it from
'
T^'^start u

^®'''^' ^'^'^bine. ^^^®"'-

-•'"^^"'- -^bus the generator
•'""s
223.
.223. The sdobT ™'^''^^'^^- generato
SDeed Ti,
f *if

Highfield iv^^ p-r—-—^i^iLrP£I?iiBgengineers.

651
Sec. 8-224 n. C. GENRRATOIfS AND MOTORS

Standard balancer sets, * as used for three-wire operation, consist

224.
of two like units coupled together, each wound for half of the total voltage
and connected in series as shown in Fig. 85. On balanced load, they both
run "Ught" as motors; but with unbalanced load, the currents flow as shown
in Fig. 85 and machine M
acts as a motor and drives G as a generator. The
current in M
is greater than that in G by that amount required to supply
the armature losses. The motor speed drops with increase of load, ancf the
generator voltage drops due to the decrease in speed and in excitation, so
that Eg is less than iE. By crossing the shunt coils, as in Fig. 86, the regula-
tion is improved. The motor field decreases with decrease of Eg and the
speed of the set increases with load; furthermore, the generator excitation,
being taken from Em, increases with load, so that with this connection the
voltages are more nearly equal under all conditions.

Fig. 85. Fio. 86. Fig. 87.

Figs. 85, 86 and 87. — Balancer sets.

226. Compound balancers are connected as in Fig. 87, so that the gen-
erator always cumulatively compounded and the motor is compounded
is
differentially,no matter in which direction the unbalanced current flows.
This connection causes the balancer speed and the generator voltage to
increase with the unbalanced load.
The generator current is expressed by the formula,

/„ = Io^-7^^^ (40)
1+VmVa
and the motor current by
/». = lo^jf (41)

The efficiency in each case being given with the shunt-excitation loss neg-
lected. The actual combined efficiency of the set is

HOMOPOLAR MACHINES
226. Theory of Operation, t Faraday
showed that, if the metal strip A, Fig. 88,
be moved so as to cut lines of force, an e.m.f.
will be established between the brushes o and
1) and a continuous current sent round the ex-

ternal circuit connecting them.

227. The radial type, shown in Fig. 89,
consists of a metallic disc, rotating between
poles which are excited by field coils wound
concentric with the shaft. The brushes are
placed at a and 6, and holes are cast in the
Fia. 88. —
Faraday's
demonstration.
yoke to allow acce.is to the brushes. In Fig.
90, there are two discs mounted on the same
shaft so that they are electrically connected

•Budd Frankenfield, Electrical World, Dec. 23, 1905; Lanier, Electrical

Journal, Vol. IX, p. 1036.
tGrav. "Impossible Honiopolar Machines," Conatiian Elec. News,Ma.T.
15, 1913.

652
 ;

D. C. GENERATORS AND MOTORS Sec. 8-228

at the hub, and the total e.m.f is twice that of one disc.
. Steel has been sug-
gested for the disc material so as to reduce the reluctance of the magnetic
circuit; this,however, would introduce a magnetic pull, due to inequalities in
the air-gaps on the two sides of the disc, and this pull could be eliminated
only by carefully adjusting the discs and then securing them in such a way
as to prevent end play.

Fig. 89. Fig. 90.

Figs. 89 and 90. — Radial type of homopolar machine. ,

228. The axial type, shown in Fig. 91, consists of a metallic cylinder
rotating in a uniform magnetic field. The voltage of such a machine is low
a 300-kw., 500-volt, 3,000-rev. per min. machine with an armature diameter
of 19,3 in. (49 cm.), effective core length of 12.2 in. (31 cm.) and a peripheral
velocity of 15,200 ft. per min. (77 m. per sec.) generates 41.5 volts per con-
ductor in a field of 112,000 lines per sq. in. (17,300 per sq. cm.) density. In
this case twelve conductors in series are required for 500 volts, and each con-
ductor requires two slip-rings, with brushes
on each ring adequate to carry the full-
load current, the rubbing velocity being
about 15,000 ft. per min. (77 m.p.s.).*
229. The brush friction loss is very
large and the total contact drop of twenty-
four contacts in series is also large. The
efficiency is about 88 per cent, at half
load and 91 per cent, at full load.
230. The output equation (Par. 69)
for a homopolar machine is
^ ,, /wattsx /60.8X10'\ .,„.
. . .

\r.p.m./\ (&o q /
where (B^ in the above 300-kw. machine is
112,000 lines per sq. in. and is limited by
saturation; q in the above machine equals
12X600/7rX 19.3 = 120 ampere-conductors
per in., a value which cannot be increased
without increasing the number of brushes,
and which cannot' reach the value given in Fig. 91. Axial type of homo-
polar machine.
—
Fig. 29 unless some brush is devised which
will collect about 1,200 amp. per sq. in.
(186 amp. per sq. cm.) of contact surface.
Substituting the above values for (Bo and g the following equation is ob-
tained.
wattSN
Da^Lc = 45 (cu. in.) (44)
'<i p.m./
• Noeggerath. Trans. A. I. E. E., Vol. XXIV, p. 1.

6,53
Sec. 8-231 n. r. oexfrators and motors
Now the flux density in section A, Fig. 91, is limited to about 130,000 lines
per sq. in. (20,000 per sq. cm.) so that Da= 1.7 Lc approximately, and there-
fore £)a'==76 watts/rev. per min., with the above limitations.
231. Weight and cost. * Because of the low value of ampere-conductors
per in., made necessary by the brush rigging, the value of Da-Lcior a homo-
polar machine will generally be greater than for a machine of the standard
type and the machine will be much heavier and more expensive. Therefore,
until suitable brushes are found, this type of machine is not likely to be widely
used except in the case of machines for low voltages and large currents.
232. The maximum output that can be obtained for a given number
of revolutions per minute may be found by assuming a limiting peripheral
velocity of 15,000 ft. per min. (77 m. per sec). Then the output in watts is
equal to Z)a'Xr.p.m./76 and
kw = 0.72(P"'P^^f-)^X:,^^ (45)
r.p.m.2 1000
= 2.5X10V(r.p.m.)2
The maximum output and the speed are plotted in curve 4, Fig. 32. The
points shown on the curve give the ratings of two machines now in operation.
233. Compound-wound homopolar machines. The idea under-
lying the compounding is explained by the diagram in Fig. 92, which relates
to a machine having six conductors. The brushes E are connected to the
stationary conductors H by means of con-
nection pieces G. Only a portion of the
whole length of G is actually employed to
carry current, and the amount of this active
portion can be varied by the brush rocker F.
In practice it is sufficient to have a flexible
lead instead of the fixed conductor G.
234. Homopolar machines may be
made
self-exciting and Noeggerath points
out that homopolar machines may oven be
operated without the use of a field coil.
235. Standard lines of homopolar
machines are not on the market; the ma-
chines are heavy and expensive if the am-
pere-conductors per in. are kept tow so as to
_, .„ _ ,. , have a reasonably satisfactory brush rigging
Fig. 92.— Compounding of (Par. 230), and are troublesome in opera-
homopolar machines. B, arm- tion unless they are excessively large. The
ature conductors; C, insulation troubles encountered in the construction
between conductors; D, slip ^nd operation of a homopolar machine are
""SS- described by Lammet in connection with a
2,000-kw., 260-volt, 7,700-amp., 1,200-rev.
per min. machine which had 16 slip-rings operating at a peripheral velocity of
13,200 ft. per min. (67 m. per sec.) and copper leaf brushes set against the
direction of rotation, the rings being lubricated with graphite.

OPERATION OF GENERATORS AND MOTORS

236. Shunt-wound generators in parallel. A and B, Fig. 93, are
two similar generators feeding the same bus bars C and D. If machine A
tends to take more than its proper share of the total load, the voltage of A
falls, and the load is automatically thrown on B, the machine with the
higher voltage. Furthermore, if the engine connected to B fails for an in-
stant, that machine .slows down, its generated e.m.f. falls, and current flows
back from the line to operate it as a motor. Since the excitation remains
unchanged, the machine will run at normal speed and in the same direction
aa before, and, as soon as the engine recovers, will again take its share of
the load.
237. Division of load between shunt generators in parallel. The
external characteristics of the two machines are shown in Fig. 96. At
• Pohl. "The Development of Tubo-generators," Journal of Inst, of Elec.
Eng., Vol. XL, p. 239. .

t Lamme. Trans, of A. I. E. E., Vol. XXXI, p. 875.

 D. C. GENERATORS AND MOTORS Sec. 8-238

voltage E, the currents in the machines are 7a and lb, and the line current
is la+Ib. To make machine -4 take more of the load, its excitation must be
increased, in order to raise its characteristic curve. If a 100-kw. machine
and a 500-kw. machine have the same regulation, and therefore the same drop
in voltage from no load to full load, then, as shown in Fig. 96, the machines
will divide the load according to their respective capacities.

J I I L
f"^^

\Ay-' \B/" ^aJ-W -Tj^J^W

i-n!wr^ '-osu^ '-'TRnnp-' L-nSTON
Fia. 93.- -Shunt. Fig. 94. — Compound.
Connections for parallel operation.

238. Compound- wound generators in paxallel. A and B, Fig. 94,

are two compound-wound machines. If machine A tends to take more than
its proper share of the load the series excitation of A increases, its voltage
rises and it takes still more of the load, so that the operation is unstable.
Furthermore, if the engine on B fails for an instant, that machine slows down,
its generated voltage falls and current flows back from the line to operate it
as a motor. Under these conditions the shunt excitation remains unchanged,
but the current in the series coils is reversed, so that, running as a motor in a
weak field, the machine will tend to increase in speed and possibly run away.
239. Equalizer bus.
To prevent instability
o
when compound-wound
machines are operated in tcE
a bus bar of large 5
parallel,
section and negligible re- ^
sistance, called an equal- ^
izer bus, is connected from "a
e to / as in Fig. 94. Points 5
e and / are then practically §
at the same potential; »
therefore the current in ^
each series coil is inversely
proportional to the resist-
ance of that coil, is inde-
Sec. 8-241 D.C.OENERATOnfi AND MOTORS

coils. A combination of series and shunt resistances can also be employed.

This adjustment is made after erection. If one machine is found to take
more than its share of the load, then its compounding must be reduced by
means of a resistance placed in series with its series field coils.
241. Starting and stopping a single shunt-wound generator.
It is generally safest to start with the machine entirely disconnected from
the external circuit and with the field rheostat all in circuit. Then bring tha
generator up to speed and cut out the field resistance until tha voltage of
tha generator is normal. The main line switch miay then be closed and
further adjustment of voltage made if necessary.
To stop the machine, open the feeder switches, insert all the resistance
in the field-coil circuit, then open the main switch and shut down the
engine.
242. Starting and stopping shunt-wound generators in parallel.
Assume that machine A, Fig. 93, is running; it is required to throw machine
B in parallel with it. This latter machine must on no account be connected
to the line while coming up to speed, otherwise it will form a short circuit
across the machine which is already in operation. To place machine
B in operation, bring it up to speed with the switch S open, adjust the shunt
rheostat until Eb = Ea, then close switch S and increase the excitation of B
until it takes its share of the load. To disconnect this machine, its excitation
should be reduced until machine A carries the entire load; the switch S may
then be opened. When shunt machines are being connected in parallel for
the first time, the polarity of the switches should be carefully tested with
a voltmeter or its equivalent.
243. Starting and stopping compound- wound generators. A
single machine is started and stopped in the same way as a shunt machine
(Par. 241). To place machine B, Fig. 94, in parallel with machine A, which
is already running, bring the machine up to speed and excite it to give
normal voltage; first close switches g and h in order to excite the series coils,
then make Eb equal to the bus-bar voltage and close switch k; the machine
may then be made to take its share of the load by increasing the shunt excita-
tion. To disconnect the machine, reduce its load to zero as in the shunt
generator, and open the three switches in the reverse order.
Three separate switches are necessary for large machines, because of the
large currents. For smaller machines, one double-pole switch for g and h,
and a single-pole switch k, are sometimes used. For small machines, a
three-pole switch is often used, but then the main switch is closed before
the series field has its proper value and there is a momentary disturbance.
244. Starting and stopping motors. All except small motors, rated at
a small fraction of a horse power, should be provided with a starting box or
starting rheostat. Such starters, on constant-potential systems, consist in
general of graded resistance connected in scries with the armature, and elimi-
nated step by step as the motor comes up to speed. The starting torque, aa
well as the running torque, is given by Eq. 36, Par. 169 ; therefore in order to
keep the starting current as small as possible, the magnetic flux should be aa
large as possible and the field coils should be fully energized before the arma-
ture receives any current. The counter e.m.f. at standstill is zero, and
therefore the series starting resistance is necessary to limit the starting cur-
rent to a safe value. Starters should be equipped with an automatic
release which will operate under the conditions of no terminal voltage, or no
current in the shunt field coils, so that the motor will not be burnt out when the
terminal voltage is re-established or when the field circuit accidentally opens.
For further information on starters see Sec. 5, and for information on motor
control see Sec. 15. u u
Shunt motors may be stopped by merely opening the hne switch; such
motors should not be stopped by returning the handle of the starting box to
the "off" position, because this method requires the opening of the field cir-

cuit while energized and gives rise to a momentary but very severe induced
e.rn.f. The handle of the starting-box should automatically return to the
" off" position before the motor finally comes to a dead standstill.

245. Field discharge. If the field circuit be suddenly opened while

carrying current, then, due to the rapid decrease of flux through the large
 D. a. GENERATORS AND MOTORS Sec. 8-246

number of field-coil turns, a large e.m.f. will be induced between the two open
ends. This may be sufficient to break down the insulation between the field
coils and the poles. To prevent this, when a motor is disconnected from a
line, the field coils should be short-circuited through the armature winding
at the instant the line circuit is opened, the necessary connections being made
by the starter.
246. Installation of motors and generators. The machine should, if
possible, be placed in a cool ventilated position which is free from dirt, dust,
or moisture. Machines required to operate in damp places should have the
coils specially treated. The foundation should be solid to prevent vibration.
If the machine is belted, the belt tension should not be too great, the distance
between belt centres too short, or the pulley too small; the pulley should not
have a diameter less than that recommended by the manufacturer. The belt
should be flexible and without lumpy joints and the bottom side should be the
tight side. After erection, clean the bearings by pouring in gasoline, drain
this off through the drain cocks and then fill the bearings with light mineral
oil. Before starting, see that there are no loose parts and that the brushes
are making firm contact.
247. Starting generators for the first time. Bring the generator
slowly up to speed with the field circuit open and see that the oil rings operate
properly; then close the shunt field switch and bring the voltage up to nor-
mal. Run the machine without load for an hour, after which the load may
gradually be increased. Generators should be thoroughly dried out in every
instance before they are placed in commission.
248. Starting motors for the first time. Check the connections to
make sure that they are correct and secure. See that the controller handle is
in the starting position, then close the line switch. If the motor does not
start on the first or second notch of the controller, open the line switch and
look for the trouble. When starting, bring the controller handle over slowly
to the running position, allowing the motor to gather speed, but do not run on
the starting notches for any length of time. Run the motor without the belt
for half an hour (this cannot be done with a series motor) and then put on the
load. When shutting down, open the line switch and see that the controller
handle returns to the starting position before the motor finally stops.
249. Operating instructions. Keep oil away from the commutator,
brushes and windings. Do not allow dirt or dust to accumulate in or around
the machine. Do not lubricate the commutator with oil; a piece of muslin
moistened with vaseline may be used to clean the commutator. Emery
is a conductor and should not be used in
fitting brushes or cleaning the commuta-
tor; use sandpaper and do not use it on
the commutator too frequently. Do
not use greater brush tension than neces-
sary; tension greater than 2 lb. per sq. in.
(0.14 kg. per sq. cm.) is seldom re-
quired. When replacing brushes, use
the quality and size originally supplied
with the machine, and fit them to the
commutator with sandpaper before use;
a strip of sandpaper should be placed on
the commutator below the brushes, sand Fig. 97.- -Field discharge resistance.
side up, and pulled through in the direc-
tion of motion of the commutator. Do not open generator-field circuits
quickly (Par. 113); open the switch slowly, permitting the arc to extinguish
gradually, which should take about 5 soc. On large generators use a field
discharge resistance, which is connected across the terminals as soon as the
field switch opens; see Fig. 97.
Do not stop quickly on account of a hot bearing, but slow down the ma-
chine and apply good clean oil. A quick shut-down will cause the bear-
ing to "freeze." Inspect and clean the machine periodically.
260. Poor commutation is generally due to one or more of the following
causes :

(a) Brushes not in the proper position.

Bad spacing of the brush sets. This may be checked by counting the
(b)
number of commutator segments between adjacent brush sets.
42 ncy
Sec. 8-251 n. a. oenerators and motors
(c) Projecting mica. This cause may be removed by cutting out the mica
between segments for A in. (0.16 cm.) below the commutator surface.
(d) Rough commutator, generally caused by suddeu rushes of current.
When such current rushes are inherent under the operating conditions, and
interpoles are not employed, it may be advisable to use abrasive brushes to
keep the commutator free from rough spots.
(e) Flat bars, produced- because some of the commutator segments are
softer than others.
(f) High bars, generally due to soft spots in the mica clamping cones.
(g) Grooved commutator, may be prevented by staggering the brush sets
so that the space between two brushes of one set is covered by a brush of the
next set and the commutator wears down evenly.
(h) Poor brush contact, due to imperfect bedding of the brushes, to dirt, or
to burning of the contact.
(i) Worn brushes being replaced by others of the wrong quality or size.

(i) Sticky brushes, which do not move freely in box

holders and so do not
follow irregularities of the commutator.
(k) Vibration due to want of balance in the armature, to poor founda-
tions, or to a badly laced belt.
(1) Chattering of the brushes, which can generally be cured temporarily by
cleaning the commutator with a piece of muslin moistened with vaseline,
and may be cured permanently by changing the brush angle.
2B1. Armature winding troubles are generally due to the following
causes:
(a) A broken coil, generally at the commutator end, caused by the wire
connected to the commutator being too tight, excessive vibration, poor
soldering at the commutator neck, or the use of copper which was not prop-
erly annealed. This trouble causes a bad arc at the instant the brush breaks
contact with the segment connected to the broken coil. The trouble can be
fixed temporarily by short-circuiting the commutator segments connected
to the damaged coil, thereby cutting it out, care being taken not to short-
circuit the coil itself. j . •

(b) A short-circuited armature coil may be due to damaged insulation

i

between turns or to an accumulation of copper dust in the commutator necks.

A large local current will flow in this coil and cause it to become hot and to
smoke.
(c) An armature coil may be reversed during repairs. The e.m.f. of the
reversed coil opposes that of the other coils so that one circuit in the armature
will generate less than normal voltage (Par. 19). At the moment of com-
mutation, the conductors of this coil will be under the wrong pole tips and
local sparking will take place.
252. Field-coil troubles are generally due to the following causes:
(a) An open circuit: If the motor is series wound, the machine will stop
and cannot be started again; if a shunt motor, the machine will speed up a^
the flux decreases (Par. 163) and the line current will increase as the back
e.m.f. diminishes, until the circuit-breakers open. If the machine is a shunt
or compound generator, the generated e.m.f. will greatly decrease and a large
current will flow into the machine from other generators which are operating
in parallel with it, and open the circuit-breakers.
(b) A short circuit will reduce the field-coil resistance and in the case of a
shunt machine, will cause the exciting current to increase and the tempera-
ture to rise. The m.m.f. of the damaged coil will be reduced and that of the
other coils increased, so that the strengths of the poles will be different (Par.
19). The average flux per pole will be unchanged in a shunt machine, but
will be reduced in a series machine.
(c) Reversed field coils will cause adjacent poles to have the same polarity.
The polarity can be tested with a compass or, if that is not available, with a
piece of soft iron which will lie along the lines of force and therefore bridge the
poles if the polarity is correct, but will tend to lie axially in the direction of the
shaft if the polarity is wrong.
253. The effect of wear in the bearings is to throw the armature out of
centre with respect to the pole-pieces and cause an unbalanced pull (Par. 19).
264. End thrust causes heating of the bearings and is generally due
to
fcnd
projection of the armature core beyond the magnetic field (Par. 96).
thrust may also be due to the fact that the shaft is not horizontal.
658
 D. C. GENERATORS AND MOTORS Sec. 8-255

256. Kesidual magnetism of the generator fields may be "killed"

by a short circuit. When this happens, the field coils must be excited from
an external source, using batteries if nothing else is available.
256. Humming may be cured by chamfering the pole tips.

TESTINQ
267. Purpose of testing. Commercial tests are made on standard
machines to make sure that they have been properly constructed. Accept-
ance tests are made on important machines to make sure that they meet
the guarantees. Special tests are made by the designer to find the limits of
a new machine and to obtain constants and data to be used on future designs.
258. No-load satiuration, friction and iron-loss tests. To make this
test the machine is separately excited, connected as shown in Fig. 98, and
driven as a generator at the rated speed by a shunt motor M
of such size that
the rated output of the motor is approximately equal to the largest loss to
be measured. The losses in the driving motor should have been previously
determined and should be known for all inputs. The generator is excited to

Fig. 98. —
large machine. curves.
—
Connections for Fig. 99. No-load Fig. 100. —Connections for
small machine.
No-load saturation, friction and iron-loss tests.

give about one and one-half times normal voltage; the excitation is then
gradually reduced, the speed being kept constant, and simultaneous readings
are taken of generator voltage, speed and exciting current, also of motor
input, speed and excitation. The losses in the motor for a definite voltage,
current, speed and excitation are known; the output can therefore be found
and is equal to the sum of the iron, windage and friction losses in the genera-
tor, an allowance being made for the loss in the belt. The results are plotted
as in Fig. 99. The loss with zero excitation is the windage and friction loss,
from which the windage and bearing friction can be separated by taking a
reading with the brushes lifted.
269. The brush loss varies greatly with the condition of the contact sur-
face and a note should be made on the test sheet as to whether the test was
made before or after the heat run and whether or not the commutator
was cleaned and lubricated before the test was made.
260. The saturation and no-load loss test for a small motor is gener-
ally made by separately exciting the machine, connecting it as shown in Fig.
100, and running it idle at normal speed. The armature voltage is varied with
a rheostat in the armature circuit and the excitation is adjusted to keep the
speed constant. This excitation will be approximately the same asthe no-load
5xcitation as a generator, since, at no load, the applied voltage is practically
'qual to the back e.m.f. (Par. 157). The armature input will be the sum of
-he windage, friction and iron-losses and also the small copper-loss due to the
:io-load armature current; the latter loss can be calculated and deducted.
261. Armature resistance. This is generally measured by passing a
inown current through the stationary armature and measuring the voltage
irop between the brushes and also across the terminals of the machine. This
atter value is not the true voltage drop between the terminals, since the con-
act resistance when the machine is running is different from that when the
nachine is stationary.
The armature resistance is sometimes determined by passing a current
trough the armature and also through a standard resistance of approxi-

659
Sec. 8-262 D. c generators and motors
mately the same value and at least the same current-carrying capacity, and
comparing the drops of potential across each, in which case the current need
not be measured.
262. The fleld-coil resistance is determined by passing a known current
through the coils and measuring the drop of potential across the field ter-
minals.
263. Load tests on machines of considerable size must be made by some
method whereby the power developed by the machine is not dissipated, but is
made available for the test; otherwise the power-house capacity may not
be large enough to test many machines and the cost of the test will be
excessive.
264. Blondel's loadinc^-back method. Two identical machines are
required for this test. They are separately excited, connected together
mechanically to run at the same speed, and their armatures are connected
electrically in opposition as in Fig. 101 so that, when equally excited, there is
no current in the armature circuit. An auxiliary motor M
is belted to the set

Fig. 101. — Blondel method.

la

Fig. 102. — Kapp method.

Loading back tests.

and should have a capacity large enough to supply the no-load losses of both
machines. The booster B must carry full-load current and is used to circu-
late the current through the armatures of both machines. The set is brought
up to speed by the auxiliary motor, the switch <S being open. The fields are
then excited until the voltage E is normal and the voltage across the switch S
is zero. This switch may then be closed and, by suitably exciting the booster,
any desired armature current may be made to circulate. The booster sup-
plies the copper-loss and the motor M
supplies the other armature losses of
both machines so that EI is the generator output; one-half the output of
M is equal to the sum of the windage, friction and iron-losses of one
machine; one-half of el is the copper-loss of one machine; and Ei equals
the excitation loss of one machine, from all of which the efficiency may b6
found.
26S. The regulation of a generator, or of a motor, may be determined
from Blondel's test. The machines in this case need not be identical, but
they must be of the same voltage, and the output of the testing machine
must not be less than that of the machine to be tested. In the test for
generator regulation, start with normal voltage E and no circulating cur-
rent; then excite the booster to give the desired current la and measure
El, the terminal voltage. Plot Ei and la as in Fig. 58. In the test for mo-
tor-speed regulation, keep the voltage across the motor terminals constant

660

i
 D. r. GENERATORS AND MOTORS Sec. 8-266

by means of the booster, and vary the speed of the auxiliary motor until M
the circulating current has the value desired. Plot the speed and la as in
Fig. 64.
266. Hopkinson's test. This test is similar to Blondel's, but the booster
is eliminated and the auxiliary motor is used to supply all the losses, the cur-
rent in the armatures being circulated by weakening the field of one machine
and strengthening that of the other. The iron-losses in the two machines are
cUfferent because the fields have different excitations, so that, while the
method is satisfactory for regulation and heating, it is not satisfactory for
efficiency.
267. Kapp's method is preferred to Hopkinson's and is the one generally
adopted in commercial work for regulation and
heating tepts; the efficiency of a machine is
generally calculated from the losses. The dia-
gram of connections is shown in Fig. 102. The
losses are supplied from' the testing circuit and
are easily measured, but, since the copper-losses
in the two machines are different, as also are
the iron-losses, the method should not be used
for an accurate determination of efficiency.

268. Load tests on series motors. When

a large number of railway motors have to
be tested the loading-back method of test is
used. Two motors are connected together as
shown in Fig. 101 and are geared to the same
countershaft so as to run at the same speed.
This countershaft, driven by an auxiliary
motor supplies the mechanical losses. The
field coils are connected in the armature cir-
cuit and a booster is also placed in this circuit
to supply the copper losses. * Fig. 103. — Prony-brake test.

269. Prony brake test. The efficiency is seldom determined by direct

measurement of input and output except in the case of small motors which are
connected directly to the line and the load then measured by means of a
water-cooled prony brake as in Fig. 103.

746x1) (r.p.m.Xri-Ti)
E£f. (46)
33,000 EI
270. In constant-current arc generators, the load losses are generally
large, and the efficiency of such machines is obtained by measuring the output
electrically, and the input by means of a driving motor whose efficiency is
known.
271. Load saturation test. The generator is driven by a motor of the
same voltage and of larger output, and the machines are connected to the
testing circuit as in Fig. 102. Starting at about 20 per cent, above normal
voltage and with full-load circulating current, the excitations of the two
machines are gradually reduced and a series of readings of Et and i are
taken, /„ being con^ant. The results are plotted as in curve 2, Fig. 19.
272. Heat run. The machine is connected as in Fig. 102 and operated at
rated speed and voltage, with the desired circulating current. The
suggestions contained in the A. I. E. E. standardization rules. Sec. 24,
regarding measurement of temperature and conditions of test, should be
followed.
273. Insulation resistance may be measured with a megger (Sec. 3)
or by means of a high-resistance voltmeter connected as in Fig. 104.
In the latter case the insulation resistance equals the resistance of the
voltmeter multiplied by the ratio {E — e)/e, where E, the voltage of the testing
circuit, should be the same as the normal voltage of the machine being

*For modifications of this test see:

Workman, R. E. " Factory Testing," Electric Journal, Vol. I, p. 551.
ay, C. J. " Testing Large Motors," Electric Journal, Vol. Ill, p. 525.

M 661
Sec. 8-274 D. C. GENERATORS AND MOTORS
tested, and e is the voltmeter reading or the drop in voltage across the volt-
meter resistance.
274. Puncture test. To test the insulation, a high voltage is applied
between the armature winding and the frame, between the field windings
and the frame, and also between the shunt
and the series field coils with the shunt wind-
ing disconnected from the armature. The
test voltage is obtained from a small testing
transformer of adjustable ratio and should
be raised to the desired value smoothly and
O 1 Y without sudden large increments; the maxi-
mum
should be applied for 1 min. unless
I

otherwise specified, and then gradually de-

I

Jl creased. The recommendations given in

„ Sec. 24, should be followed.
,_.
Fig. 104.
,,
—
Measurement^ -;,_
^76.
»
Acceptance ^ ^
tests.
.

A compound, .

of insulation resistance.
generator to be tested for efiiciency, regula-
tion, temperature, commutation and insulation would be handled as follows:
(a) Grind the brushes in place with sandpaper.
(b) Measure the armature and the field coil resistances.
(c) Place full load on the machine (Par. 272). Adjust the brush position
so that the machine is sparkless over the desired range of operation. The
brushes should not be set further forward than necessary, otherwise the arma-
ture reaction will be greater than it need be. Adjust the current in the series
coils with a temporary shunt to give the required voltage at no load and at
full load.
(d) Keep the machine on
full load until the temperatures, as indicated by
the have become approximately stationary; then shut
field coil resistance,
down and take temperatures.
(e) Measure the armature and the field coil resistances before the machine
has time to cool.
(f) Give the machine an overload run, if that is desired.
(g) Make the regulation test (Par. 265 and 267) then since the machine is
;

properly connected, a full-load saturation test may be made for the informa-
tion of the designer, if required.
(h) The no-load loss may be determined by running the machine idle as a
motor (Par. 260), but the designer will probably want information in regard
to the separate losses (Par. 268). The test results are then worked up, and,
if the machine is satisfactory, the insulation resistance is measured and the
puncture test made.
276. Commercial or shop tests. For standard machines on which the
designer has all the information he requires, such a complete test (Par. 278)
is not necessary. The machine should be run idle at normal speed and volt-
age to make sure that the no-load losses are not too high due to poor materia]
or poor construction, and that the excitation is not too large or too small.
The armature and field coil resistances are checked with the calculated values.
The machine is run for an hour at 25 per cent, overload to test the mechanical
construction and then run idle at 50 per cent, above normal voltage to test
the insulation between turns. The speed may be increased during this
latter test. The insulation resistance is then measured and the puncture
test made. For further information see the series of articles on shop testing
by R. E. Workman in Vol. I of Electric Club Journal.
BIBLIOGRAPHY
—
277. Selected list of reference literature.
Arnold, E. "Die Gleichstrommaschine." Berlin, Julius Springer,
Vol. 1, 1919 and Vol. 2, 1907.
—
BuRCH, E. P. "Electric Traction for Railway Trains." New York,
McGraw-Hill Book Company, Inc., 1911.
—
Crocker & Arendt. "Electric Motors." New York, D. Van Nostrand Co.,
1910.
Crocker & Wheeler.— "Management of Electrical Machinery.' New
York, D. Van Nostrand Co., 1908.
Gray, A— "Electrical Machine Design." New York, McGraw-Hill Book
Company, Inc., 1913.

662
 D. C. GENERATORS AND MOTORS Sec. 8-277

—
Bbaymer, D. H. "Armature Winding and Motor Repair." New York,
McGraw-Hill Book Co., 1920.
—
Hawkins & Wallis. "The Dynamo." New York, The Macmillan Co.,
1913.
HoBABT, H. M. —"Electric Motors." New York, The Macmillan Co., 1910.
HoB.uiT & Ellis. — Armatvire Construction." New York, The Macmillan
"

HoBAHT & Ellis. — "High Speed Dyanmo-Electric Machinery." New

Co., 1907.

York, John Wiley & Sons, 1903.

Kapp. — 'The Principles
' of Engineering," Vol.
Electrical London,
2.
Longmans & Co., 1919.
—
Karapetofp, V. "Experimental Electrical Engineering." Vol. New I;
York, John Wiley & Sons, 1908.
Lawrence, R. R. — "Principles Direct Current Machinery." New
of
York, McGraw-Hill Book Co., 1919.
Livingstone, R. — Mechanical Design and Construction
" Genera-of
London, The Electrician
Murdoch. — "Ventilation
tors." Series.
Machinery." New York, Whitta-
of Electrical
ker & Co., 1911.
Raymond, E. B. —"Motor Troubles." New York, McGraw-Hill Book
Company, — 1909.
Inc.,
Still, A. ' Design." New York, McGraw-Hill
'Principles of Electrical
Book Co., 1916. —
Thompson, S. P. "Dynamo-Electric Machinery." Vol. New York,
I;
Spon & Chamberlain, 1904.
Turner & Hobart. — Insulation " Electrical Machinery."
of New York,
Whittaker & Co., 1905.
Walker, Mile.s. — "Design and Specification Machinery."
of Electrical
London, Longmans & Co., liUo.

668
I
 SECTION 9

CONVERTERS AND DOUBLE -CURRENT

GENERATORS
BY F. D. NEWBURY, M.E.
(anager, Power Engineering Dept., Westing ho use Electric <& Manufacturing
Co., Fellow, American Institute of Electrical Engineers

AND
ALEXANDER GRAY, M.S., WhitSch.*
rmer Prof, of Electrical Engineering, Cornell University, Member Am,erican
_
Institute of Electrical Engineers, Author of "Principles and Practice
of Electrical Engineering " and 'Electrical
'

Machine Design, "

CONTENTS
(Numbers refer to Paragraphs)

SYNCHRONOUS CONVERTEBS
General Theory 1 General Appiicationa 66
General Design 30 Operation 66
Characteristics 45 Testing 86
INVERTED CONVERTERS, 95
MOTOR CONVERTERS, 103
DIRECT-CURRENT CONVERTERS, 118
DYNAMOTORS, 126
DOUBLE-CURRENT GENERATORS, 134
BIBLIOGRAPHY, 139

'Deceased.

663
 SECTION 9

CONVERTERS AND DOUBLE-CURRENT GENERATORS

SYNCHRONOUS CONVERTERS
BY F. D. NEWBURY, M.E.

GENERAL THEORY
1. Gompaxison with separate synchronous motor and direct-cur-
rent generator. The theory of the synchronous converter is best explained
by the similarity of the converter to a synchronous motor driving a direct-
current generator. The converter combines the characteristics of both motor
and generator in the single armature binding. This winding is provided on
one end with a commutator as in a direct-current generator, and on the other
with collector-rings and taps to the winding as in a revolving-armature
synchronous motor. Alternating current is supplied through the collector-
rings, and with no direct-current load the synchronous converter operates
purely as a synchronous motor. Its speed is determined by the frequency*
and number of poles and the fiux is fixed by the impressed voltage, just as
in a synchronous motor.
2. Excitation. _
In the synchronous converter, as in the synchronous
motor, the magnetic flux and the corresponding net exciting amporc-turns are
determined solely by the impressed voltage. If it is attempted to vary the
exciting ampere-turns and flux by variation of the main field excitation, the
latter variation is neutralized by an equivalent change in excitation brought
about by a change in phase and value of the armature current, so that the
flux and net excitation remain constant. Increased excitation in the main
field winding produces a leading current in the armature (leading with respect
to the line voltage) which, in the majority of transmission lines serving syn-
chronous converters, is beneficial to line power-factor and voltage. Con-
versely, under-excitation produces a lagging current which is detrimental to
the power-factor and voltage of such lines.
S. Ratio of alternating voltage to direct-current voltage. Assum-
ing the synchronous converter to be operating without direct-current load,
it will be clear that the direct-current voltage between brush arms will,
through the action of the commutator, have a value equal to the maximum
instantaneous value of the alternating voltage, giving proper consideration
to the relative points in the armature winding to which, at any instant, the
brushes and collector-rings are connected. In the single-phase, two-phase,
and six-phase diametrically connected converters, the direct-current brushes
and collector-rings are connected to equivalent points on the armature wind-
> ing, so that the ratio between the alternating and direct-current voltages is
simply the ratio between the effective and the maximum alternating voltages.
In the throe-phase converter, the collector-rings are connected to points 120
electrical degrees apart, while the direct-current brushes are connected to
points 180 electrical degrees apart, so that the voltage ratio is affected by this
difference. The theoretical ratios are shown in Par. 4. See Par. 36 and
Figs. 9 to 14, inclusive, for further information.
These theoretical ratios are based on the assumptions that the impressed
alternating-current waveform and the counter e.m.f. waveform of the con-
verter are both sine-waves, that there is no loss in the converter, and that the
direct-current brushes are at the no-load neutral position. Variations in
waveform are small in commercial circuits and apparatus. The effect of the
resistance of the windings, brushes, and brush contact is appreci.ible. and
may vary the ratios (Par.'B) from 2 to 4 per cent. Changes in brush position,
'«6G
 CONVERTERS Sec. 9-4

even within the small limits perinitted by commutating conditions, may

affect the ratio 1 per cent. A lagging current in the converter winding has
the same effect as narrowing the pole-face and will thus increase the ratio of
alternating voltage to direct-current voltage. In general, therefore, actual
ratios are slightly higher than the theoretical ratios (Par. 4), assuming con-
version from alternating to direct-current.

4. Table of Theoretical Voltage Ratios

Number of converter phases

Sec. 9-8 CONVERTERS
Where Ea is the alternating voltage. Values of Y are given as follows:

Number of phases 1 Value of Y

 CONVERTERS Sec. 9-U

_J j^30 « 90 5JE Power r«clor

t Current

iTending

A.C.TendingtoFlow

power-tactor.
^FiG. 2.-Armature current in conductor. 80.5 per cent,
i

Di»iributi(|iuof A-m. Co )pcr Lisa

in 3 & 6 Phas* Couv^rters

30 CO
60 Loss Cross Hatched 3(/> Loss Cross Hatched
and 95 per cent.
Fio. 3.— Distribution of losses at 100 per cent, power-factor
power-factor.

669
 Sec. 9-12 CONVERTERS
greatly to increase the current and loss in conductors near one side of the tap
coils and to reduce the loss in conductors on the other side of the same tap
coils. The average effective current and the loss are considerably increased.
The effects of power-factor are illustrated by Fig. 2 which shows the same
condition.^ as Fig. 1, except that the power-factor is 86.5 per cent, instead of
100 per cent. It will be seen that the alternating-current wave has been
shifted with respect to that of the direct current, thus causing an increase In
the effective current. Fig. 3 shows the difference in distribution of losses and
difference in average losses with 100 per cent, and 95 per cent, power-factors.

12. Table showing Relative Converter Losses on Basis of Direct-cur-

rent Generator Losses taken as Unity
Calculations based on 3 per cent, rotational losses
(Calculated by C. E. Wilson)

Relative .armature loss in Relative maximum loss in

complete winding one conductor

P.F. P.F. P.F. P.F. P.F. P.F. P.F. P.F. P.F. P.F.
No. of
collector
100 98.5 94 86.6 76.6 100 98.5 94 86.6 76.6
per per per per per per per per per per
rings I

cent. cent. cent. cent. cent. cent. cent. cent. cent. cent.

1.451 1 522 1 734I2 160 2 940'3 121 13 653

. . . . . . 4.3585.342 6.808
0.587 0.627 0.753'1.005 1.468 1.249 1 594 . 2.04812.673 3.596
0.391 0.426 0..532 0.740;l. 137 0.751 1.017 1.367 1.861 2 596
.

0.274 0. 304 0.400iO. .58910. 935:0. 430 0.614 0.87411.249 1.825

0.209 0.236 0.32610.500 0.824(0.249 0.354 0.525,0.792 1.232

13. Losses affecting rating. Par. 12 shows the relative average losses
and maximum loss per conductor compared with those of the equivalent
direct-current generator for various phases and power-factors. It shows a
large increase, particularly in the maximum loss due to small changes in
power-factor. It is this characteristic that limits the use of synchronous
converters to operating power-factors near 100 per cent. This table also
shows the advantage of a large number of rings. Practically all converters
abovs 200 or 300 kw. are now built with six collector-rings and phases, while
12 rings have been considered for the largest ratings. A distinction must be
made, however, between copper loss and rating. This table does not repre-
sent relative capacities of the various armatures, since the rating depends on
many other factors besides armature coil heating. In general, the current
capacity of a given armature will be increased by increasing the number of
rings and will be reduced by a reduction in power-factor, even slightly below
100 per cent, power-factor, although not to so great an extent as is indicated
by a direct comparison of the losses.
14. The armature reaction of the synchronous converter is relatively
small compared with that of the equivalent direct-current generator on
account of the relatively small effective armature current. In this character-
istic the converter is very nearly equal to the compensated direct-current
generator. In a six-phase converter, the effective armature reaction varies

\ from 7 per cent, to 20 per cent, of the armature reaction in an equivalent

uncompensated direct-current generator. •
15. Commutation in the synchronous converter offers the same
problem as in the direct-current generator, differing only in degree. Due to
the smaller effective current the armature reaction and, to a lesser extent,
the self-induction, are smaller than in the direct-current generator of equal
rating, so that allowable commutation limits are much higher. The syn-
chronous converter, without commutating poles, holds a position between
the simple direct-current generator and the direct-current generator with
commutating poles and with a compensating pole-face winding. For this
reason the commutating poles with their attendant complications were not
added to the synchronous converter until long after they had been success-
• Lamrae. H. G. and Newbury, F. D. " Interpoles in Synchronous Con-
verters;" Trans. A. I. E. E., Vol. XXIX, page 1625.
 CONVERTERS Sec. 9-16

fully used with direct-current generators and motors. During the past 2
years, however, this refinement has been added to the synchronous converter
and considerable gains have been made due to its use. In the synchronous
converter the commutating-pole winding has approximately 25 per cent, to
40 per cent, of the ampere-turns which are necessary in the equivalent direct-
*
current generator.
16. Therelation between power-factor and main field excitation is
the same in the synchronous converter as in the synchronous motor or in
synchronous generators in parallel. For reasons already stated (Par. 11, 12,
and 13), the synchronous converter is not used for operation at low power-
factor except at small loads, so that this question is not of practical
importance.
17. Control of direct-current voltage. Due to the fixed ratio between
the alternating voltage and the direct-current voltage, variation in direct-
current voltage can be obtained only by three general methods, which are as
follows: (a) by varying the alternating voltage; (b) by varying the direct-
current voltage; (c) by varying the flux without correspondingly varying
the alternating voltage, as in the split-pole converter.
18. For varying the alternating voltage, the important commercial
methods are: (a) by an induction regulator or regulating transformer; (b)
by a synchronous booster; (c) by the combined action of reactance and series
field winding.
19. A regulating transformer (also called a Stillwell regulator) consists
of a transformer with a large number of taps and a dial face plate for connect-
ing the converter terminals to the various transformer taps. The transform-
ers and switching devices are large and expensive, and the switches are sub-
ject to rapid deterioration due to sparking while changing the voltage.

The Secondarj Voltage Varies with the

Relatlre Positive of the Primary
and Secondary Coils Potential Regulator

Fig. 4. —Connections of synchronous converter and induction regulator.

The method also has the objection that the voltage cannot be varied by small
increments unless an excessive number of taps is provided. In the past this
method has been used extensively but, with the development of preferable
methods, has been abandoned. An induction regulator accomplishes the
_

same result with infinitely small increments and without interrupting the elec-
trical circuit. The induction regulator consists of a stationary winding (usu-
ally the secondary) and a rota table winding (usually the primary), the change
in voltage being obtained by rotating one element through part of a revolu-
tion, which changes the ratio of the secondary and the primary voltages.
It is simply a polyphase transformer with rotatable primary. The connec-
tions are shown in Fig. 4. Through suitable relays the alternating voltage
may be changed automatically or from a distance. The disadvantages of this
method of regulation are the additional floor space and complicated wiring
required and the diflSculty of designing the induction regulator to withstand
the mechanical stresses incident to connecting the converter to the line
slightly out of step, and also to withstand short circuits.
20. The synchronous booster converter consists of the combination of
an ordin ary converter with an alternating-current generator having the
* Lamme, B. G. and Newbury, F. D. " Interpoles in Synchronous Con-
verters; " Trans. A. I. E. E., Vol. XXIX, page 1625.
 Sec. 9-21 CONVERTERS
same number of poles as the converter and having its armature winding
connected in aeries with the converter armature winding. This booster
alternator, by a change in its own excitation, varies the voltage applied to the
terminals of the converter. The excitation is so arranged that the booster
fields and voltage may be reversed without opening the field circuit. The
possible variation in voltage is double the rated booster voltage, since it may
be added to or subtracted from the line voltage. The connections are shown
in Fig. 5. The voltage may be controlled automatically through relays and
regulator, or the booster may be series wound, thus automatically compound-
ing the converter. This method of voltage variation has largely superseded
the methods previously described, particularly in the larger installations.

Alternating Current

Fig. 5. —Synchronous booster converter.

31. Types of syncbxonous booster. The booster may be a revolving-
armature generator located between the collector-rings and main armature, or
it may be a revolving-field generator located outside of the collector-rings.
The revolving-armature construction is the more usual since it eliminates
additional collector-rings and external wiring, and the large number of par-
allel circuits in the converter winding favorable to low-voltage generation
may be conveniently used in the booster winding. The rotating-field booster
is sometimes preferable since it may be added to a standard converter with
less change in existing parts. There is also less interference with the ven-
tilation of the main armature. *
S2. The application of commutating poles to the booster con.verter
involves new features due to the motor action, or the generator action, of the
converter when the booster is excited. The converter acts as a motor to the
extent of the booster output plus all losses, when the booster is excited to
increase the direct-current voltage, and, conversely, the converter acts as a
generator to the same extent when the booster is excited to lower the voltage.
I Due to this motor or generator action the effective current in the converter
armature varies with the booster excitation as well as with the output of di-
rect current, t If the effective armature current varies, the commutating-
pole flux must vary correspondingly if the commutating poles are to be of
benefit. This variation is accomplished by providing two windings on the
commutating poles: A series winding that provides the correct excitation
when the booster is not excited; and a shunt winding in which the current is
varied, in amount and direction, in proportion to the change in armature
reaction caused by the booster. There are numerous methods used in prac-
tice to control the current in the shunt winding of the commutating poles.

* Newbury, F. D. " Voltage Regulation of Rotary Converters; " Electric

Journal, Vol. V, page 616.
t Yardley, J. L. McK. "Efficiency of Synchronous Booster Con-
verters; " Elec. Journal, Feb., 1913.

672
 t

CONVERTERS Sec. 9-23

One of the simplest consists in connecting the shunt commutating pole wind-
ing across a double-dial " potentiometer-type " rheostat, which is mech-
anically connected to a similar rheostat that controls the booster field ex-
citation. Any change in booster excitation causes a corresponding change
in commutating pole excitation. The commutating pole excitation is
further controlled by connecting a resistance in series with the field winding
that is varied automatically in proportion to the direct-current load on the
*
converter.

Impedance Volts Reactance Volta

Lergy Component
Drop in Line and Coil DlopinCoU = F8
of Conrerter Voltage

Reactance Volts
^V^Drop In Coil s FS
/ j^,.^ Impedance Volts
Drop in Line and CoU

Resistance Volts
Drop in Lina

Onrrent Leading
Generator Voltage

Current in Phase
with Generator Voltage

Fio. 6- -Variation of converter voltage with reactance in circuit and with

varying power-factor.

23. Automatic compounding. With reactance in the supply circuit

of the converter, the voltage at the collector-rings may be varied through a
small range by changing the phase of the supply current. As previously
explained, the current phase may be altered by varying the excitation of the
main field winding. In practice this is accomplished automatically by pro-
viding a series-field winding in addition to the shunt-field winding. The
direct-current voltage is varied in the compound-wound converter by the
combined effect of the series winding and the reactance in producing a varia-
tion of the alternating voltage. While the arrangement of field windings is
the same as in the compound-wound direct-current generator, the theory and
the action are entirely different. The effect of the reactance in varying the
voltage may be seen from the diagrams in Fig. 6. At lagging power-factors
the reactance voltage diminishes the line terminal voltage and at leading
power-factor it increases the line terminal voltage.
24. Heating effect of automatic compounding. On account of the
additional heating at power-factors less than unity, it is customary to operate
at low lagging power-factors at light load (when the additional heating is of no
consequence) and at leading power-factors only sUghtly below 100 per cent,
at overload.

* A detailed description of this method of control will be found in an article

by M. W. .Smith, " Commutating Pole Windings of a Synchronous Booster
Converter," Elec. Journal, Dec, 1917.
t Lincoln, P. M. "Voltage Regulation of Rotary Converters;" Elec.
Journal, Vol. I, page 55.

43 673
 ;

Sec. 9-25 CONVERTERS

26. Conditions affecting direct-current volxage regulation of
the compound converter.* It ia apparent that the direct-current
'

voltage regulation of the compound-wound converter depends on many

elements internal and external to the converter, and that the change
in voltage is limited by the inability of the converter to operate at
low power-factor and heavy load. The range of voltage is more re-
stricted and the results are much more difficult to predetermine than
in the compound-wound direct-current generator. The voltage range
is affected by certain factors which are as follows: (a) the resistance
drop between the point of constant voltage and the converter; (b)
the reactance drop between the same points; (c) the ratio of armature'
ampere-turns to shunt- field ampere-turns; (d) the ratio of series- field
ampere-turns to shunt- field ampere-turns; (e) the setting of the shunt-
field rheostat; (f) the transformer secondary voltage; (g) the total drop
through the converter.
26. Customary values for these factors (Par. 26) are as follows: (a) the
full-load armature ampere-turns are approximately equal to the no-load shunt-
field ampere-turns; (b)thefull-load series-field ampere-turns are approximately
one-third the armature or shunt-field ampere-turns; (c) the shunt-field
.

rheostat is so set that the lagging component of the line current will be
approximately 25 per cent, of the full-load energy component; the shunt-
field current will then be about 50 per cent, of its normal no-load 100 per
cent, power-factor value under the previous assumptions; (d) the transformer .

secondary voltage is chosen higher than the correct no-load value to com-
pensate for the under excitation of the shunt field.
Under the above conditions, an approximately flat direct-current voltage!
regulation curve will be obtained from no load to full load with constantl
voltage at the high-tension transformer terminals and 15 per cent, reactance!
in the transformer. It is impossible to over compound the converter (orl
compensate for alternating-current line drop) unless the series field strength]
and the reactance are considerably increased.
27. Relation between power-factor and load in compound con-
verters. With the average conditions stated in Par. 26, the power-factor
will vary with the load approximately as is shown, Par. 28. With larger over-
—
loads carried for a sufficient length of time to make heating a consideration
— the shunt field winding should be further under-excited in order to bring
the power-factor nearer unity at the extreme- overloads, or the series field
should be shunted to reduce the change in power-factor with load.

28. Table of Power-factor Variation with Load in Compound

Converters

Load
 CONVERTERS See. 9-30

lower in cost and requires less floor space and wiring; it is, however, diflBcult
80 to design the transformers when the required reactance is more than 10
per cent. It is also more difficult to obtain high reactance in 25-cycle than
in 60-cycle transformers, and in the core type than in the shell type
(Sec. 6).
30. The split-pole method of voltage control utilizes a difFerent
principle from any previously discussed. Variation of direct-cmrent
voltage is secured, not by a variation in the impressed alternating voltage,
but by a change in the shape of the magnetic field, such that the total flux
and the direct-current voltage are changed, while the alternating voltage
remains substantially unchanged. This is pos-
sible because of the fact that in polyphase wind-
ings in which the phases are tapped 120 electri-
cal degrees apart, third harmonics and multiples
thereof cancel out and do not appear at the
120-deg. terminals. The action of the split-
pole converter therefore depends on variations
in the field flux distribution which produce third
harmonics, in conjunction with taps on the
alternating-current side 120 deg. apart. The
reason for this will be understood by reference
to Fig. 7. It is evident that the armature coils ac Tap \ /acTap
between the 120-deg. taps on the alternating-
current side will always include two equal and Fig. 7.— Flux distribu-
opposite areas of the third-harmonic variation ^^on in three-part pole,
of flux which neutralize each other and so pro- split-pole converter,
duce no change in alternating-current wave
form. On the other hand, the armature coils between the brushes on the
direct-current side, which are 180 electrical degrees apart, will always in-
clude three areas of the third harmonic variation in flux, only two of which
neutralize each other, leaving one to change the average ordinate of the
field flux curve, and, consequently, the direct-current voltage.
With the split-pole converter, the 120-deg. connection on the alter-
nating-current side is preferable; consequently the three-phase delta connec-
tion or the six-phase double-delta connection should be used. However, any
secondary connection of transformers may be used providing the primary
is Y connected and the neutral is not fixed.
Harmonics other than the third and multiples thereof will appear at
the alternating-current terminals and will cause a corrective current to
flow from the supply circuit through the converter windings so as to neutral-
ize the flux producing these harmonics in the converter. It is desirable,
therefore, so to design the converter that the wave form will be as nearly
as possible a combination of the fundamental, third and ninth harmonics.
In practice this is so nearly accomplished that the effect of the split-pole
converter on the supply circuit wave form is negligible.*
31. Action of the split-pole converter. When the split-pole con-
verter is operated at a higher voltage than that corresponding to the alter-
nating line voltage, the additional output due to the increased direct-
current voltage is supplied by an increased current on the alternating-
_

current side. This current moreover is a " motor "current dividing in the
converter in the same way as the motor current necessary to supply the
losses. The value of the effective current is, therefore, considerably in-
creased. At lower voltages the converter acts as an alternating-current
generator decreasing the line alternating current, but due to the distribu-
tion of the current in the armature the effective current is increased.
sa. Two types of split-pole converter. The first converters of this
type were designed w-ith two regulating poles for each main pole. This
arrangement resulted in symmetrical flux and voltage wave forms through-

.! (a) Stone, C. W. " Some Developments in Synchronous Converters;"

; Trans. A. I. E. E., Vol. XXVII, p. 181.
(b) Steinmetz, C. P. " Variable Ratio Converters;" G. E. Review, 1908,
page^ 26-84, 1909.
(c) Burnham, J. L. "Modern Types Synchronous Converters;" G. E.
Review, page 74, 1912.

675
Sec. 9-33 CONVERTERS
out the entire voltage range, and was favorable to commutation but re-
quired machines of comparatively large diameter. The split-pole con-
verters as built at present have a single regulating pole for each main
pole. This construction obviously permits a considerable reduction in
diameter and cost for a given output, and the detrimental effect of the
varying magnetic field in the commutating zone can be compensated
for by providing favorable commutating condition.s in other respects.
The field-flux wave forms and the corresponding voltage wave forms for
various voltages, with both the three-part pole and the two-part pole con-
structions, are shown in Fig. 8.

ISOTapE.M.P,

Three Part Pole Two Part Pole

Fig. 8. — Flux-distribution and alternating
converter.
voltage wave forms in split-pole

Upper curves, max. voltage. Middle curves, mid. voltage. Lower

curves, min. voltage.

Transformers
Syn. Converter
Fig. 9. — Single-phase connections.

Syn. Converter Transformers

Fig. 10. — Two-phase connections.
S3. Limits of voltage variation with the split-pole converter.
In varying the voltage, the excitation of the regulating poles is increased in
the same direction as the excitation of the main poles to increase the
voltage, and is reversed to decrease the voltage. The split-pole converter
is limited to approximately 20 jjer cent, variation in either direction, but
this is sufficient to cover the majority of applications.
84. Direct-current booster. —
The direct-current voltage can be
varied directly bv inserting a booster in the direct-current circuit. This
booster may be direct-connected to the converter or driven by a separate

07(>
 CONVERTERS Sec. 9-34

motor. It 13 generally used in the latter form as an addition to existing

equipment, since it does not affect the converter either structurally or in
respect to operating voltage. All methods involving change in alternating
voltage necessitate the operation of the converter at the highest voltage.

Syn. Converter Transformers

Fig. 11. —Six-phase diametrical connections.

Syn. Converter Transformers

Fig. 12. —
Three-phase delta connections.

" JA
T

0J55.B
Transformers
Syn. Converter

Fig. 13. —Three-phase Y connections.

K-

ITT

Diagram Syn. Converter

In:. 14. — Three-phase interconnected Y connections (for 3-wire direct-
current circuits).
I The weight, floor space and cost of a converter with a direct-connected
[
. direct-current booster are greater than the same factors in a converter with
f
an alternating-current booster. A further serious disadvantage of the direct-
\
current booster is the additional commutator, which is equal in current capac-
jity to the converter commutator.
i

677
 Sec. 9-35 CONVERTERS
35. Transformer voltages and connections. The various trans-
former connections with voltages commonly used are shown in Figs. 9
to 14, inclusive. Fig. 14 shows the transformer connections necessary
when the converter is used to supply three-wire direct-current circuits;
this modification in the transformer windings is necessary to avoid magnetic
unbalance due to the unbalanced currents obtained with unbalanced loads
on the direct-current circuits.
GENERAL DESIGN
36. Similarity between converter and direct-current generator.
The general design of the synchronous converter closely resembles that of
the (Erect-current generator. The design of the magnetic circuit is iden-
tical; the types of armature and field windings are the same, except for the
taps to the collector-rings; the number of armature slots per pair of poles
must be some multiple of the number of phases; the design of the electric
circuit is the same, except for the reduced value of the effective current.
This reduction of effective armature current permits smaller conductors
and smaller armature slots— a condition favorable to commutation; it als^o
permits a higher ratio of armature ampere-turns to shunt- field ampore-turns,
resulting again in a smaller armature core; and furthermore, it reduces the
flux distortion on overload, permitting the converter to carry large mo-
mentary overloads without flashing. In commutating-pole converters,
the reduced effective armature current permits a relatively small commutat-
ing-pole winding, which is favorable to heavy overloads. With the small
number of commutating-pole ampere-turns necessary, it is easy to provide
sufficient section in the commutating pole so that large overloads can
be carried without saturating the commutating pole and thus destroying the
equivalence of commutating-pole flux and armature-coil flux. In the direct-
current generator this is not true, and conamutating-pole saturation is
usually a limit to the overloads that can be carried.
There are, however, various requirements in design, due to the rigid
relationship between poles and speed, that do not enter into direct-current
generator design. Following directly from this relationship, the maxi-
mum distance between adjacent neutral points on the commutator of any
synchronous converter is a direct function of the frequency and the pe-
ripheral speed of the commutator. The peripheral speed of the commutator,
in feet per min., is equal to the alternations per min. (cycles per sec. times
120) multiplied by the distance in feet between adjacent neutral points
on the commutator surface.
37. Comparison between ZS-cycle and 60-cycle converters.
This simple relationship between poles and speed (Par. 36) is responsible
for most of the difference between high-frequency and low-frequency con-
verters. It follows from this law that the distance between neutral points
in a 25-cycle converter is 2.4 times the distance in a corresponding 60-cycle
converter for the same commutator speed. Thus while ample room is
available in the 25-cycle converter for a large number of commutator bars
at a low peripheral speed, the reverse is true in the 60-cycle converter. The
600-volt 60-cycle converters that compare in freedom frorn flashing and
sensitiveness with 25-cycle converters have been built only since it became
r possible to construct commutators of high peripheral speed.
Up to the year 1909, 60-cycle 600-voIt converters were usually built with a
maximum distance between neutral points of 7.5 in. (19.0 cm.) and a peripheral
speed of 4,500 ft. per n)in. (22.9 m. per sec). Since that time, through
improvements in the mechanical design of commutators, the peripheral
speed has been increa.sed to 5, .500 ft., increasing the distance between neutral
points to 9 in. (22.9 cm.). Thi.s greater distance has directly and indirectly
improved the operating characteri.itics. As a direct benefit there i.s less
chance that a flash under a brush will reach to the adjacent brush arm, caus-
ing the converter to buck; and, indirectly, the greater distance permits the
u.se of more commutator bars, reducing the maxinuiin voltage between bars
and so reducing tlie danger of an arc spreading from bar to bar. With 9 in.
(22.9 cm.) available between neutral points, it is possible to proportion 60-
cycle converter commutators much more conservatively than was possible
in older designs with resulting improvement in performance.
The distance between neutral points becomes a design limitation only with
678
 CONVERTERS Sec. 9-38

the higher line voltages. At 250 volts the design of the 60-cycle converter
has not been handicapped as it was at 600 volts, although it has unjustly
suffered in reputation. During the past five years 60-cycle converters have
practically displaced motor-generator sets for 250-volt lighting and industrial
power service.

38. Table of Weights, Speeds and Efficiencies for 600-volt, 26-cycle

and 60-cycle Converters

Kw.
Sec. 9-40 CONVERTERS
The efficiencies given in Par. 38 and 39 are those calculated from separ-
ately measured or calculated losses as prescribed by A. I. E. E. Standards
for conventional efficiencies. (See Par. 94.)
40. Commutator design for synchronous converters follows that for
direct-current generators except that long high-speed commutators are
more frequently used. The longest commutators are built with three
V-ring supports, or with two V-ring supports and a central shrink ring.
Shrink rings alone are not as effective as either of these constructions for the
majority of cases, on account of the large diameters involved. With large
diameters, large tangential stresses are produced in the shrink ring by rela-
tively small radial forces. The V-ring construction without shrink rings
is generally to be preferred since the commutator can ba readily taken apart
for repairs and also can be more easily insulated from adjacent parts. A
construction embodying four V-rings has been employed to a limited extent;
this consists, in effect, of two separate commutators flexibly connected
together. The inaccessibility of the middle V-rings is a serious objection
to this construction.
Long commutator necks must be braced from each other. This is done
by fibre plugs set into each neck, by interlacing heavy twine between the
necks, or by roping wooden spacing blocks to each neck.
41. The ventilation of commutators, in cases where the necks do not
provide sufficient cooling surface and windage, has been most successfully
accomplished by attaching radiating vanes about 2 in. square to the outer
end of each bar. These vanes not only provide additional cooling sur-
face at the most effective point,fbut considerably increase the air circulation.
42. Armature equalizer connections are used in synchronous converters
just as in direct-current generators (Sec. 8) to equalize the effect of the
flux under all poles. The collector-rings are also equalizing rings, so that the
equalizers are usually spaced with respect to the collector-rings. To secure
greater accessibility, the equalizer rings are generally located on the collector
end of the armature. Special constructions have been developed in order
to place the equalizing connections in such a manner that there will be no
interference with the collector connections and no increase in the length of
the commutator.
43. Damper windings. Almost without exception synchronous con-
verters are provided with damper or amortisseur windings to prevent
hunting (Par. 61). These are usually of the built-up grid type, commonly
employed on the rotors of induction motors, consisting of a large number of
bars located in slots in the pole-face, and connected on the ends by con-
tinuous rings. A cast-copper damper winding is sometimes employed,
consisting of relatively few bars of large cross-section in the pole face.
In the commutating-pole converters, the end rings are sometimes made in
— —
disconnected segments one for each pole so that the commutating poles
If the commutating poles
will not be enclosed by the damper winding.
are individually enclosed, changes in the commutating-pole flux are damped,
thus preventing the commutating-pole flux from changing as rapidly as the
armature current and flux when sudden changes in load occur.
44. The machine ventilation problem varies widely in converters for
different frequencies and voltages. In high-speed 25-cycle converters of
medium output, the armatures are small in diameter and relatively long.
Every means is used to increase the natural air circulation. In these
machines, heating and commutation are of approximately equal effect in
limiting the output. In large 25-cycle converters of both voltages (250
and 600) and in 60-cycle converters for 250 volts, the natural air circulation
is ample for the dissipation of the losses, but not excessive. In 60-cycle
600-volt converters and particularlv in those of large size, the armatures are
of large diameter and narrow, and the peripheral speeds are high. Under
these circumstances, the natural air circulation is much greater than is neces-
sary and greatly increases the windage loss. In such machines the natural
air circulation is restricted as much^as possible by stopping the air entrances
in order to eliminate the unnecessary windage loss.
CHARACTERISTICS
45. The no-load saturation curves are very similar to the same curves
for direct-current generators. —
There are two such curves one with direct-
680
 "

CONVERTERS See. 9-46

current volts and one with alternating volts as ordinates. From these curves
the actual no-load voltage ratio may be determined for any desired voltage.
46. Heating of synchronous converters occasions practically no diffi-
culty either in design or in operation under proper conditions of power-factor,
etc. The problem, however, varies with converters of different frequencies
and voltages (Par. 44).
47. The overload capacity, as determined by heating and by flashing, is
inherently large, due in great measure to the small armature reaction. The
latter is particularly important since it results in small field distortion due to
load. Consequently, on sudden changes in load, there is very little increase
in voltage between commutator bars or shifting of the flux in the commutat-
ing zone, both of which, if present, would tend to cause flashing.
48. The losses may be divided into constant losses (with varying load)
and variable losses. The constant losses are: core loss; friction and windage
losses (including commutator and collector friction) and shunt field and
;

rheostat loss (assuming that rheostat resistance and direct-current voltage

remain fixed). The variable losses are: armature copper loss; series-field
copper loss; commutating-field copper loss; brush I''R and surface-contact
losses; and load loss.
49. Additional losses in the synchronous booster converter. In
the synchronous booster converter, the only additional losses at the mid-vol-
tage are the booster armature copper loss and the load loss. At higher vol-
tages, the converter copper loss is increased due to the larger " motor
current and the core loss is increased due to the higher voltage. At lower vol-
tages the converter core loss is reduced, since the flux is reduced; the con-
verter copper loss is increased due to the larger "generator" current, and the
booster losses are the same as for a corresponding increase in voltage.
60. Additional losses in the split-pole converter. In the split-pole
converter there are no additional losses at the mid-voltage, but at either lower
or higher voltages the converter core-loss is increased, since the flux density
is increased (Par. 32 and Fig. 8). The converter copper loss is increased, as
in the booster converter, at higher and lower voltages (Par. 31).
61. Hunting of synchronous converters, as in other forms of synchro-
nous apparatus, is the periodic variation of the rotor from the true synchro-
nous position with respect to the supply system. • During hunting, the rotor
is alternately ahead and behind its true synchronous position. In forging
ahead, energy is expended in the converter, the latter acting as a motor; in
dropping behind, the converter acts as a generator and gives up energy.
This alternate motor and generator action is accompanied by a variation in
the value of the flux due to the armature reaction, by a fluctuation of alter-
nating-current and power-factor, and by a shifting of the commutating field
which causes periodic .sparking at the brushes. The frequency of the hunting
cycle may often be determined frorn the frequency of the sparking. Hunting
may be caused by periodic variation in the supply frequency, by sudden
changes in load, or by excessive line drop. It is more likely to occur in 60-
cycle than in 25-cycle converters, because of the greater number of poles and
consequently smaller actual angular variation corresponding to the limiting
electrical angular variation. *
52. Hunting may be practically eliminated by providing suitable
damper or amortisseur windings in the pole faces. Since hunting is
accompanied by a shifting of the flux across the pole face, the winding placed
in the path of this flux will oppose any such change, and will tend to damp out
the oscillations as soon as they begin. Practically all converters are now built
with such windings (Par 43). Hunting troubles have also been greatly
reduced by the use of generators driven by steam turbines or water turbines
in which the angular velocity is much more uniform than in reciprocating
engines.
63. Interruption of energy supply. If a converter is operating alone
• (a) Steinmetz, G. P. "Hunting;" G. E. Review, May, 1913.
(b) Newbury, F. D. " Hunting of Rotary Converters;" Elec. Journal,
June, 1904.
(c) Lamme, B. G. " Causes of Hunting;" Elec. Journal, June, 1911.

681
Sec, 9-54 CONVERTERS
or in parallel with other converters supplied from the same alternating-cur-
rent feeders, the interruption of the alternating-current supply will bring the
voltage on the direct-current side to zero, and the converters will stop. If,
however, there is another source of direct-current connected to the same
direct-current bus and not dependent on the same alternating-current feeders,
interruption of the alternating-current supply will not cause the converter to
stop; the direct-current voltage will be maintained and the converter will
be driven as an inverted converter. If the shunt field happens to be weak or
is interrupted, or if the converter should supply energy to an inductive load
on the alternating-current side (such as a short-circuit on the high-tension
side of the transformers) the speed will greatly increase. To guard against
danger under such conditions, converters are usually provided with a speed-
limit device, and the alternating-current and direct-current breakers are
so interlocked that opening the alternating-current breaker opens the direct-
current breaker. In addition, the direct-current breakers are sometimes
provided with a reverse-current tripping relay. When the alternating-cur-
rent supply is subject to serious drop in voltage due to short-circuits or other
cause, it may be advisable to provide the alternating-current breakers with
low-voltage tripping coils. This is particularly necessary with commutating-
pole synchronous converters due to the flashing that would occur should the
converter drop out of step as a result of low voltage, and later start with the
brushes down when the voltage resumes normal value.
64. The speed-limit device (Par. 63) consists of a pivoted weight rotat-
ing with the converter shaft; the centrifugal force acting on the weight is
counter-balanced by a spring. The weight moves outward and operates a
switch when the predetermined overspeed is reached. The switch closes (or
opens) the circuit of the shunt tripping coil of the direct-current breaker.

GENERAL APPLICATIONS
Comparison of efficiency with that of a motor-generator set.
66.
The efficiency of a 60-cycle converter including its transformers will be from
3 per cent, to 5 per cent, higher than an equivalent synchronous motor-gener-
ator set without transformers. The 25-cycle converter shows a further gain
in efficiency overthe motor generator set of from 0.5 to 1.0 per cent. If the
line voltage is above 13,200 volts, transformers will usually be required with
the motor-generator set as well as with the synchronous converter, so that the
difference in efficiency in favor of the latter will be further increased by 2
per cent. This higher efficiency of the converter is such an important advan-
tage that it is sufficient alone to justify the use of synchronous converters
wherever possible.
56. Comparison of required floor space with that of a motor-^rener-
ator set. The floor space required by 60-cycle converters and transformers
isapproximately equal to the floor space required by 60-cycle motor-generator
sets of compact design. The fact, however, that the transformers may be
placed in some remote location makes the arrangement of synchronous con-
verters and transformers more flexible and gives them in many cases the
advantage of reduced floor space.
67. Comparison of cost with that of a motor-^renerator set. The
combined cost of synchronous converters and transformers is approximately
equal to the cost of synchronous motor-generator sets without transformers,
assuming a motor voltage of 2,300 volts or lower. For higher alternating
voltages the motor cost increases appreciably, making the comparison favor-
able to the converter equipment. With alternating pressures above 13,200
volts, transformers are necessary with the motor-generator set as well as with
the synchronous converter, so that the cost of the converter equipment is
relatively still lower. With 60-cycle apparatus under 200 kw. capacity and
alternating voltages of 2,300 volts and lower, the comparison is somewhat in
favor of the motor-generator set, while with larger apparatus the comparison
is somewhat in favor of the synchronous converter. In few cases, however,
will there be sufficient difference in cost alone to determine the choice of
the apparatus.
68. Comparison of reliability with that of a motor-generator set.
The design and construction of synchronous converters has been standard-
ized to such an extent that in respect to reliability the comparison ia mainly
concerned with the number of machines involved. Compared with a three-

682
 t

CONVERTERS Sec. 9-59

unit motor-generator set consisting of a synchronous motor, direct-current

generator and direct-current exciter, the single unit converter has a decided
advantage. The comparison between the motor-generator set and the booster
converter is apparently leas favorable on account of the additional booster
generator, but there are so few troiibles that can reasonably be expected in a
relatively small low-voltage alternator that the difference is more apparent
than real. *
69. Comparison of voltage control with that of a motor-generator
set. In this characteristic the synchronous motor-generator set has an
advantage over the synchronous converter. The independence of alternat-
ing and direct-current voltage in the motor-generator set may justify its use
on alternating-current circuits in which the voltage fluctuates badly and
where it is essential to maintain steady direct-current voltage. Even under
such conditions of fluctuating alternating voltage it is considered preferable,
hy some engineers, to employ the converter and obtain the desired steady
direct-current voltage by means of a regulator.
60. Comparison of power-factor control with that of a motor-gen-
erator set. The motor-generator set, including a synchronous motor, may
be designed to correct power-factor more economically than can the syn-
chronous converter. _
For this reason, the motor-generator set is usually
employed where considerable power-factor correction is necessary.
61. For railway service compound-wound synchronous converters are
generally used, sufficient reactance being placed in the alternating-current
supply circuit to obtain the necessary voltage regulation. For this service
on 25-cycle systems, synchronous converters are used to the practical exclu-
sion of motor-generator sets and other forms of conversion apparatus. On
50-cycle and 60-cycle systems, the use of motor-generator sets, and in Europe
the use of motor converters has, in the past, been more general; but even
for these higher frequencies the use of the synchronous converter has become
general.
62. For lighting and power service, the shunt-wound converter with
induction regulator or the more specialized form of booster converter is
used. On the larger 25-cycle systems, the use of converters is general. On
60-cycle systems, their use, particularly in the booster form, is rapidly grow-
ing, due mainly to the gain in efficiency. Very few motor-generator sets are
now being installed for this service.
63. The synchronous converter can be used to supply 3-wire direct-
current circuits without any structural change, except in the case of
compound-wound or commutating-pole converters, in which the series wind-
ings on alternate poles are connected in the positive and negative leads so
that unequal currents in these leads will not affect the magnetization of the
converter. See Par. 35 and Fig. 14 for the transformer connections necessary
to obtain the neutral lead. The synchronous converter will operate under
extreme differences of current value in positive and negative leads with very
small differences in voltage between the outside leads and the neutral lead.
For example, a 1,000-kw., 60-cycle, 280-volt commutating-pole booster con-
verter, operated with full-load current in the positive lead and half-load
current in the negative and neutral leads, had a difference of only 1 volt
in the pressures from neutral to positive and neutral to negative leads. The
same converter, operated with full-load current in the positive and the
neutral leads and zero current in the negative lead, had a difference of 4 volts
in the pressures from neutral to positive and neutral to negative leads.
Without the resistance drop of the booster armature winding, the voltage
balance would have been still better.
64. For electrolytic work, either shunt-wound converters without means
for varying the voltage, or the same types of variable voltage converters as
used for lighting service, are generally employed.
OPERATION
65.Alternating-current self-starting. The synchronous converter
may be started as an induction motor if alternating current at reduced vol-
* Lincoln, P. M. "Motor Generators versus Synchronous Converters:"
Proc. A. I. E. E., March, 1907.
t Walker, Miles. " Rotary Converters versus Motor-Generators;" Jour.
I. E. E. (London), Discussion, Vol. XXXVIII, page 428.

683
Sec. 9-66 CONVERTERS
tage is applied to the collector-ringa. The armature winding acts as the pri-
_

mary and the squirrel-cage winding imbedded in the pole faces acts as the
secondary. For the smaller converters one starting voltage only is required.
The middle terminals of a double-throw switch are connected to three of the
collector-rings, one set of outer terminals is connected to the starting-voltage
taps of the transformers and the other set of outer terminals is supplied with
the full voltage of the line. With six-phase converters three leads are carried
direct from the transformer to the converter, and three through the main and
N0.13P.D.T.
^.S»a. Note To Start Rotary
rmer f
1 Throw both Switches Up
2 " JTo.l Switch Down
S Phase 3 " No.2 Switch Down
Incoming Line 4 Open No. 1 Switch
Shunt Field
\^-

Series Field

Fig. 15. — Alternating-current self-starting connections with two starting

voltages.

starting switches. With the largest converters, it is usual to employ two

starting voltages for which two double-throw three-pole switches are re-
quired. The connections for this arrangement are shown in Fig. 15.
66. Field "break-up" switch. During the starting period the field
winding has voltages induced in it of magnitudes depending upon the ratio of
armature and field turns. To prevent a dangerous induced voltage in the
field winding, the field circuit may be opened in several places during the
starting period by means of a multi-point double-throw switch, which is
usually located on the frame of the converter. Appreciable voltage rise in
the field circuit may also be prevented by closing the field circuit during start-

Shunt Field CoilB

Shunt Field Rlieottat
B-Pole Doubie Throw This is always Connected In
Shunt Field Breali-Up
the Upper Switch Position which
and Reveroin^ Switch
1b the Running Position

iTFSTSUm

JEqualii

Fio. 16. —Converter connections on direct-current side (alternating-current

self-Started).

ing. This method is employed generally because it only requires a double-

pole double-throw field switch which may be conveniently located on the
starting panel adjacent to the main switch.
67. Series-field switch. If a series-field shunt is used, a switch is usually
provided for opening the closed circuit formed by the series field and its
shunt. If this low-resistance circuit were left closed, the single-phase current
induced in it would tend to decrease the starting torque. This effect, how-
ever, is small. The detail connections of the direct-current side of the con-
verter are shown in Fig. 16.

684
 CONVERTERS Sec. 9-68

63. Reversed polarity with alternating-current self-starting con-

verters. In thia method of starting with a self-excited field winding, there
isno method of predetermining the polarity of the direct-current terminals.
However, if the converter falls into step with the wrong polarity, the machine
may be forced to "slip a pole" (if the armature is connected to the low-vol-
tage taps) by reversing the field switch. When the voltmeter indicates that
the voltage is reversed, the field switch should be brought back to its original

V 1(VVW\A^/V»-

Fia. 17. — Direct-current self-starting connections.

position. In some converters, the field set up by the alternating-current
may be so strong even at the lowest starting voltage that the converter can-
not be made to "slip a pole" by reversing the field. Under these circum-
stances it is necessary momentarily to open and close the starting switch,
repeating this operation until the correct polarity is obtained.
69. Direct-current self-starting. The converter may be started as a
direct-current shunt-wound motor. The current flow at starting is limited
by an adjustable resistance controlled by a multi-point starting switch. The
connections for this method are shown in Fig. 17. If the transformers are
solidly connected to the converter the starting current will be approximately
doubled. *
Main Line gwituh A.C. Maim

Equalu
Converter
Armaturt
ihQ
Fig. 18. —-Alternating-current motor-starting connections with manual
synchronizing.
70. Alternating-current motor starting. A motor usually of the
induction type is mounted on the converter shaft. The motor has fewer
poles than the converter and, therefore, a higher synchronous speed. In
starting, the motor is usually connected directly across the line. The con-
nections for this method are shown in Fig. 18.
A modification of this method has recently been brought out by
Dr. Rosenberg of Manchester, England, and by James Burket in this country,
which consists in connecting the starting-motor windings in series with the
converter armature. This limits the starting current to a low value, and the

Newbury, F. D. and Smith, M. W. "Starting Rotary Converters,"

Elect. Journal, Jan., 1918.
t See U. S. Patent 1073662.
Sec. 9-71 CONVERTERS
alternating current in the converter armature causes it to lock automatically
in synchronism.*
An older modification of the simple motor-starting method, designed to
eliminate the necessity for synchronizing, is the addition of reactance in the
main circuit as shown in Fig. 19. When the starting motor has brought the
converter armature near synchronous speed, the main-line switches are closed
with the reactance in circuit. The resulting current in the converter arma-
ture causes it to lock in synchronism, after which the reactances should be
short-circuited.
Sjnohronising Keactmna«

FiQ. 19.—Alternating-current motor-starting connections self-synchronizing

with reactance.

71. Starting small single-phase converters. A method of starting,

adapted to small single-phase converters, has been developed by the Wagner
Electric Manufacturing Company, and is used on the small single-phase
converters built by that company for charging electrical vehicle batteries,
the supply of direct current for moving-picture arc lamps and similar pur-
poses. A special distributed field winding is provided on the stator, so
connected that with the double-throw starting switch in the starting position
the converter starts as an alternating-current series-wound commutator
motor. When the starting switch is thrown to the running position, the
alternating-current leads are transferred to the collector-rings, the main-field
winding is connected in shunt with the main direct-current armature leads
and a part of the field winding is short-circuited to act as a damper winding.
See Sec. 17, " Garage Equipment."
72. Methods of synchronizing. With the simple motor-starting
method, or with the direct-current self-starting method, the converter must
be synchronized with the alternating-current supply circuit before the main-
line switches can be closed. The theory and methods involved are the same
as employed in synchronizing two alternating-current generators (Sec 7).
Lamps or specially designed instruments (Sec. 3) may be used for indicating
synchronism, as with generators.
With the motor method of starting, the running spfeed of the starting motor
should, in general, be higher than the synchronous speed of the converter.
The speed may be brought down to synchronous speed by increasing the load
on the converter. This can be accomplished by increasing the voltage, thereby
increasing the converter losses, or by connecting a resistance across the
alternating-current terminals of the converter. Small adjustments in speed
may be made by alternately opening and closing the starting-motor switch.
With the direct-current self-starting method, the speed regulation for
synchronizing is obtained by varying the converter shunt-field current.
The series-field circuit is opened to insure more constant speed under the
condition of varying armature current. To prevent a rush of current at
the instant of synchronizing, it is usual to leave a small amount of resistance
always in the starting-rheostat circuit.
73. Comparison of diSerent starting methods. The alternating-
current self-starting method is used in most cases on account of its simplicity
and its automatic synchronizing feature. Its principal defects are the un-
certainty in polarity and the large starting current required. In most
cases wrong polarity can be corrected by means of the reversing field switch
(Par. 66), and the amount of starting current is of importance (aside from
the momentary line drop) only when the converter rating approaches the rat-
• Report of Com. on " Electrical Apparatus," National Electric Light Asso.
Proceedings, 1914.

686
 CONVERTERS See. 9-74

ing of the alternator supplying it. With commutating-pole synchronous

converters, the simplicity of this method is decreased by the necessity of
lifting the direct-current brushes. The presence of the steel of the com-
mutating poles greatly increases the armature flux during starting, which
causes destructive sparking at the direct-current brushes. To avoid this
objectionable feature, commutating-pole converters are provided with a
special device for Lifting all but two of the brushes (which indicate polarity)
during the starting period.
The advantage of the alternating-current motor method of starting is
the small current required and the certainty of obtaining correct polarity;
the principal disadvantage is the necessity for synchronizing. This disad-
vantage is overcome by the Rosenberg method or by the use of separate
reactance coils (Par. 76). As compared with the alternating-current
method, this method is somewhat more complicated and the
self-starting
necessary apparatus is more expensive. In some cases, however, where
small values of starting current are imperative, it is the only method which
will meet the requirements.
The direct-current self-starting method can only be used where direct
current in sufficient amount is always available. It is very often used in
large city lighting and railway substations. It has the advantage of
minimum starting current and the absence of disturbances on the alternating-
current supply system (which is particularly important on underground dis-
tribution systems). As with the simple alternating-current motor method,
it has the disadvantage of necessitating manual synchronizing. This
disadvantage has been overcome in some cases by combining the direct-
current and the alternating-current self-starting methods. The converter
is started by means of direct current, and when a speed near synchronous
speed has been reached, the alternating-current switches are closed.
74. Parallel operation. When two or more converters are connected
to the same low-tension bus on the alternating-current side and to the same
bus on the direct-current side, the total direct-current load will divide among
the several converters in the inverse ratio of the counter e.m.fs. of the
converters and the resistances of the circuits. If two or more converters
are so connected, the alternating-current and the direct-current bus bars
close the circuit through any pair of converters; hence if the counter e.m.fs.
of the two converters vary even slightly, considerable current will circulate
between them. The counter e.m.fs. of different converters are seldom exactly
the same, and the resistances, made up mainly of the direct-current
—
brushes and brush contacts, are extremely variable even in the same con-
verter at different times. For these reasons it is not considered good
practice to operate converters in parallel on both the alternating-current
and the direct-current sides. Separate banks of transformers are usually
—
provided one for each converter. These not only open the circuit between
converters, but also provide means for correcting slight differences in the
voltage ratio of different converters. *
76. Division of load on the direct-current side is controlled by
the same factors as in direct-current generators, and in addition by factors
peculiar to the synchronous converter. Division of load is controlled by
the voltage, so that all factors affecting voltage affect parallel operation.
Parallel operation of shunt-wound converters, with or without auxiliary
means for controlling the voltage, is as simple as parallel operation of
shunt-wound direct-current generators. With compound-wound convert-
ers, equalizer leads are necessary as in direct-current generators. (Sec. 8.)
76. Corrections for improper division of load. With two converters
operating in parallel on the direct-current side, one of which takes less than
its proportionate share of the load, the load may be equalized by one or a
combination of the following adjustments:
(a) Adjustment of the series-shunt resistance. The shunts on the
series-field windings can be adjusted, decreasing the resistance of the shunt,
if possible, on the overloaded converter or increasing the shunt, on the under-
loaded converter. It should be borne in mind, however, that changing the
ampere-turns in the series field by changing the shunt resistance also changes
the resistance of the complete series-field circuit. This change in shunt
resistance must be compensated for by a corresponding change in the re-
isistance of another part of the series-field circuit, so that the resistance of

|!
• Newbury, F. D. "Parallel Operation," Elec. Journal, July, 1917.
Sec. 9-77 CONVERTERS
the total circuit remains unchanged. From another standpoint, a shunt
on one converter aeries field may be considered to be a shunt on both series
fields, the effect varying only by reason of the fact that the resistance of
the leads and busses is added to one shunt circuit and not to the other
(Sec. 8).
(b) Insertion of resistance in leads between series-field and equali-
zer bus. If the relative ampere-turns are correct but the series-field
resistances are differently proportioned, the resistance of the leads between
the series field and the equalizer bus may be changed to compensate for a
difference in the series-field resistances. The resistance in the series circuit
of the converter taking more than its share of the load should be increased.
This adjustment varies the resistance of one series field without introducing
a third parallel circuit between the equalizer and the main bus. Adjustment
by this method is less complicated than an adjustment of the series-shunt
resistance.
(c) The transformer ratio can be changed. This increases the
voltage by the same amount throughout the range of load, and will not correct
for an unequal division which changes with the total load. An increase
in no-load voltage of one converter will cause, at lighter loads, a greater in-
crease in proportionate load on that converter.
(d) The reactance can be increased in the circuit of the lightly
loaded converter, which will raise its direct-current voltage and cause
it to carry more nearly its proper share of the load. This method is similar
in effect to an increase in the number of series-field turns, but the effect is
obtained at the expense of a greater range in power-factor. It sometimes
happens that the reactances of converters in parallel are worked at different
saturations, with the result that the reactance voltages of the two converter
circuits will have different ratios at light and at heavy loads. Such a relation
will cause the converter with the more highly saturated reactance to take
less than its share of the load at heavy loads.
(e) The relative shunt-field currents of the two converters can b«
changed. The converter having the smaller ratio of series-field ampere-turns
to armature ampere-turns should have its shunt-field current increased. This
will increase its no-load voltage (on account of change in power-factor)
and cause it to take a greater share of the load at light loads. The voltages
will tend to equalize as the load increases, a correct division being obtaine4
at only one value of the load.
77. Load-division study. Since there are so many variables affecting
load division, it is important to make a careful and systematic study of thp
particular case before making any changes. Such a study should be con-
ducted as follows:
(a) Adjust the transformer ratios so that at no-load and with the shunt
field adjusted to give equal power-factors, all converters have the same
no-load direct-current voltage.
(b) The series fields should be adjusted by shunts so that the ratio of series-
field ampere-turns to armature amporc-turns is the same.
(c) The resistances of the series fields (including shunt) plus the resist*
ances of the leads from the series fields to the main bus (positive or negative)
should be so adjusted that the resistances are inversely proportional to the
rated capacities of the converters.
(d) The reactances should be adjusted, if possible, so that the.reactance
volts of the various circuits throughout the range of load are equal. If
they cannot be made equal, the series ampere- turns should be greater in the
converter having the smaller reactance, to afford an approximate
compensation.
It is only possible to obtain correct division of load and equal power-
factor on all converters when the machines are properly proportioned witJi
respect to all four elements, namely: the transformer ratio, the series-field
ampere-turns, the series-field resistance and the reactance.
78. Interruption of alternating-current supply by circuit breaker
in substation. Under such conditions, if the converter is connected to
another source of direct current, the converter will " motor" unless the direct-
current breaker is opened by interlock with the altornnting-currcnt broal^er
(Par. S3) or by a reverse-current relay. A compound-wound converter will
run in the same direction when the direct-current power is reversed, the

688
 CONVERTERS Sec. 9-79

current in the series winding will be reversed (unless there are several con-
verters in the same station connected to an equalizer bus), and the current
in the shunt winding will remain the same in direction. With a single con-
verter in a substation which is connected to other converters in other sub-
stations on the direct-current side, the converter will increase its speed due to
the reversed series field. It may also increase its speed if the shunt field is ad-
justed for less than 100 per cent, power-factor. The increase in speed from
the reversed series field will not be serious unless there is a circuit connected
to the alternating-current side which will provide a load. Under these
conditions the overspeed device will operate, thereby opening the direct-
current breaker.
79. Interruption of alternating-current supply outside sub-
station. In this case an interlock between the substation alternating-
current and direct-current breakers will not operate to open the direct-
'current breaker, and reverse current or overspeed must be depended upon to
protect the converter. In case of interruption of alternating-current supply
the converter should be manually disconnected from the direct-current linos
(if this is not done automatically) and the switches on the alternating-current
side opened for starting.
80. Commutating-pole converters require more complete pro-
tection from low alternating voltage because of the excessive sparking
at the commutator which is encountered when the converter is not in phase
with the supply circuit. If the alternating voltage is lowered momentarily
by a short-circuit or other cause, the converter may fall out of synchronism.
When the voltage is restored the converter will not be in phase and the spark-
ing may be sufficient to make the converter "buck." The conditions are
similar to those which exist when starting the converter with the brushes
down.
81. Protection of high-voltage converters. High-voltage converters
(1,200 volts and above) should be more completely protected from abnormal
conditions than low-voltage converters on account of the more destructive
nature of the "bucking" when once started.
82. Sparking at the brushes may be due to any of the following causes:
(a) brushes incorrectly set with reference to the neutral point. Correct
setting is of particular importance in commutating-pole converters;
(b)
brushes of improper characteristics; (c) defective electrical design; (d)
hunting; (e) severe overloads or extreme variation in load; (f) in non-com-
mutating pole converters, low alternating voltage with large direct-current
loads; (g) brush holders insufficiently supported; (h) brushes stuck in holders
or inaccurately fitted to commutator; (i) improper brush tension;
(j) rough
commutator due to high bars, to high mica or to flat spots.
83. Bucking or flashing may be brought about by any condition
causing excessive voltage in the coils short-circuited by the brush or between
adjacent commutator bars, or may be caused by abnormally low-surface
resistance on the commutator between adjacent brush arms. Any condi-
tion tending to produce poor commutation increases the likelihood of
buck-
ing. Excessive voltage under the brush is usually caused by short-circuits
of varying degree. Most direct-current machines will flash if short-circuited
at the terminals and the direct-current voltage is maintained.
Short-circuits
in serviceusually occur on the line, so that some resistance
exists between the
short and the machine, thereby limiting the current. Taps from feeders
to trolley should always be located some distance from the
substation *
Excessive voltage between commutator bars is caused directly by increased
lino voltage, or IS indirectly caused by extreme
current overloads which dis-
np'd.flux Increased hne voltage may be due to disturbances on
I IS
the I,- t
high-tension distributing system induced by lightning, switching, short-
circuits, etc. A decrease in the insulation strength between brush arms may
be due to the presence of conducting gases formed by
a relatively small
"asf" or of foreign substance such as dirt or water.
'

Most flashing is caused

Dy the formation of conducting gases. Ordinary types of circuit
breakers
ao not act quickly enough to protect machines from abnormal
changes in
• Smith C H. "Relation of Trolley Feeder Taps to Machine Flash-
overs," Elec. Journal, Jan., 1915.

44 C89
Sec. 9-84 CONVERTERS
current or voltage. On short circuits, for example, the current increases
far beyond the setting of the breakers before the circuit is finally opened.
84. Reactance used as a protection against short circuits. Shunt-
wound synchronous converters may be protected from the effects of short
circuits by inserting reactance in the alternating-current leads.

TESTINQ
85. The tests ordinarily made on synchronous converters are as
follows; (a) resistance measurements; (b) polarity determination; (c) ratio
of voltages; (d) core-loss and saturation test; (e) alternating-current short
circuit or synchronous-impedance test; (f) starting tests; (g) voltage regula-
tion test; (h) temperature tests; (i) commutating-pole saturation test.
86. Measurement of resistance. Resi.stances may be measured either
by the bridge method or by the use of ammeter and voltmeter as in direct-
current machines. It is customary in obtaining the armature resistance
to measure the resistance both on the direct-current side between the proper
commutator bars, and on the alternating-
current side between the corresponding slip-
rings.
87. Determination of polarity. The
correct polarity of the field windings is de-
termined in the same manner as for direct-
current generators. The relative polarity of
the shunt and the series windings in the com-
pound-wound converter is also determined the
first time the converter is under load.

88. Determination of voltage ratio. In

order to determine whether the various taps
from the armature winding have been brought
out correctly and connected to the proper
rings, readings of voltages between each nng
and every other ring are taken. During the
test the direct-current voltage is held constant
at some convenient value. The armature
—
Fig. .^0. Diagram of con- winding is usually connected to the collector-
verter voltages between col- rings so that adjacent rfngs have the minimum
lecter-rings. voltage possible between them. Under these
conditions the voltage between adjacent rings
is given by the following formula, A^ being the number of rings:
Ed. 180 deg.
Eoc = (sin (volts)
1.415 ^ N J
(3)

A convenient method of checking the values obtained on test is to construct

a diagram such as that in Fig. 20. The numbers outside of the circle repre-
sent the collector-rings. The voltages shown were actually obtained from
a 600-volt six-ring converter.
89. Determination of core-loss, saturation, friction and windage
losses. This test is made either by driving the converter by a small direct-
current motor or by driving the converter itself as a direct-current shunt-
wound motor. The test is the same as the corresponding test of a direct-
current generator except that alternating voltages are obtained as well as
the direct-current voltage, in order to obtain the actual voltage ratio. If
the converter is self-excited during the test, the measured loss must be de-
creased by the field-winding and rheostat losses. The brush friction is
determined by the difference in the measured losses with the brushes down
and the brushes up. This reading is of no value unless the commutator has
a good polish and the brushes are well seated. The friction and windage
losses are determined by the difference in measured converter losses with the
brushes removed, and with the driving motor running disconnected from the
machine under test.
90. Starting tests. With the alternating-current self-starting method,
a test is made to check the sufficiency of the starting voltage to bring the con-
verter up to synchronous speed. It is customary to measure the voltage,
current and time required to reach synchronous speed. With the induction-
motor method of starting, the test is made to ascertain whether the load on
the starting motor (provided by the converter) is such as to permit it to

690
 CONVERTERS Sec. 9-91

operate sufficiently near the converter synchronous speed at the normal con-
verter voltage, so that synchronizing will be possible. If the normal losses
of the converter are not sufficient to reduce the starting-motor speed to the
converter synchronous speed, it is necessary to determine the additional
load required.
91. The voltage-regulation test can be made only when the entire
equipment of transformers and reactances to be installed with the converter
is available. Even under such circumstances the test must be made on
the basis of constant alternating voltage on the high-tension side of the trans-
formers. This is rarely, if ever, true in practice, so that the test unless made
after installation is of little value and is seldom made. Furthermore, there
is no object in adjusting the series winding of a converter except in conjunc-
tion with all other converters with which it is to operate in parallel on the
direct-current side. With compound-wound converters, the alternating
voltage should be adjusted to the desired value, and the shunt field of the con-
verter should be adjusted to give the correct voltage at no load. If the trans-
former ratio is correct, this will require considerable lagging current, which
may be obtained by under-excitation. Load is then placed on the converter
and the desired full-load voltage is obtained by adjusting the series-field
shunt. This test is never made with shunt-wound converters since a slightly
drooping voltage characteristic would always be obtained, and there is no
means within the converter of modifying it. With converters designed for
wide voltage ranges, it is customary to observe the operation at the maximum
and minimum pressures to insure that there is sufficient range in the field
windings and rheostats to obtain 100 per cent, power-factor at all voltages,
and that satisfactory commutation is obtained throughout the voltage range.
To A.C. PowCT

Conrerter on
Tett

S''"-'
?JS&ULr- To Power for

Fig. 21. —Loading-back temperature-test connections.

92. The temperature tests at the factory are performed either by direct
loading on resistances or by "loading back" on a similar converter or power
circuit. In the loading -back method (using a similar converter), the losses
can be supplied from either the direct-current or alternating-current sides
as is found convenient. The alternating-current sides of the machine under
test and of the test machine may be connected together by a complete metallic
circuit, or through transformers having a one-to-one ratio. The latter
arrangement is preferable, as conditions are thus made more stable and can
be more easily controlled. The connections for such a test are shown in
Fig. 21. When the machines under test are compound-wound, it is necessary
to reverse the series field of tlie converter running inverted. In Fig. 21 the
losses are supplied partly from the alternating-current side and partly by a
booster in the direct-current side. Temperature tests are usually made wdth
100 per cent, power-factor at the converter collector-rings. To obtain this

691
 t

Sec. 9-93 CONVERTERS

condition, the shunt field should be adjusted for the proper no-load voltage,
and the series field shunted to give 100 per cent, power-factor, that is, a
minimum value of armature current, at the tested load.
93. Commutating-pole saturation test. On commutating-pole
converters this test is made to determine the sensitiveness of the converter
to proper adjustment of the commutating-pole ampere-turns. The converter
is so connected that it can be loaded with the commutating poles separately
excited, in order that the excitation can be adjusted. For various loads and,
in variable voltage converters, for various voltages, the minimum and the
maximum commutating-pole excitations are determined between which satis-
factory commutation is obtained.
94. Determination of efficiency. Efficiencies are usually determined
by separate measurements of the various losses. This method does not
derive the true efficiency, as the so-called load losses or stray losses cannot
be included by direct measurement This is the conventional efficiency
defined in Sections 3524 and 4335 A. I. E. E. Standardization Rules, 1921
Edition. Stray lo.sses, however, in converters are small and no appreciable
error is introduced by omitting them. They are less in low-frequency con-
verters than in high-frequency converters. On account of the relatively
small losses involved and the large number of instruments to be read, input-
output efficiency tests can be made satisfactorily only under laboratory
conditions where the power input and output are absolutely steady, and
where carefully calibrated instruments are read by skilled observers. Unless
the test can be' made under such conditions more accurate results will be
obtained by calculating the efficiency from the separate measurable losses,
and including a reasonable allowance for the stray losses. *
The reason for the greater accuracy of the efficiency calculated from the
separate losses is apparent when it is remembered that a 2 per cent, error in
the measurement of the losses results in only 2 per cent, of the 5 per cent losses
(using 95 per cent, as the true efficiency) or 0.1 per cent, error in the effi-
ciency, while 2 per cent, error in the input-output test affects the efficiency
by an equal percentage.
INVERTED CONVERTERS
BY F. D. NEWBURY, M.E.
95. Any synchronous converter can be operated inverted; that is.

itcan be used to convert direct current into alternating current.

The internal action of the inverted converter is the same as
96.
that of the synchronous converter except that the losses are supplied from
the direct-current side, so that the distribution of currents in the armature
is slightly different.
97. The inverted converter has the speed characteristics of a direct-
current motor instead of a synchronous motor, except that when the con-
verter operates in parallel with another source of alternating current the
speed is controlled by each of the two alternating-current sources in propor-
tion to its share of the load. When an inverted converter operates singly,
its speed may be seriously affected by a change in load or power-factor on
the alternating-current side. A lagging alternating-current load will demag-
netize the main fields and the converter speed will increase, as would that of
any direct-current motor with weakened field.
98. Alternating voltage control. There is no means of varying the
alternating voltage corresponding to the reactance and series-winding method
used with the synchronous converter. The alternating voltage may be con-
trolled by any of the other methods discussed in connection with the syn-
chronous converter.
99. Inverted converters are usually shunt^wound in order to secure
as nearly constant speed and frequency as possible.
100. Correction for overspeeding. Where inverted converters are
subject to loads of varying power-factor and where constant speed is essential,
it is customary to use a separate ly excited field winding, the excitation being

• Olin and Henderson. 'Load Loss Correcting Factors," Transactions

'

A. I. E. E., page 479, Vol. XXXII, Part I. Robinson, L. T. "Determina-

tion of Stray Losses from Input-output Tests," Transactions A. I. E. E.,
page 531, Vol. XXXII, Part I.
t See footnote, Par. 23.
692
 CONVERTERS See. 9-101

supplied by a direct-connected exciter. The exciter is designed with an

unsaturated magnetic circuit so that a change in speed will produce a maxi-
mum change in exciter voltage. With this arrangement an increase in speed
of the inverted converter is at least partially corrected by the increase of its
excitation due to increased exciter voltage.
101. Protection against overspeeding. Where the conditions do not
require the separate exciter, it is customary to install an overspeed tripping
device to protect the converter and its alternating-current load from excess-
ive speed due to unusual conditions.
102. Applications of the inverted converter. The following applica-
tions of the inverted converter may be mentioned: (a) to supply a small
amount of alternating-current from an existing direct-current supply; (b)
to form a connecting link between alternating-current and direct-current
systems for the transfer of energy in either direction. Under the latter
condition the converter may operate either direct or inverted. An induction
regulator or other means of varying' the voltage is necessary to control the
transfer of energy through the converter or, in the case of operating the load
on one system entirely through the converter, to compensate for the voltage
drop in the converter and transformers, (c) To enable a storage battery to
be used to equalize the energy input in an alternating-current system. Here,
also, a means of varying the voltage of the converter is necessary to control
the charge and discharge of the battery. A notable installation of this kind
is at the Indiana Steel Company, where a 2,000-kw. 250-volt, 25-cycle split-
pole converter is used.

MOTOR CONVERTERS
BY F. D. NEWBUEY, M.E.
103. Structure. The motor converter, or cascade converter, as it is
sometimes called, consi.sts of two elements, or machines, coupled together
mechanically and electrically. The primary element, having the structure
of an induction motor with a phase-wound rotor, performs the functions of a
voltage, frequency and phase converter and of an induction motor. The
secondary element, having the structure of a synchronous converter (with
taps to the winding but without collector rings), performs the functions of a
direct-current generator (driven by the induction motor, the rotors being
mounted on the same shaft) and of a synchronous converter (receiving energy
of suitable voltage, frequency and phase from the rotor winding of the pri-
mary element).* u
104. Starting resistance. Three of the inside terminals of the rotor
winding of the primary element are attached to collector-rings, to which the
starting resistance is also connected. When operating at synchronous speed,
all of the inside terminals of the rotor winding of the primary element are
connected together to form the neutral.
106. The rotor of the primary element is wound with either 9 or
12 phases, the large number of phases being used to decrease the arma-
ture_ copper loss of the commutating machine. The large number of con-
nections between the two rotors does not lead to any complication as they
can be made solidly without collector-rings.
106. Transformers are required only when the line voltage exceeds the
highest voltage for which the primary element can be safely and economically
wound. In this respect the motor converter is on nearly equal footing with
the synchronous motor-generator set. The difference in favor of the latter
is due to the fact that the synchronous motor can be satisfactorily wound for
higher voltages than the induction-motor element of the motor converter.
107. Applications. The motor converter occupies a position between
the motor-generator set and the synchronous converter. Its main advantage
over the motor-generator set lies in the fact that a part of the energy is trans-
formed electrically and, therefore, more efficiently than in the motor-gener-
* (a) See German patent 145434 (1902); English patents, 3704
(1903),
7807 (1904); U. S. patent 72400 (1904).
(b) See Arnold u. la Cour, " Der Kaskadenumformer " Enke, Stuttgart,
1904.
(c) Hallo, H. S. " The Theorv and Application of Motor Converters,"
Journal, I. E. E. (London), Vol. XLIII, page 197.

693
Sec. 9-108 CONVERTERS
ator set in which all of the energy is transformed mechanically. For the same
reason it is less efficient than the synchronous converter in which the entire
output is transformed electrically. Its main advantage over the synchronous
converter lies in the fact that the commutating machine of the motor con-
verter operates at a frequency lower than the line frequency
half the line frequency.
usually at
This advantage applies only in the case of line
—
frequencies above 40 cycles per sec. and for the higher direct-current
voltages, and has been lessened even for these conditions by recent improve-
ments in high-frequency synchronous converters. The motor converter
has found its most extensive application in England and Germany. In
England approximately 150,000 kw. of capacity has been installed since
1904, and in Germany approximately 65,000 kw. of capacity has been in-
stalled, mainly since 1908. These figures, were compiled in July, 1913.
Practically nothing has been done in the United States toward introducing
the motor converter commercially, mainly due to the previous development
of the high frequency synchronous converter.
108. Equations of the motor converter.
Synchronous speed =
,
-5
Sum
-.—
Line frequency X 120 -—
^
, ..
of poles of both elements
. — ,
.

(r.p.m.)
. ...
(4)

Rotor frequency = Line frequency — ( --^- ) (r.p.m.)

(cycles per sec.) (5)

„ /Secondary poles \ ,-.
Power transformed electrically =
, , , . ,, r.^ . , ,
1 otal output
.
(—;^—-~. r- -j (6;

Power transformed mechanically = Total output

lotal poles '
(
\
—_, .
—
-, ,
) (7)

When the numbers of poles of both elements are equal, as is usually the
case, these relations obviously become very simple.
109. The average armature current and heating in the commu-
tating element is less than in a direct-current generator of equal rating, but
more than in the corresponding synchronous converter. Assuming an equal
number of poles in the two elements of a motor converter, the commutating
element is operating half as a direct-current generator and half as a synchron-
ous converter. Assuming further a twelve-phase rotor circuit and 100 per
cent, power-factor at the terminals of the primary element, the average loss
will be approximately 0.34 (relatively), the equivalent direct-current
generator loss being unity. This is about 30 per cent, greater than the
average loss in the ordinary six-phase synchronous converter, also at 100
per cent, power-factor. The maximum loss in one conductor is approxi-
mately 10 per cent, less than the maximum loss in the six-phase synchronous
converter, at 100 per cent, power-factor.
110. The armature loss increases less rapidly with reduction in power-
factor than in the 6-phase synchronous converter, due to the generator
current loss, which docs not vary with power-factor, and to the higher
number of phases employed.
111. Power-factor. The power-factor at^the line terminals of the primary
element may be varied as in the simple synchronous converter by varying
the field excitation of the commutating machine. The magnetizing current
for the primary element may be taken from the line or from the secondary
clement as desired. This is controlled by the excitation of the commu-
tating machine. If the set is operated at 100 per cent, power-factor, it follows
that the secondary element is operating at a leading power-factor (with
respect to Une voltage) in the neighborhood of 93 per cent, at full-load.
This has an important bearing on the heating and size of the commutating
machine. See Far. 117.
112. Voltage control. A fixed voltage ratio exists between the alter-
nating-current, and the direct-current sides of the commutating element
of the motor converter, as in the synchronous converter, and the same means
for varying the direct-current voltage must be employed. In a shunt-
wound motor converter the direct-current voltage drops with the load
assuming constant alternating voltage. In this case the necessarily high
reactance of the primary element is a disadvantage. In a certain 500-kw.

694
 CONVERTERS Sec. 9-113

motor converter the voltage dropped 5 per cent, between no load and full
load. This is less than in a corresponding direct-current generator but
more than in a corresponding synchronous converter. The motor converter
is well adapted to voltage regulation by reactance and series-field excitation.
In general, the primary element will contain inherently sufficient reactance
to obtain a 10 per cent, voltage increase (assuming constant primary
alternating voltage) with permissible range in power-factor. This range in
voltage is ample for the ordinary railway system. Voltage ranges of 20 per
cent, to 30 per cent, required by lighting systems using storage batteries
cannot be obtained economically by reactance and series-field excitation.
For such voltage variation an induction regulator, alternating-current
booster or direct-current booster is required. The alternating-current
synchronous booster must have the same number of poles as the secondary
element and must be connected, electrically, between the primary and
secondary rotor windings.
113. Relative size and cost. The cost of the primary or induction
element will be approximately the same as that of an induction motor with
phase- wound rotor at double the running speed (assuming equal primary
and secondary poles). The cost of the secondary or commutating element
will be less than that of a direct-current generator of the same rating and more
than that of a synchronous converter of the same rating and operating
frequency. The cost of the induction element will be somewhat more than
that of stationary transformers necessarily used with the synchronous
converter. On the basis of a line voltage so low that transformers are un-
necessary with the motor converter, the cost without transformers is approxi-
mately the same as that of the higher-frequency synchronous converter and
the necessary transformers. In case transformers must be used with either
form of converter on account of high line voltage, the cost of the motor
converter installation will be from 30 per cent, to 40 per cent, greater
than the synchronous converter installation.
114. Efficiency. At capacities of 500 kw. and above, the efficiency of
a synchronous converter and transformers would be 1.5 per cent, to 2 per cent,
better than the motor converter without transformers, assuming American
conditions which require the use of open armature slots in the primary
element. Including the transformer in the motor converter installation
would reduce its efficiency below that of the equivalent synchronous con-
verter installation from 3 per cent, to 4 per cent.
116. The method of starting^ is the same as in an induction motor
with phase-wound rotor, a three-phase resistance controller being used as
indicated in the diagram in Fig. 22. It will be noted that, during starting,
three phases of the rotor winding of the induction element are in series with
the armature winding of the commutating element, the other phases remain-
ing open at the neutral. After the main-line switch is closed, the rotor circuit
of the induction element is closed through the starting resistance. As the
rotor begins to revolve, two alternating currents are superimposed in the
rotor circuits, one at maximum frequency decreasing with the speed, due to
the induction element, and one at minimum frequency increasing with the
speed, due to the commutating element. The latter current is appreciable
only near synchronism or in the case of separate direct-current excitation of
the secondary element. As the rotor approaches its normal running speed,
these two currents approach the same frequency, which is indicated by a
slow oscillation of the needle of the voltmeter connected in the starting
circuit. At the moment the voltmeter needle passes through zero, the
starting resistance is short-circuited and the set will thereafter operate syn-
chronously. The neutral points of all the rotor phases are connected
together and the starting brushes lifted from the rings by a mechanical
device. By proper selection of the starting resistance, the starting current
may be maintained at a low value throughout the entire starting operation.
Due to the small armature current during starting, the direct-current
voltage will always build up with the correct polarity. The field reversing
switch commonly used with alternating-current self-starting synchronous
converters is unnecessary.
116. The motor converter may be used to supply a three-wire
direct-current circuit without change except that the brushes are left on
the rings after starting. They are connected to the middle terminals of a
695
 Sec. 9-117 CONVERTERS
three-pole double-throw switch, one set of outside terminals being connected
to the starting resistance and the other set being short-circuited and con-
nected to the direct-current neutral lead.
117. Commutating poles may be used on the commutating
element as in any synchronous converter. Due to the combined generator
and converter action the ampere- turns required on the commutating poles
more nearly approach the ampere-turns on the equivalent direct-current
generator than on the equivalent synchronous converter.
S
High Tension
Staler Wlndingj

t© Jlotor Windings

Fia. 22. — Diagram of connections of motor converter.

DIRECT-CURRENT CONVERTERS
BY ALEXANDER GRA7, M. S.

118. Theory of operation. A three-wire generator, operating with no

current in one side of the system, may be used as a direct-current converter
with a ratio of two to one. Such conditions of operation are shown diagrnm-
matically in Fig. 23. If the armature be connected across the terminals a
and 6, it will rotate as a direct-current motoi
armature and will take a current ia, at a volt-
age 2e, to supply the no-load losses in the
machine. If now two diametrically opposite
points c and d be connected through a coil C
of high reactance and negligible resistance, and
if the middle point / of the coil be connected
as shown in Fig. 23, the machine will become
\ a three-wire generator (Sec. 8, Par. 193)
The point / is then midway in potential be-
tween c and d and, since the c.m.f. between <

and d is alternating, an alternating current

supplied from the mains, will flow in the react-
Flo. 23.— Current distn- ^^pg p„ii This current will bo small since
bution in a direct-current t^e reactance is large.
converter. A load current at voltage « may now be
drawn from terminals / and g, and the current distribution in the system
will then be as shown in Fig. 23, the no-load currents being neglected.
The
currents in sections M flow against the generated e.m.f., so that these
the currents sections G flow
sections may be considered to act as motors; in
in the direction of the generated e.m.f., and so these sections may be con-
sidered to act as generators. The driving torque due to the motor section!
must overcome the retarding torque due to the generator sections.
 CONVERTERS Sec. 9-1 19

119. Armature currents. The current in the armature conductors

varies as the armature revolves; this may be seen from Fig. 24 where the
armature is shown in four different positions.
In position A, the resistance from c to o is equal to that from c to 6, and
the current i, entering the armature at c, divides into two equal parts. In
position B, the resistance from c to a is less than that from c to b, and the
current ia is greater than the current u.
In position C, the current in ca is practically equal to i and that in eb
practically zero. In position D, the currents in all the conductors are zero.

Fig. 24. — Relation between current and position of armature.

25 shows approximately how the current varies in two coils m and n
Fig.
aa the armature makes one revolution. In coil m, the current varies from
sero to » while in coil n it varies from — ji to +it; the armature coils are
therefore not equally heated. Those next the leads c and d are the hottest
and those midway between the leads are the coolest.
120. The rating of a direct-current converter depends upon the num-
ber of phases of the reactance coil. With a 2-phase reactance coil, as
Jlhown in Fig. 26, the maximum current in the conductors is less than i, and
^e current in each armature coil is more nearly constant than when only one
lireactance coil is used. For the same average armature copper loss in each

r
Fig. 25. — Variation of currentof armature.
in coils m and n during one revolution

case, a direct-current generator can be given the following ratings when used
as a direct-current converter:*
1.00 as a direct-current generator;
1.22 as a direct-current converter with one reactance coil;
1.55 as a direct-current converter with two reactance coils;
1.64 as a direct-current converter with three reactance coils.
The cost and weight of the equivalent direct-current generator may be
Obtained from Fig. 67 (Par. 178) Sec. 8, an addition of 5 per cent, being
ide for the slip-rings.
121. The secondary voltage of such a system cannot readily be
tntrolled independently of that of the primary; it decreases with increase of
Bad according to Eq. 38 in Sec 8, Par. 194 and, with a reasonably priced
• Steinmetz, C. P. " Elements of Electrical Engineering," p. 337.

697
Sec. 9-122 CONVERTERS

reactance coil, this decrease in voltage can hardly be less than 3 per cent, at
full load.
122. The rating of the necessary reactance coil may be found from
Sec. 8, Par. 197. The frequency, which equals the number of poles multi-
plied by the r.p.m. and divided by 120 will generally be between 15 and
40 cycles per sec.
123. The Dettmar and Kothert split-pole machine (Sec. 8, Par. 192)
when used as a direct-current converter has the advantage that the secondary
voltage can be controlled independently of that of the primary. Each
pole of this machine is split so as to form two polar projections of like polarity
and these are excited independently of one another. The neufi?al brush is
placed on the commutator midway between the positive and the negative
brushes and, by varying the excitation of one polar projection relative to that
of the other, the flux entering the armature between the positive and the
neutral brushes may be changed relative to that between the neutral and'the

Fig 26. —Current distribution in a direct-current converter with a two-

phase reactance coil.

negative brushes, or the potential of the neutral brush may be varied as

desired. By the use of suitable shunt and series coils on the polar projec-
tions, any desired degree of compounding may be obtained and, in the
extreme case, a constant current may be obtained from the secondary of
such a machine while the primary is operating at constant potential.
124. The C. M. B. autoconverter is another type of split-pole machine
with the armature tapped by brushes placed between the main positive and
negative brushes. A standard line of these machines is on the market and
can be supplied with a transformation ratio as high as four to one, and with
such a combination of shunt-field and series-field coils that a drooping second-
ary characteristic may be obtained if desired for constant-current operation.
They are supplied with ball bearings and have an efficiency which varies
from 75 per cent, for a 1 kw. unit to 86 per cent, for a 10 kw. and 94 per cent,
for a 50 kw. unit.
126. Applications.* Direct-current converters of this latter type are
used in place of motor-generator sets for many purposes, among others,
to obtain 50 volts from a line of higher voltage for the operation of arc
lamps at 50 volts in bioscope sets and search lamps. A constant-current
characteristic is the most suitable for arc-lamp operation. They are also
used for electric welding, the machines being built with such characteristics
that, on short-circuit, the current is only 10 per cent, more than full-load
current, while the voltage drops practically to zero.
• For further information on direct-current converters see:
Steinmetz, C. P. " Theoretical Elements of Electrical Engineoriiij,'," page
337; New York, McGraw-Hill Book Co., Inc.
MacFarlane and Burge. London Electrician, July 9, 1909.
Thompson, S. P. Report at Turin Congress; London Electrician, Sept. 29,
1911.

698
 CONVERTERS Sec. 9-126

DYNAMOTORS
BY ALEXANDER GRAY, M. S.
126. General description. The dynamotor issimilar to the motor-
generator set except that the two armature windings are on the same core
and revolve in the same magnetic field, each winding being connected either
to a commutator or to collector-rings, in accordance with its use for direct
or for alternating current respectively. It is rarely necessary to change from
direct current to alternating current, so that machines for such purpose are
special. Achange from alternating to direct current may be realized with
less expense by the use of a rotary converter, with a transformer if necessary,
than with a dynamotor.
127. Armature reaction. The armature for a direct current to direct-
current type of dynamotor is shown diagrammatically in Fig. 27. Here the
transformation ratio is four to one, so that there are four times as many
effective turns in one winding as in the other. The direction of the generator
current is that of the generated e.m.f., but the current in the motor winding is
in the opposite direction. If the losses in the machine be neglected, then the

Fig. 27. —.\rrangemcnt of dynamotor armature and commutator.

motor input, Emim equals the generator output, Eglg, and the value of effec-
tive ampere-turns in the motor armature, iimlm equals the value of effective
ampere-turns in the generator armature, Uglg. Therefore the m.m.fs. of the
two windings are equal and opposite and there is no resultant armature
reaction. For this reason, the dynamotor can be allowed a smaller air gap,
a smaller exciting current, and a lighter field coil than a standard machine
built upon the same frame.
128. The commutation of these machines is exceedingly good if the
brushes on the two commutators are so placed that the short-circuited coils
of each of the two windings lie in the same slot. Under such conditions the
currents in these coils change at the same time and in opposite directions, so
that the rfeactance voltage is small (Sec. 8, Par. 43). Dynamotors can
therefore have deep slots and low-resistance brushes and in consequence are
*
suitable for delivering large currents at low voltages.
129.Voltage regulation. The principal objection to the standard
dynamotor is that the secondary voltage cannot be regulated without chang-
ing the excitation of the primary. The ratio of the terminal voltages is
fixed by the ratio of effective armature turns and by the voltage drop due
to the resistance of both armature windings, so that the terminal-voltage
ratio is independent of the excitation and changes with the load. The
transformation ratio for a given load can be changed only by inserting a
resistance or a booster in the primary or the secondary circuit.
130. Combined dynamotor and booster. A machine which is equiva-
lent to a combined dynamotor and booster can be made by extending one
armature winding a longer distance axially along the core than the other,
and applying to this extended part of the core a magnetic field from an
auxiliary field system. The exciting current for this auxiliary field can be so
regulated as to change the voltage of one winding independently of that of
the other. If this field system be excited with series-field coils, the secondary
voltage can be made to vary with the load, as desired. The chief advantage
of this latter machine over the motor-generator set is that it requires less

'
Sheldon and Hausmann. " Dynamo-electric Machinery," Vol. I, page 206.
690
 Sec. 9-131 CONVERTERS
floor space and will have a higher efficiency, but will probably not be cheaper
if the machines are of corresponding construction.
131. A special dynamotor is extensively used for telephone ringing.
The motor winding is for direct current and the other winding is connected
to two slip-rings in order to deliver alternating current at from 16 to 19 cycles
per sec, and about 75 volts (effective).
132. Dynauxotors can be used in place of motor-generator sets
only when the regulation of voltage is not of great importance as, for example,
in the ringing of bells and gongs, the operation of signals in connection
with fire alarms, telephone systems, annunciators and many other kinds of
signaling, and the operation of magnetic contactor switches. For telegraphic
work, dynamotors are often used in place of primary batteries, the secondary
voltage being 50 to 500 volts direct current, depending on the length of the
line (Sec. 21).

2 4 6 8 10 12 11 16 18 20
Kw. Output
Fio. 28. —Weights and costs of small dynamotors and motor-generator sets.

133. Cost of Dynamotors. Since the two armature windings are upon
the same core, that core will be larger for a dynamotor than for a generator
of the same output. Fig. 28 shows the shipping weights and selling prices of
small dynamotors and motor-generator sets of substantial make on a single
bed plate, the motor-generator set consisting of two machines joined by a
flexible coupling.

DOUBLE -CURRENT GENERATORS

BY F. D. NEWBUEY, M.E.
Armature currents in the double-current generator. A
134.
machine having the same structure as the synchronous converter may be
used to generate both alternating and direct current if driven by a suitable
prime mover. Unlike the synchronous converter, the armature currents in
') the double-current generator are not less than in the corresponding direct-
current generator. The alternating and direct-current are not subtractive,
as shown in Figs. 1 and 2, but are additive, since both are generator currents.
For the same reason, the generation of both alternating and direct current
in the same armature winding is not favorable to commutation as in the
synchronous converter, but is detrimental.
135. Dependance of direct-current voltage on alternating voltage.
A double-current generator has none of the advantages of the synchronous
converter and has many disadvantages of its own. One of the most serious
disadvantages is the dependence of the direct-current voltage on the alter-
nating voltage and on variations in alternating-current load and power-
factor. A change in alternating-current load or power-factor will cause a
change in the magnetizing effect of the alternating current in the armature
winding and thus change the resultant magnetization on which the direct
and alternating voltages depend. To assist in maintaining steady direct-
current voltage.it is customary to excite double-current generators separately.
700
 CONVERTERS SeC. 9-136

136. Alternating-current parallel operation. If double-current

generators are operating in parallel with a relatively large alternating-
current system on which the alternating voltage is held constant, the direct-
current voltage will also be constant and cannot be varied independently of
the constant alternating voltage.
137. Limitations of design. From the design standpoint, the double-
current generator is handicapped by the rigid relationship between poles and
speed required by the frequency. This, in general, results in the use of
many more poles than would be employed in an equivalent direct-current
generator, causing an appreciable increase in cost. This is particularly true
with slow engine speeds and high frequency. It is also impossible to use
commutating poles on account of the effect of variation in alternating-current
load and power-factor. No machines larger than 2,500 kw. have ever been
built in this type.
138. Abandonment of slow-speed type. During the past 10 years,
no slow-speed engine-driven double-current generators of any importance
have been installed. The reasons for this have been the disadvantages of the
double-current generator already enumerated and the lower cost and greater
flexibility of alternating-current generators used in conjunction with syn-
chronous converters.

BIBLIOGRAPHY
139. Selected list of references to literature on converters.
I. History and General Theory
Steinmetz, C. p.- — "The Rotary Converter." Sibley Journal of Engineering,
June, 1897.
Thompson, S. P.
—"Rotatory Converters." Journal E. E. (London), Vol.
I.
XXVII,
CoLLES, G.
p. 651.
—
W. "History Rotary Transformers." Journal Franklin
of
Institute, Serial
Scott, C. F. —beginning March, 1901.
"The Induction Motor and Rotary Converter and Their
Relation to the Transmission System." Trans. A. I. E. E., August, 1901.
Thompson, S. P.— "Report on Motor Generators, Converters and
Rectifiers." International Electrical Congress, Turin. Electrician (London),
September 29, 1911.
—
Newburt, F. D. "The History of the Rotary Converter." Electric
Franklin, — "Energy Transformations in Rotary Converters."
Journal, January, 1915.
W. S.

Steinmetz, C. P. — "4Iternating Current Phenomena." New York, Mc-

Trans. A. E.
I. Vol. XXII,
E., p. 17.

Graw-Hill Book Co.,

Blondel. Andre E. — "Synchronous Motors and Converters." New York,
1908.Inc.,

McGraw-Hill Book Co., Inc., 1913.

II. Compound-wound Synchronous Converters and Converters for Railway

Service
Baum, F. G. —"Method Compounding Alternators and Synchronous
of

Lincoln, P. M. — "Voltage Regulation

Converters." Trans. A. E. June, 1902.
I. E.,
Rotary Converters."
of Electric

WooDBRiDGE, E. — "Features
Journal, March, 1904.
J. Railway-converter Design and Operation."
of
Trans.
Bache-Wiio, Jens. — "Voltage Regulation of Compound-wound Rotary
A. E.
I. Febru.ary,
E., 1908.

Converters;" Electric Journal, November, 1910.

III. Synchronous Booster Converters and Split-pole Converters

.Stone, C. W. —
"Some Developments in Synchronous Converters." Trans.
A. I. E. E., February, 1908.
Adams, Comfort A. —
"Voltage Ratio in Synchronous Converters." Trans.
A. I. E. E., June, 1908.
—
Newbury, F. D. "Voltage Regulation in Rotary Converters." Elctcric
Journal, November, 1908.

701
Sec. 9-139 CONVERTERS
—"Variable Ratio Converters." G. E. Review, Deo., 1908,
Steinmetz, C. p.
and Feb.,
Jan.
BuRNHAM, J. — 1909.
"Modern
Types Synchronous Converters." G. E. Review,
L.
1912.
p. 74,
Yardley, L. McK.
J.
—"Efficiency Synchronous-booster Converters.!'
of

McK. — "Synchronous-booster Rotary Converters."

Journal, February, 1913.
Electric
Yardley, J. L.
Electric Journal, May, 1914.

IV. Commutating Pole Synchronous Converters

Lamme, B. G. and Newbury, F. D. "Interpoles in Synchronous Con-c—
verters." Troras. A. I. E. E., November, 1910. Electric Journal, Decemhei,
1910.
—
Yardley, J. L. McK. "Charactertistics of Large Commutating-pole
—
Converters." Electric Journal, August, 1912.
BuBNHAM, J. L. "Recent Designs of Synchronous Converters." O. E.
Review, May, 1913.

V. Power-factor Control
Stahl. N.—"Hazard of Power-factor Correction by Rotary Converters."

Yardley, L. McK.
—"Power-factor Limitations of Rotary Con-
Journal, February, 1912.
Electric
J.
verters." Electric Journal, September, 1913.
VI. Hunting
Newbury, F. D. — "Hunting of Rotary Converters." Electric Journal,
June, 1904.
Lamme, B. G. —-"Causes of Hunting in Synchronous Machinery." Electric
Journal, June, 1911.
Steinmetz, C. P. "Hunting."
— G. E. Review, May, 1913.

Synchronous Converters
Lamme, B. G. —VII. Sixty-cycle
"Sixty-cycle Rotary Converters." Electric Journal,
November, 1913.
Crecilius, L. p. — "Sixty-cycle Synchronous Converters." Trans. A. I. £S.
E., March, 1914.
VIII. Synchronous Converters Versus Motor Generators
—
Eglin, Wm. C. L. "Rotary Converters and Motor-generator Sets."'
—
International Electrical Congress, St. Louis, 1904., Vol. II, p. 532.
Waters, W. "Synchronous Converters and Motor-generator
L. Sets."

M. — "Motor Generators versus Synchronous Converters."

Trans. A. E.I. June, E., 1905.
Lincoln, P.
March,
M. — "Efficiency
Trans. A. E.I. E., 1907.
Farmer F. Motor Generators versus Synchronous
of
Converters."
— N. E.Proc.
Stahl, N. "Power-factor Effects
L. A., 1909.
Railway Rotary Converters and
of
Motor-generators." Electric Journal, December, 1913.
IX. Motor Converters
—
Arnold und la Cour. Der Kaskadenumformer, seine Theorie, Berech--
nung, Konstruktion und Arbeitsweise; Enke, Stuttgart, 1904.
—
.,

Arnold und La Couh. Wechselstrointechnik; Baud V, 1 Teil, Dif

Induktionsmaachinen.
—
Walker, Miles. "Rotarv Converters versus Motor-generators (anc|
<}

Motor Converters)." Journal I. E. E. (London) Vol. XXXVIII, p. 428. I

—
Gregory, H. W. "Motor Converters." Journal I. E. E. (London), Vol|
XLI, p. 803.
Hallo, H. S.
—"The Theory and Application of Motor Cc nverters."*
Journal I E. E. (London) Vol. XLIII, p. 197. Electrical Engineer (London)|
May 21, 1909.

702
 SECTION 10

POWER PLANTS
BY REGINALD J. S. PIGOTT
Works Manager, Crosby Steam Gage & Vahe Co., Member, American
Institute of Electrical Engineers, American Society of Mechani-
cal Engineers, Society of Automotive Engineers

ARTHUR T. SAFFORD
Consulting Hydraulic Engineer, Member, American Society of Civil Engineers,
Member, American Society of Mechanical Engineers

GEORGE I. RHODES
Consulting Engineer with Ford, Bacon, and Davis, Member, American Institute
of Electrical Engineers

CONTENTS
(lumbers refer to Paragraphs)

STEAM POWER PLANTS

Laws of Heat Transfer 1 Steam Turbines
 r. o .1

SECTION 10

STEAM POWER PLANTS

BY asaiNALD J. S. PiaOTT
LAWS OF HEAT TBANSFEK
1. No heat can be transmitted from a cold body to a hotter one
flue gasea must, therefore, leave the boiler at not leas than the steam tempera'
ture in an ordinary boiler, or at not less than the incoming feed-watei
temperature in the counter-current type of boiler.
3. Two kinds of heat transfer take place in a boiler; absorption b]
radiation from incandescent fuel direct to heating surface, and heat trana-
mission by contact and convection
Drj Surface Stefan and Boltzmann's law states thai
Heat from Fuel* ^\ rm absorption by radiation is proportiona
Bed and Hot \% ' *
to difference of the fourth powers of th<
funiaoe Walls )
%
'''

two temperatures involvea.

ucTection B.t.u. radiated per sq. ft. per hour =
JBoUel 16X10-1" (Ti*-T2<) (i:

where Ti «= absolute temp, in deg. Fahr

)Se»t from Hoi CJ,
of "black" incandescent body, anc
t

UoTing Gues r
;
Ts = absolute temp, in deg. Fahr. o:
receiving body.
A "black" body such as carbon, ir
any form except the crystalline, wil
jSsoood •'* absorb all heat transmitted, reflectini
2 ": * none. Metal and other materials wil
I
*,.~, - j-» S . 3 s i reflect from one-fourth to one-half o
|i600^^-\
\l l%l that received.
I 3. Heating by convection from ho
gases to water is proportional to somi
power of each of the velocities of thi
moving gases and water or steam. Th
heating is also proportional to tl;
A x-Average Teiaperature of Moving Gases density of the fluids and to the absi
S-» Average Temperature of I>r; Surface lute temperatures, since these influenc
C»AverftgeTemperatur«of Wrt Surface the molecular energy. The formula fo
/>« Temperature of Water iiLBoUer
heat transfer by convection is,
Fxo. 1. —Transmiasion of heat. H-Af/(T,-T2) (i

where = B.t.u. transmitted per hr

//
A — area, sq. ft., (7 = tranamission coefficient, 7'i — rj = mean temp. diff.
4. The transmission coefficient for normal rating is somewhere aroun
6 to 8 B.t.u. deg. of mean temperature difference, per sq. ft., per hour, bv
may be much larger than this in boilers with much surface exposed to radiar :

heat and well scrubbed by the gases. The upper limit has probably nev«!
been reached, the maximum value for recorded tests being about 20.

) B. Effect of dirty surfaces. One important difference noticeah'

between absorption of heat by conduction and by radiation is that the rell
tive cleanness of the surface affects the rate of conduction very_ readily, bi
absorption of heat by radiation is practically unaffected. Soot increases tt
thickness of the film of motionless gas, besides adding its own resistance i

heat flow.
6. The resistance of the film of inert gas entangled in the rough surfai
of thetube (or soot) is from 20,000 to 35,000 times as great as that of tl
metal tube alone, so that the thickness of the dead gas film is the controllir

704
POWER PLANTS Sec. 10-6

i
Sec. lO-f) POWER PLANTS

700
 POWER PTTANTfi Sec. 10-7

factor. In absorption of heat by radiation, however, the interposition of a

gas film or layer of soot has practically no efifect, since conduction does not
bear a part in the action.

Fig. 4. — B. & W. marine type boiler with superheater, and Westinghouse

stoker with clinker crusher.
BOILERS
7. Boiler types: in the following classification modern types only are
considered. \^

f Horizontal return tubular (Fig. 2).

Fire Tube. . . -I
Scotch (Fig. 3).
[ Continental and other internally fired types (Fig. 3).
[
Rust
Stationary
(
^^^^
R &\V
(Fig. 5).
Marine (Fig. 4).
Definite circulation path. Heine, etc., etc., \ Stirling(Fig. 6).
and 7
Water Tube. Yarrow
.
Thorney croft.
Field Tubes Niclauase
 •

Sec. 10-7 POWER PLANTS

All types give efficiencies not differing widely when subjected to the same
kind of furnace and flame conditions, the structure having less inherent
influence upon efficiency; the cross-baffle types have a slightly higher
efficiency, due to greater turbulence of the gas flow over the tubes. But
inasmuch as the structure may influence very materially the conditions of
combustion, by restricting combustion spaces, by altering the length and the
hydraulic rriean depth of gas passages, and by extinction of flame and accumu-
lation of dirt, it may alter the efficiencies somewhat. If combustion could'
be entirely complete, so that the flame would be extinct before reaching
any heating surface, it would make little difference what type of boiler were
employed so far as eflSciency is concerned.

'." **'.''- ;<>%: •;

1*
•;©•-,; -.--f
%< -o -a.^^^^ :'o 1. o '.'«-• -5 .%••• V'--. ' .0'- "'' /*

Fio. 5. —B. & W. stationary type boiler with superheater, and Riley stoker.
8. Flre-tubo boUera are cheapest in first cost, but lowest in capacity
for space occupied; in general they are the most difficult to keep in good
operating condition, especially with dirty water, since the water space is not
accessible. _ The internally fired boilers such as the Scotch and the Conti-
nental (or similar) types are somewhat superior in capacity, but not up to the
water- tube type. As a class, fire-tube boilers, from the standpoint of _

safety, are least desirable, as they carry a large body of hot water, storing
considerable energy to be liberated at the instant of rupture.
9. Water-tube boilers are much lighter and smaller per unit of capacity,
and higher in first cost than tubular boilers, buteasier to maintain inasmuch
as the water surface is allpractically accessible, either for hand cleaning or (or
turbine tube cleaners. They are very safe, having very small water storage

708
 POWER PLANTS Sec. 10-10

(subdivided into many smaller bodies by the tubes), and are made up almost
entirely of the strongest natural shapes — cylindrical— with little or no stayed
surface. There are practically no records of serious accidents resulting from
the explosion of water-tube boilers.

Fig. 6.- -Duplex stoker setting for obtaining high combustion efficiency and
extremely high boiler ratings. {
10.Field-tube boilers are almost unused except for the French marine
boilerknown as the Niclausse. The principal objection to theis use is the
uncertain and spasmodic nature of the circulation which may partake of the
nature of flash generation, alternating with periods of flooding with water,
causing strains due to rapid and unequal expansion and contraction.

709
Sec. 10-10 POWER PLANTS
26' 6^^

Fill. 7. — Stirling double-end boiler. Delray type, with double Honey stokers.

710
^1
 POWER PLA.Vr.S Sec. 10-11

11. Flash generators are at present unused except for steam automobile
boilers and some torpedo boats. In American power stations they are
unknown. However, if any standard boiler, such as the B. & W. or Stirling,
be forced much above its normal rated capacity, the generation, in the lower
rows of tubes at least, becomes of the flash type by reason of the extreme
conditions.
12. Superheaters are of two general types: self-contained, and separately
fired. The separately fired superheater is unpopular in America, chiefly
because it has not shown such pronounced economies as the self-contained
type. The two types of self-contained superheater are the plain tube and the
protected tube types. To the former class belong the Heine, the B. & W.
(Fig. 5) and the Stirling; to the latter class belong the Foster (Fig. 8) and the
Schworer.

wkkkkhkkkM^

FiQ. 8. —Foster superheater.

13. Superheaters may be located (usually) between the first and the
second passes, or in the breeching. With later boilers of the ordinary sta-
tionary types the first position is popular. With the marine types now some-
times used in power stations, the latter position is satisfactory, as the gases
leave the boiler at a higher temperature (see Marine B. & W. boiler. Fig. 4).
14. Heating surface is defined as any surface in a boiler or superheater
which is exposed to hot gases on one side and water or steam on the other.
In water-tube boilers the heating surface is defined as
rdln tDLN (sq. ft.)
"^ (3)
12 24
where d — outside diameter of tubes in in. 1 = length of tubes in ft.>
n = number of tubes, D = outside diameter of drums in in. L = length
of drums in ft. and N = number of drums, headers not included.
15. Bating of superheaters. Superheaters are not usually rated by sq.
ft. of surface, but are figured for each case. A good average rule is 15 sq. ft.
of heating surface per boiler h.p., for unprotected tubes; 18 sq. ft. of heating
surface per boiler h.p., for protected tubes. The reason for using larger
figures for superheaters than for steam-making surface is that heat trans-
mission ia much more difficult between gas, iron and gas, than between
gas, iron and water, or between gas, iron and vapor, the latter two conditions
obtaining in the boiler proper. The protected tubes interpose an additional
resistance to heat transfer because of the cast-iron protection rings, the rough-
ness of which also materially increases the thickness of the dead gas film.
16. Orate surface is any surface upon which coal is being burned. In
hand-fired furnaces this amounts to the horizontal dimensions of the furnace,
side wall to side wall, and front wall to bridge. With the automatic stoker,
the term becomes more or less anomalous, since part of the surface may be
used exclusively for coking, and the grates may not be horizontal; and part
of the grates may be used only for accumulating clinker and ash. With under-
feed stokers, coal is not burned upon the grates to any appreciable extent. (
The term is useful for comparison, if the projected area of the furnace is used
in each case.
17. The ratio of heating surface to grate surface was once considered
important and was generally made 60 to 1 when good coals were used.
Tlu» ratio shows a tendency to decrease to 30 to 1 or 40 to 1 recent instal-
lations, particularly with stokers intended for forcing to high capacities, or

711
 ;

Sec. 10-18 POWER PLANTS

where low-grade fuel such as culm, or No. 3 buckwheat is burned.
18. The value of the boiler h.p. is at present 34.5 lb. of water evaporated
from and at 212 deg. Fahr., per hour; this is equivalent to 33,479 B.t.u. per
hour. A unit proposed to eliminate this somewhat illogical unit, is the
myriawatt, * a multiple of the watt, having a value of 34,150 B.t.u. per
hour, about 2 per cent, larger than the boiler h.p. It would be better to
eliminate these units altogether, and rate the boiler in square feet of heating
surface.
19. Evaporation. Taking dry coal, the actual evaporation per lb. is,
W
E= — (4)
w
E'=-EF (5)
H-h
^ = K=^m
970.4
(6)

E = actual evaporation
E' = equivalent evaporation
F = factor of evaporation
H = total heat of steam at boiler pressure and quality.
h = hea,t in the feed water = feed temperature — 32.
Tr = lb. steam per hr.
to = lb. dry coal per hr.

970.4= latent heat at atmospheric pressure = heat to convert 1 lb. of

water to steam, from and at 212 deg. Fahr.
Or the above evaporation may be used "per lb. of combustible," substitut-
ing lb. of combustible per hour in place of lb. of dry coal per hour. All
temperatures are expressed in deg. Fahr., and all pressures in lb. per sq. in.,
and all heat in B.t.u.
20. Losses in boilers comprise: (a) sensible heat escaping in flue gases;
(b) sensible heat lost in hot ashes; (c) radiation of heat to external air from
boiler setting; (d) incomplete combustion; (e) excess air. Theoretically some
of these losses are avoidable. Actually, about the following proportions hold
good in recent practice.
Heat in coal. 100 per cent.
Heat absorbed in steam (overall efficiency) 72 to 80 per cent.
Stack loss, sensible heat only 10 to 15 per cent.
Incomplete combustion 3 to 8 per cent.
Hot ashes Negligible
Radiation and leakage 5 to 7 per cent.
21. The combustion efficiency of automatic stokers runs as high as
96 to 97 per cent, and is maintained up to a very high rating in some cases.
That of a hand fire is seldom over 90 to 92 per cent, and generally much less,
due to inevitable carelessness in operation.
22. Radiation is kept down by thorough lagging of exposed parts and by
the usual double- walled construction of boiler settings (Figs. 5 and 6). It
does not vary greatly for any type of boiler, but is reduced somewhat by
setting in batteries instead of singly.
2S. Excess air is caused by the slight vacuum in the setting due to draft
itcan be reduced by painting or white-washing the setting and stopping up all
cracks between metal and brick with plastic asbestos. In some cases enamel
brick or sheet-iron settings are used, but the expense is not generally justified
from this pointof view alone. Another method of reducing setting infiltra-
tion is by the use of balanced-draft systems; in these the methods of forced
draft, and natural or induced draft are so employed as to give practically zero
pressure in the fire-box, by this means reducing the average difference of
pressure from atmosphere, over the whole setting.
24. Furnace efficiency is expressed by the formula
Combustible burned
-, _, .
Furnace einciency =
•>, —
f --.-, ,—_——,—
Combustible fired
,_.
(7)

Combustible burned = (Combustible fired) — (Combustible in ash) —

(Combustible in unburned gas) -(Combustible in eoot). (8)

•Stott and O'Neill. . p. 411, rron*. A. I. E. E., Vol. 32, 1913.

712
 POWER PLANTS Sec. 10-25

B.t.u. Combustible fired = (lbs. dry coal) X (B.t.u. per lb. [by calori-
meter]). (9)

B.t.u. Combustible burned = (combustible fired) —

(B.t.u. per lb. of ash) X
(lbs ash) — (B.t.u. per lb. of soot) (lb. of soot)X —
(B.t.u. in unburned
(10)

The last item is derived from the flue-gas analysis and as it always involves
several assumptions, its accuracy is not very certain.
25. Boiler eflBciencies. In Fig. 9 the lower curves show the amount of
coal burned per square foot of grate surface at the corresponding capacities
and efiiciencies. The upper curves show the efficiencies when the number of
pounds of coal indicated by the ordinate produce the capacity indicated by
the abscissas.

2 4 6 8 10 12 14 16 18 20 22
Boiler Hp. per Sq. Ft. Grate Surface

Fig. 9. —Boiler efficiency.

26. Combined furnace and boiler efficiencies. The table below gives
the pounds of water evaporated per pound of coal, and the pounds of coal
required per boiler hp. hr. with coals of various heat content and with
boiler installations having varying combined boiler and furnace efficiencies.

B t u
 Sec. 10-27 POWER PLANTS
Efficiencies at head of columns are combined boiler and furnace efficiencies.
Evaporation is given in pounds of water "from and at" 212 deg. Fahr. per
lb. of dry coal. The heating value can also be taken for coal "as fired"
whence the "evaporation per lb. of coal" and the "pounds coal per
boiler h.p. hr." will elso be referred to coal "as fired." This latter use
of the table will contain a slight error due to the absorption of a portion of
the heat by the moisture in the coal.
87. The failure of a furnace to burn all of the combustible is due
to two principal causes: (a) molecules of oxygen are not brought into
contact with all the particles of combustible material; (b) the temperature
may be too low for ignition when they are in contact. The first condition is
found where some of the fixed carbon in the lumps of coal becomes surrounded
by a coating of fused ash, so that the air never reaches it during the time that
the lump is upon the grate. Another cause, in the case of bituminous coal,
is the lack of proper mixture of the volatile matter with air. The second
condition is found as a result of the first, if streams of stratified hot com-
bustible gas and air leaving the furnace are brought into contact with the ^
'
comparatively cold heating surface, they will quickly be chilled below the
ignition point, and will sweep through the boiler without further combus-
tion taking place.
28. Water-tube boilers are generally rated on one boiler h.p. for each
10 sq. ft. of heat surface; Scotch marine types on 8 sq. ft., and horizontal
return-tubulaxB on 12 sq. ft. Superheater surface is usually based on a
transmission coefficient of 5 to 8 B.t.u. per deg. of mean temp, difference per
sq. ft., per hour.
An empirical formula given by Bell (Trans. A. S. M. E., May, 1907) is,
Sq. ft. superheating surf, per boiler h.p. =
107^
S'
2(T„-To)-T. ^ ^

The temperature of gases at the superheater may be found from the fol-
lowing relations:
S. = superheater surface per b.h.p., sq. ft.
Sa = per cent, of total surface passed over by gases before reaching
superheater.
T. = superheat, deg. Fahr.
To = saturated steam temp., deg. Fahr.
Tg = temp. of gases at superheater, deg. Fahr.
(0.172Sa-|-0.294)(r„-r„)»'i« = l (12)
These two formulse are based on the following assumptions: constant coeffi-
cient of heat transmission; furnace temperature 2,500 deg. Fahr.; flue tem-
perature 500 deg Fahr. steam pressure 1 75 lb. gage one boiler h.p. equivalent
; ;

to 10 sq. ft. of heating surface.

29. Boiler design. Since the efficiency of boilers is so little influenced
by the disposition of heating surface, comparatively little original designing
can or should be done outside of standard forms. For centraNstation work,
the water-tube boiler has practically the whole field, the specifications for a
boiler therefore look more to the safety and reliability, by rigorous attention
to materials, than to the actual detailed design. The management of the
furnace and combustion have much more to do with the efficiency of a boiler,
than the arrangement of heating surface.
30. Boiler settings have become more or less uniform in general type;
For the water-tube boilers, a steel structure or skeleton for supporting the
boiler proper, the brick walls being merely self supporting, is now usual prac-
tice. Common red brick is used for the outer walls, a double-wall construc-
) tion being employed to allow for the differential expansion of inner and outer
surfaces (on account of the great temperature difference), to minimiBe
radiation by interposing dead air space, and to reduce air filtration. Where-
ever the temperature exceeds 1,000 deg. Fahr., fire-brick is employed for this
inner lining. In some cases silocel and other insulating materials are
employed between the fire brick and the red brick.
31. The bafiBes are always of fire-brick, of various special shapes, some-
times backed or supported on the cooler side by cast-iron bars or plates.
Figs. 5 and 6 show these constructions.

714
 POWER PLANTS Sec. 10-32

32. The setting for tubular boilers, generally supports the boiler; for
internally fired boilers, no setting is required (see Figs. 2 and 3).
33. The computation of superheater surface is much complicated by
the change of temperature of the flue gases at the superheater with load on
the boiler, and the uncertainty of the transmission coefficient. The amount
of superheater surface installed for superheats of 100 deg. to 175 deg. Fahr.
varies from 13 to 20 per cent, of .the boiler heating surface. Fig. 10 gives
results of actual tests.

200
180
160

J» 140
g 120

S 100
1 80
60
40
20
Sec. 10-38 POWER PLANTS
38. Connection of safety valTos. There must be no Talves between the
safety valve and the boiler connection; seats and valve discs must be ol
such material as will not rust together; no valves are allowed in the discharge
from safety valves; in fact it is preferable to have only a muffler on the
valve, and no discharge pipe at all.
39. Gage glasses of the ordinary type should be connected, preferably,
directly to the steam drum and protected by wire gauze if near the level
where firemen or others are working. The Klinger type of gage glass with
heavy corrugated plate glass and brass casing is much safer, but more costly;
the water level is much more clearly distinguished.
40. Quick-closing gage cocks operated by chain or rod are now
almost universally used. The gage glass and blow-off cocks should nevei
be so arranged that the fireman must stand close to the gage glass when
"blowing down."
41. Manholes provided for entry to boiler drums, preferably in the heads
where they least affect the strength, are made of pressed plate steel and fitted
from the inside of the drum against a bumped hp or saddle in the drum by
means of one or two bolts made fast to a dog spanning the opening on the
outside. The pressure inside the boiler keeps the manhole tight, the bolts
being used only to pull the cover to a seat. The gasket between manhok
cover and seat is of asbestos, lead alloy or corrugated copper. The standard
dimensions are 11 in. X15 in.
42. Handholes are placed in mud-drums, headers, etc., which are too
small to admit the body, but must be cleaned and inspected. They are made
in the same manner as manholes, but the dimensions are usually 4 in. by 6 in,
or 6 in. by 8 in.
43. The blow-off should be connected to the lowest and quietest place
in the boiler, where the mud and scale settle, or from specially designed
chambers in which the sediment is induced to collect. The blow-off pipe
must be protected from the fire, as it has normally no circulation of water to
protect it. Many installations have been made with a plug cock next the
boiler, followed by a gate valve to prevent leakage. There are now, how-
ever, one or two successful valves on the market which do not require the
additional gate valve.
44. The feed pipe should enter the boiler so that the flow is in the direc-
tion of natural circulation in the boiler. Outside the drums the feed pipes
are generally of brass to eliminate the chance of a break at this point from
corrosion. A check valve is fitted at the entrance to each drum, to prevent
water flowing back.
45. The steam gage is connected to the steam space of the boiler, to
prevent blocking of the pipe by scale or mud. A condensing coll should be
applied to prevent hot water or steam from getting into the Bourdon tube oi
the gage. Thermometers are practically never used as a measurement
of steam pressure, except on tests, but are much more reliable.
46. Pyrometers are used for measurement of flue gas temperature,
leaving the boiler, and are very valuable aids in checking the operation and
efficiency.
47. Safety plugs are made of pure Banca tin, and are so placed that the
active fire will play upon them, or at least in the first pass through the tubes.
They are placed about 10 or 12 in. above the danger limit of low water;
they are ordinarily protected by the water, but melt in case the level falls
below them. The fire side of the plug must be kept clean of soot, or it may
become so protected as to be inoperative.
48. Boiler corrosion is caused either by direct oxidation of the iron by
oxygen dissolved in the water or by reaction with some acids present in the
feed-water, having their source cither in natural acidity or from the producta
of decompo.sition of impurities introduced into the feed. Corrosion by oxida-
tion is the more important, as the other is always avoidable by proper puri-
fication of feed water. Oxidation goes on continuously wherever dissolved
air is present, and is much increased by the vibration or flexure of any par-
ticular point. The constant bending breaks off the film of iron oxides formed
by the process, and exposes new surface to be attacked; for this reason pitting
is commonest near jointa where the flexure of some one portion of a plate
is apt to be severe.

716
 POWER PLANTS Sec. 10-49

49. Incrustation is caused by the deposit of solid matter during the heat-
ing and boiling of the water. It may be merely a mechanically entrained
impurity, such as mud and sand, or it may be the result of precipitation of
various salts insoluble in hot water, or by super-saturation. The salts of
magnesia, lime and iron are those giving most trouble in boiler water. Some
of these salts are soluble and cause the formation of scale by super-saturation;
others are insoluble in hot water and precipitate as the water is heated.
50. Treatment of feed water. The principal salts are iron, calcium
and magnesium carbonate, bicarbonates, and sulphates. The bicarbonates
are usually decomposed by boiling. The general method of treatment is by
adding lime (CaO), and sodium carbonate (NaiCOs) called in the impure
commercial form, soda ash.
61. Removing the precipitation. Where the character of the water or
the plant layout does not allow the treatment in a separate purifying sys-
tem, these reagents are added in the boiler feed, and the precipitation takes
place in the boiler, assisted by the heat. The main object in this case is to
precipitate the salts as soft scale, or mud, in order that it may be readily
blown out. Periodic cleaning with some kind of mechanical cleaner is neces-
sary, however, even with feed-water treatment, as some of the hard salts are
bound to stick, especially in the hardest worked tubes over the hottest fires.
62. Periodic inspection of boilers is in itself a good preventive of acci-
dent. The straight tube, water-tube boilers lend themselves most readily to
thorough inspection, as every part can be seen, and the whole of the shells
can be hammer tested.
63. Boiler insurance covers the possible damage done by boiler explosion.
The boiler insurance companies exercise a vigorous and valuable control over
the manner of operation of boilers, and by their frequent enforced inspection,
prevent little flaws from
becoming disastrous weaknesses.
64. Cleaning. Those operations which make for safety in the boiler
generally aid efficiency. A good rule is never to allow more than
i'^ in. thick-
ness of scale to collect; and to overhaul thoroughly every part of the boiler
twice a year. In a well-operated plant, with moderately good water, this
generally means cleaning
20 OOOr
the two rows of tubes near- ' '

est the fire about once a

month, and the remainder 16,000-
of the boiler, twice annu-
ally. It generally pays,
both in safety and effi- 12,000-
ciency, not to use water S
requiring more frequent
^
"o
cleaning of the boiler than Q 8000-
kst stated, but instead to »
purify the water in separate jR
apparatus. ^ 4000-
66. The removal of
soot from the outside of
the tubes is usually re-
quired once a day in well-
operated plants; but for
high rates of forcing, and
especially for low-grade
Sec. 10-58 POWER PLANTS
stant at $22.00 to $25.00 per h.p. This is partly due to the fact that most
of the smaller boilers are built for lower pressures than the larger units. If
all were built for high pressures, say 200 lb. gage, the cost would follow
approximately the rule given below (Jan., 1921).
Cost in dollars = 950 + 18.6 X (rated h.p.) for boiler alone. (14)
88. The average setting cost for 300-h.p. to 600-h.p. units is $5.50 per
h.p., and varies little. The
delivered price is approxi-
mately 71 per cent., the
erection co.st 9 per cent.,
and the setting 20 per cent,
of the total cost, which
remains very nearly con-
stant at about $25.00 per
h.p. for horizontal water-
tube boilers between 3C)0
h.p. and 750 h.p. (Jan., 1921).
69. The
cost of vertical
water-tube boilers aver-
ages 10 per cent, less than
horizontal water-tube boil-
ers. The cost in dollars =
950 +
18 X (rated h.p.), for
vertical water-tube boilers
(delivered only).
 POWER PLANTS Sec. 10-64

64. Types of furnace and stoker: Hand firing always necessitates a

horizontal or slightly inclined grate, so that coal may be fired through open
doors all over the surface of the grate; most of the air is fed through the fire
from below the grate. In the case of anthracite practically no air is admitted
over the fire, because the compact nature of the small sizes of anthracite makes
the use of air blast generally a necessity, and more than enough air can be
supplied from below the grates. With bituminous coal, not enough air can
be supplied from below, and some must be admitted by way of the fire doors
or other openings for the purpose above the fire. The required reverbera-
tory action for soft coals must be obtained chiefly by methods of firing.
Regenerative action can be improved by the use of Dutch oven furnaces, in
which the whole furnace is roofed over with fire-brick, which reflects heat
instead of absorbing it, raising the temperature of the furnace. The soft-coal
furnaces should always have as high a combustion chamber as possible, but
with anthracite coals 18 in. is sufficient. Fig. 14 shows one type.
Steel Support
N' ozzl e o.
Safety Valve 7^ "TTrf

Damper

Bridge Wall
Fig. 14. —Hand-fired grate.

65. Tlie overfeed stokers are those in which coal is fed somewhat in the
manner of hand firing; green coal is pushed in at one end, or side of the com-
bustion chamber, coked under a combustion arch, and finally burned to ash
in a continuous progress across the furnace, the combustion of fixed carbon
taking place upon the grates. The best known inclined types are the Roney,
Murphy, Model, Detroit and Wetzel. Fig. 15 shows the Roney type; coal
is fed in at the top and worked down by gravity and the continual rocking
of the grate bars.
66. The chain grate types are the B. & W., Green, Coxe, Illinois,
etc. Fig. 16shows a typical chain grate.
67. The underfeed stokers supply coal from below the fire, coke it as it
approaches the incandescent top bed, and drive the gases, along with the
blast air, through the white-hot coke on top. No combustion arches are
required and there are no grate bars, strictly speaking, as little or no com-
—
bustion takes place on iron only upon a bed of coal.
68. Types of underfeed stokers. The Jones was the original of this
type, followed by modifications utilizing gravity as well; the earliest one
of the latter type is the Taylor, followed by the Riley and the Westinghouse
underfeeds. Lately, extension grates of the overfeed type and continuous
dumping devices have been incorporated in this type of stoker, lowering
the combustible content in the ash, and reducing the operating labor.

719
Sec 10-68 POWER PLANTS

Fia. 15. — Roney stoker.

!5S^SSS>

Fio. 16. —Chain-grate stoker.

720
 POWER PLANTS Sec. 10-69

69. Orates tor hand fires are of three types, stationary, shaking and
dumping. Stationary bars are of three principal forms: (a) plain girder-
shaped straight bars, spaced from each other i in. or f in. by lugs, for air
—
supply; (b) herringbone bars two straight girder
apart, cast with herringbone-shaped tie ribs; (c)
bars about 4 in. to 6 in.
pinhole bars, for burning
sawdust, fine dust and culm, tan bark and similar materials. Rocking
and shaking grates are made in a multitude of variations of these simpler
forms; and are so arranged that the bars may be rocked in groups, to aid in
cleaning the fire, or overturned to dump entirely.
70. Hand stoking of hard coals is done in the following manner. Coal,
generally of small size (No. 2 or No. 3 buckwheat), is thrown well over the
fire, and maintained about 6 in. to 8 in. thick and under considerable blast
(1.5 in. to 2.5 in. of water). As fast as a hole blows through any portion,
it is covered with fresh coal. This implies frequent firing, and in order to
minimize the inrush of cold air at open fire doors some form of balanced
draft is very desirable. Portions of the fire are allowed to burn out and are
then dumped bodily and fresh fire raked over the bare grate. With shaking
—
grates the dumping periods may be farther apart 4 to 8 hr., depending on
the coal and rate of firing, as part of the ashes are removed at more
_

frequent intervals by shaking the grate without opening the fire doors.
71. Bituminous coal can be hand fired in two ways: the alternate and
the coking methods. In the first method, one side of the fire is at the period
of hottest combustion while firing green coal on the other, to provide the
necessary heat to volatilize and ignite the large volume of gas given off. When
this green coal has finished giving off gas and becomes well coked and white
hot, the other side, now burned out, is fired. In the coking method, the front
part of the grate near the fire doors is made solid and is called the dead
glate; green coal is fired upon this, under a coking arch, and receives enough
eat from the main body of the fire and from this arch, to become coked.
The gas thus given off passes out from the coking arch over the hot part of the
fire, is mixed with air admitted over the fire, and thus ignited. The green
coal, now coked, is pushed back over the hot part of the fire. As portions
burn out, they are dumped and fresh coke raked over the bare grates. There
are many variations in the manner in which these operations are performed,
depending on the kind of coal. One man can ordinarily take care of one
boiler up to 600 h.p., or two boilers at the utmost.
72. Automatic stoking in the overfeed type occurs almost in the same
order as the hand firing of bituminous coal, except that all the processes,
feeding, coking, segregation of ash, and sometimes dumping, are done by
power and are continuous, instead of intermittent. The advantage in avoiding
irregularity in the processes is obvious.
73. Automatic stoking in the underfeed type requires no regenerative
devices in the furnace (such as the coking arch), since the gases and the
air are mixed by passing through_ the bed of coal together and are finally
heated by direct contact with the incandescent coke, before issuing into the
furnace. The underfeed stokers are capable of almost unlimited forcing
without serious loss of furnace efficiency, and are much lower in mainte-
nance costs than the overfeed types, as no hot fire is carried on cast-iron
parts.
74. Maintenance costs of stokers. The following costs applied in
1914, but should be doubled for 1920-21 conditions. The maintenance of
Roney stokers with good coal, varies from about $0. 10 to $0. 12 per ton fired;
the Murphy, Model, Detroit, Wetzel and Wilkinson vary from $0.11 to
%0. 14, the higher cost being due to the use of long bars in the fire, which are
injured only in about the lower third, necessitating the scrapping of about
two-thirds of the bars practically uninjured. With the Roney finger grate,
the parts actually in the fire are separately removed, and consequently
the efficiency of use of the metal is higher. Chain-grate stokers are com-
parable in maintenance with the Murphy type. Jones stokers require
about $0.04 to $0.06 per ton fired for maintenance, and the Taylor stoker
from $0,025 to $0.04 depending on the coal. Highly volatile coals, which
must be fired thinner on account of clinkering, use up more iron, as the heat
is nearer to the fingers and retorts.

76. Stoker labor. One stoker operator to each four stokers, and one
coal passer to rake up siftings for each five stokers is good practice for the

721
 ^
Sec. 10-76 POWER PLANTS
Roney type. The size of the stoker makes comparatively little difference,
and hence the larger the stoker the better. One stoker operator for 6
stokers, and one coal passer for raking sittings to 6 stokers, is good practice
for the Green or B. & W. types. One stoker operator to 15 stokers is needed
for the Riley and similar types but no coal passers, as there are no siftings.
The Jones type requires about the same labor as the Roney as the ashes must
be raked out by hand.
76. The rate of combustion for hand fires is normally 10 lb. to 12
lb. of coal ft. of grate tor anthracite, and 15 lb. to 20 lb. for bituminous
per sq.
coals. forcing the rate may go as high as 80 lb. per sq. ft. of grate,
Under
with forced draft. For power plants the usual maximum is 40 lb. to 50 lb.
of soft coal.
77. Natural or chimney draft is common for bituminous coals.
On hand fires 0.3 in. to 0.6 in. water draft at the breeching will generally
produce rated capacity from the boiler; 0.3 in. draft at the breeching will
produce rated capacity on the overfeed slope-grate types with high percent-
age of air space (35 per cent, to 45 per cent.). With the restricted types
(Wilkinson) and the chain-grate stokers, where the air space is only 8 per cent,
to 15 per cent., the required draft to produce rating is usually 0.4 in. to 0.5 in.
78. Forced draft with underfeed stokers and anthracite hand fires
is practically a necessity, as the resistance through- the fires is very much
greater (Par. 80). The small sizes of anthracite pack very closely, and in
6 in. or 8 in. thickness may offer as much as 1 in. to 2 in. difference of
pressure above and below the fire. In the underfeed stokers the fire ia
much thicker than in the overfeed type (the latter is about the same as
hand-fired bituminous grates or 10 in. to 14 in.), or usually about 2 ft. 6 in.
or 3 ft. thickness of fuel bed.
79. The amount of air required varies with the volatile content of the
coal. The combustible constituents are carbon, hydrogen and sulphur.
As far as heat and
supply are concerned, the carbon and hydrogen alone
air
are important, the sulphur seldom exceeding 3 per cent, being low in heat
value.
C-|-02 = COj (15);
= 2H20
-— ^-—
2Hj-|-0!

2 vol. 1 vol. 2 vol.

' (16)J

The combining weights are in the proportions of the molecular weights,

so that 12 lb. C +32 lb. 0j = 44 lb. CO2 (17
1 lb. C + ?5 02 = U lb. C02 = 3.67 lb. COj
lb. (18
Air is 20.9 per cent O2 and 79.1 per cent. N
by volume, and 23.6 per cent. O
and 76.4 per cent. N
by weight, so that, as 1 lb. C requires 2.67 lb. O2, i
will require o'?Bi!X2.67 = 11.30 lb. of air per lb. of carbon. Similarly
hydrogen requires 34 lb. of air per lb. Then the air required per lb. of anj
coal will be given by
(fraction C per lb.) X 11.3 + (fraction H per lb.) X34 =lb. (Itt
air required per lb. of coal.
The theoretical amount cannot be used because mixing is imperfect
Usually 18 lb. of air per lb. of coal are supplied for underfeed stokers and 2(
lb. to 24 lb. for overfeed and hand fires.
80. Automatic damper regulators are used to maintain substantia
constant boiler pressure under variable load. A diaphragm operated bS
steam pressure controls a pilot valve admitting water or oil under suitabu
pressure to a cylinder which in turn operates the damper lever. If increase ii
load causes drop in pressure, the diaphragm and pilot cause the presnun
cylinder to open the damper wider, increasing the draft and the rate of com
bustion, thus making more steam to recover the proper steam pressure; am
vice versa. This device may be employed in the stack or oreeching fo
natural draft; or it may control the fan-engine throttle for forced o
induced draft, producing the same results.
81. In the balanced-draft systems, a steam pressure regulator con
trols the forced-draft fan, and a oombustion-ohamber pressure regulator cod
trols the stack damper or induced-draft fan, so as to maintain zero prcsaur
difference over the fire. This is specially advantageous for hand firing, as th

722
 —

POWER PLANTS SeC. 10-82

fire may be opened and shut without a rush or cold air over the fire.
doors
It is alsoa convenience with any forced-draft stoker.
82. The
accessories of the automatic stoker consist of the forced-draft
fan (if required), the stoker engine, and usually, for overfeed stokers a
slice bar and a poker, needed occasionally for obstinate clinkers. In the
later types of underfeed stokers, automatic dumping devices are attached,
which eliminate the need of hand manipulation of the fire almost altogether
(Fig. 5).
i

83. The stoker engines required with all stokers except the Jones and
'

the Wilkinson, may be of any standard type. The slope-grate overfeed

stokers require about 1.5 to 2 hj). per stoker, the highest being for the largest
: sizes— say 150 in. in width. Chain grates require 2 to 3 h.p.; underfeed
stokers, 3.5 to 4 h.p. per stoker. The Riley requires about 0.4 h.p. per retort.
The Jones type has a steam cylinder attached individually to each plunger
and requires no other drive. The Wilkinson type generally has a hydraulic
cylinder operating each stoker.
84. Furnace efficiency is defined in Par. 24. Its value for hand fires
may be l^rought up to 94 or 95 per cent, but seldom runs higher than 88
per cent, in regular operation. Automatic stokers can be made to operate at
efficiencies as high as 96 to 97 per cent. It is a question chiefly of adequate
air supply, intimate mixture of gases, and high temperature.
86. Flue-gas analysis. The Orsat apparatus is the simplest and com-
monest means of analyzing flue gases. It appears in several forms, all of
which employ some form of graduated glass gas-measuring chamber, usually
water jacketed, and has means for exposing the sample of gas successively to
solutions of potassium hydroxide, potassium pyrogallate, and cuprous chlor-
de (generally the acid solution), for removing COj, Oi and CO, respectively.
' The gas is returned to the measuring chamber after each absorption, to meas-
ire the reduction of volume. Several automatic machines have been devised
• 'or measuring and recording COi content in flue gases continuously; but
" t is now well known that CO2 measurement alone is an insufficient indica-
.
ion of boiler efficiency. Flue temperature and sometimes the full gas anal-
1 /sis are desirable. The absorption of CO is particularly troublesome, as a
ule, because the cuprous chloride must be used fresh, and is apt to throw oflf
,

• he absorbed CO if diluted; this also may happen in the Elliott apparatus.

The Elliott apparatus differs from the Orsat in using long burettes and
lipettes for greater accuracy, and the pouring of the absorbents through the
,-, tbsorbing chamber by hand; also, an explosion pipette for measuring the
.nburned hydrocarbons is added. The Hempei apparatus is still more
:

'•!'
.ccurate and refined, but is strictly a piece of laboratory apparatus. The
)r8at type is made in easily portable form for use at the boiler.
0:

: 86. Smoke consists chiefly of unburned carbon suspended in the

>

:i!
ue gases; it may be in the form of particles of unburned coke blown up from
he fire by heavy driving or high blast, or in the finely divided lamp-black
ii!

jrm, developed by the breaking up of hydrocarbongases, deficient in air, and

ixposed to high temperature.
ij
The latter form is chiefly indicative of bad
ombustion; the cure consists of thorough mixing of volatile matter and
ir in .the furnace, and the maintenance of a high temperature of this mixture
;^
ntil combustion is complete, or in other words, until there is no more flame.
v;;^

'" 1 so far as any furnace or

method of firing accomplishes these two things, in
lat degree it will be smokeless.
if 87. Specifications for stokers should cover the following: (a) general,
id terms of delivery and erection; (b) drawings of stokers and dimensions of
)ilers to which they are to be attached; (c) operating conditions of boilers
id rating; (d) general description of stokers; (e) dampers, doors, drive,
labor used; (f) fan requirements, foundations, air ducts and brickwork;
i

tests and operating conditions for tests, including full description and
ximate analysis of coal to be used; (h) guarantees, capacity, efiiciency,
.-aor to operate, gas analysis, smoke, maintenance; (i) time of shipment,
ice and terms of payment; (j) detailed description of stoker and all parts.
88. The cost of automatic stokers per rated h.p. of boiler (May,
* 20) varies but little with size, as most of the stokers are made up of parts
•

? ;;h that increase in size means merely increase in unit structure.

•
The
litiifj^oe is given delivered but not erected, although superintendence of erec-
j.aiW'a 19 included; common labor for erection is furnished by the purchaser.

'
723
Sec. 10-89 POWER PLANTS
The cost of Roney and other step-grate stokers is from $6.50 to $8.00 p
rated boiler h.p., average $7.50; chain grates, $13.00 to $20.00, averai
$16.00; underfeed (Jones type), $7.00 to $11.00, average $8.50; underfei
(gravity plunger), $12.00 to $16.00, average $14.50.
89. The forcing capacity of these different types is extremely variabl
the overfeed step-grate types usually cannot exceed 200 per cent, of ratin
the chain grates are about the same. The underfeed types are readi
reaching 300 per cent, and over. The cost per rated h.p. is therefore n^
entirely fair as the sole criterion.
90. Cost figures from a very large stoker installation using three typ
are as follows, complete with blowers and stoker drive (1920).
 POWER PLANTS Sec. 10-93

93. Draft required. The required draft is difl5cult to compute accurately,

since it la made up of the sum of draft losses for accelerating the gases,
friction loss through boiler, flues, and stack, and loss of head at each change
of section, turn, and air leakage into the system. Fig. 16a shows the draft
losses which should ordinarily result in normal design, from the boiler,
breeching on, and also indicates the flue velocities for computing areas. The
stack velocities should run 1400 to 1500 feet per min.
94. Boiler draft loss. Fig. 166 shows the draft required from furnace to
breeching, for stokers using forced draft, and is based on 0.1 in. draft over
the fire; the blast pressure does not affect the problem, in this case. Fig.
17 shows the draft required between ash-pit and breeching, for hand-fires,
ind stokers using natural draft.
The draft loss through economizers
/aries from 0.25 in. to 0.75 in.

95. Total draft. The total draft

rillbe the sum of the draft required
or flues, etc., from Fig. 16a, and that
equired for the boiler at maximum
ate of driving, from Fig. 166, or Fig.
7. Formula 20 may be rewritten,
OT convenience in solving for H,

H= ^\ , ..
1.04\
(21)
0.255 Pj
Ti ) ik
h will be the total draft found
^ove, and H
the corresponding
;ight. The figures thus obtained
ill be on the safe side, a very de-
rable condition for the draft sys-
m. A draft system made too
_

iiall is an exasperation in operating 100 200 300

id an expensive thing to correct, Per Cent Rating
pecially now that the tendency is
ways toward higher forcing. Fio. 166. — Draft loss through boilers.

96. Stack capacity. _

be noted that the old method of rating in
It will
p. is not employed; it is much better to design the stack on a gas basis.*
>r most purposes, 500 cu. ft. of hot gases per pound of coal (50 per cent,
cess air, 600 deg. Fahr.) is a perfectly safe basis.
From the total weight of coal burned per hour, the total gases per minute
n be obtained; dividing by the velocities given in Par. 93 and Fig. 16a, will
.'e the stack and flue areas required.

9T. Chimneys are built of the followingr materials :

( red brick, fire-brick lined; (b) radial buff brick, fire-brick Uned; (c)
nforced concrete, lined; (d) steel plate, lined; (e) steel plate, unlined.
natural draft, the radial brick, the lined steel plate and the concrete
pea of chimney are in general use.
M._ Brick chimneys. The red-brick chimney cannot be less than 0.7
thick at the thinnest portion; in other respects it is designed for stability
linst a wind pressure of 50 lb. per sq. ft. and against crushing. The walls,
irefore, are always thicker at the bottom, and the stack is tapered. This
)e is not often used for power stations. Radial-brick chimneys may be
8 ft. thick at the thinnest part, as the brick is specially moulded the ;

as-section is always circular, and tapers in the same manner as red-brick

mneys. Brick chimneys are the most durable of all the types. The
i-brick portions of lining need be carried up only 30 ft. above the grates.
•9. Steel chimneys have the advantages of lightness and strength, but
ce they are better conductors of heat, must be lined with brick for heights
ir 75 ft. except in forced-draft installations. They must be carefully
pected and painted from time to time, as they are subject to deterioration
corrosion.

)!^' A. S. M. E. Trans. (SOt i;

1915, A. L. Menzin.

726
Sec. 10-100 POWER PLANTS
100. Keinforced concrete is much stronger than brick and will stan(
high tensile strains like the steel chimney. The stack is therefore often buil
straight Uke the steel chimney, and is always considerably lighter than brick
as it may safely be much thinner. It is usually poured in 5-f t. or (i-ft. sections
which may be carried up a section a day, making erection rapid. No linini
is required other than the short section of fire-brick above the grates (30 ft.)
It is one of the cheapest and most durable forms if well designed and buill
but like all reinforced concrete, is dependent upon care and watchfulnes
during construction.

^1.4

1.2

Ili
a
"1,0

•S -9

a
 POWER PLANTS Sec. 10-104

104. The cost of steel stacks may be figured on a basis of $0,045 per lb. of
steel erected.

MECHANICAL DRAFT
106. Limitations of natural draft. From the figures in Par. 91 to
evident that for high rates of combustion the stack becomes imprac-
)$, it is
acably high, or the sensible heat loss due to high flue temperature becomes
X)o large for economy. To mitigate this, mechanical or artificial draft of
lome form may be employed.
 ''

Sec 10-107 POWER PLANTS

Fig. 18 gives the h.p. required at any pressure, for average fans. 1
characteristics of a forced draft fan for underfeed stokers are given in I
19. The static pressure and volume of any size fan, at any speed, can
found approximately from Fig. 20, which assumes similar shape of vai
and static efficiency about 55 %.
107. Forced draft. If the fan is placed so as to blow under the f
the pressure is greater than atmospheric; this system is termed forced dri
108. Induced draft. If the fan suction is connected to the boiler fl
and delivers to the stack, the pressure in the furnace and ashpit is '.

than atmospheric; this system is termed induced draft. The two syste
may be used together, one fan forcing air through the fire, and the ot
drawing from the flue, maintaining a more or less balanced pressure over
fire. A forced draft fan also may be used, in connection with a chimnej
draw off the gases.
109. Induced draft for hand fires with bituminous coals may
substituted for natural draft since the required maximum is not usually o
2 in. of water.
110. Forced draft combined with either natural or induced draf
always used with the underfeed stokers and frequently with the chain gra
Forced draft cannot be used alone, as without some suction at the breechi
there would be pressure above atmosphere in the fire-box, causing flame
issue from all openings.
111. Cost data on blowers and fans are difficult to furnish about ;

only factor remaining nearly constant is the price per lb. at $0.30 to $0.3«i
112. The comparative advantages of mechanical draft are:
greater forcing capacity than with natural draft, since it is easy to prod
much greater differences of pressure than are at all practicable with stac
(b) entire flexibility of control; (c) better- combustion conditions w
balanced draft arrangement; (d) low cost of apparatus.
113. The objections to mechanical draft are increased operating c
due to energy consumption by driving apparatus, and increased maintena
cost, which .are balanced against the low maintenance of stacks. But
energy consumption (of steam, for turbine drive, say) is not a net loss, a
may be profitable to use the steam exhaust in feed heating, and the st
requires a certain loss of fuel due to flue gas temperature, in order to open
This temperature can be lowered when using induced draft. Forced-dr
fans have low maintenance costs, as they handle cool air; induced-dif
fans, however, are likely to have high maintenance, as they deteriorate fl
handling hot flue gases.

PROPERTIES OF FUEL
114. Anthracite, or hard coal, contains very little volatile matter
mainly fixed carbon and ash; is difficult to ignite; hard and bright f ract
not soiling the fingers in rubbing; oldest coal formation, being nexti
graphite.
116. Semi-anthracite contains a little less fixed carbon, more voh
matter; is easier to ignite and softer. Semi-bituminous is the nex i

order, having enough volatile matter to coke, with moderately long fls
and soft crumbly fracture.
116. Bituminous coals are rich in volatile matter, which may be aa :1
as 40 per cent.; usually fairly low in ash — 5 to 9 per cent.; and ma^<
divided into many different classes with regard to flame, caking and co i
qualities. They are very easy to ignite, brittle and dull fracture, crum'i
and soil the fingers in handUng, due to softness.
117. Coke is the resulting fixed carbon and ash which remain-
mass after driving off the volatile matter from a bituminous orsenn
ous coal. It is largely a product of the coal gas industry; but a
station fuel, its price is practically prohibitory. Oven coke, whi.
hard, is used for blast furnace and crucible furnace work.
118. Lignite is a more recent formation than the bituminous coi^.., i.j
hardly distinguishable from the lower grades of these; it is non-hbrou^
often brownish in appearance, whereas the coals are all black; a
oxygen and gives off CO2 at ordinary temperatures. It contains qufti
of oxygen and the volatile matter given off is mainly OOj, which distingt
the lignites still further from the coals, whose volatiles are oI]|
hydrocarbons.
728
 '

POWER PLANTS Sec. 10-119

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Sec. 10-120 POWER PLANTS

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730
 POWER PLANTS Sec. 10-121

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731
 Sec. 10-123 POWER PLANT!?

m
 POWER PLANTS Sec. 10-124

124. Peat is the most recent of the formations. High-bog peat is formed
from swamp moss, etc.; low-bog peat is formed from grasses around low
bodies of water. They show the fibrous structure of vegetable origin, and
range in color from ochre to brown and black; are very soft in texture, with
no fracture; carry large moisture, oxygen and nitrogen content; the volatile
matter is poorly combustible, containing largely CO2.
125. Wood is still higher in oxygen and nitrogen, up to 40 to 45 per cent.,
with carbon from 45 to 49 per cent. Its scarcity and cost make its use as
a power station fuel impossible except for saw mills and logging camps
where the unmarketable waste may be profitably used.
126. Briquettes* are small artificial lumps of solid fuel made up by
pressing peat, bituminous slack or anthracite culm, with a suitable tarry
binder, so as to recombine the soft peat or unmanageable coal dust into a
convenient lump form. Briquettes oehave somewhat Uke lumps of soft
coal, but usually are very troublesome in giving smoke. The cost of bri-
quetting presses, and the need of suitable inexpensive binder, have pre-
vented the wide use of briquettes in America. With peat briquetting is
practically a necessity.
127. Mineral oils have their source in crude petroleum. The heavy
oU engines, such as the Diesel and the Junkers run on raw petroleum; many
of the smaller engines, however, are designed for kerosene and gasolene.
128. Gas for power production may be natural gas,t producer gas,
coke-oven gas.t or blast-furnace gas. § Illuminating gas is too expensive to
use for anything but very small isolated plants. See Par. 121, 122 and 123.
129. The main feature in the use of gas is the engine compression
pressure which is practicable; blast-furnace gas, being lean and much
diluted with neutral matter, will stand very high compression; producer
gas, natural and coke-oven gas, being richer (especially in hydrogen), can-
not be compressed as much.
130. The cost of anthracite No. 1, No. 2, or No. 3 buckwheat is
about 82.50 to $0.00 per ton at the plant in quantity. The mine cost is
not over $2.00 to §3.00. Bituminous coal costs from $5.50 to $9.00 at
the plant. The cost averages $0.17 to $0.19 per million B.t.u. (1921).
131. Fuel oil costs from $0,025 to $0.07 per gal. The cost averages
about 80.18 to $0.20 per million "S.t.u., in the oil-burning districts. While
jta cost per million B.t.u. is about the same as coal, or somewhat better,
in the districts where it is available, it has a further advantage in the better
boiler efficiency obtained, and in the elimination of some of the power-
station auxiliary apparatus (1920-21).
132. Natural gas costs $00.13 to $0.16 per million B.t.u. All of these
figures apply chiefly to large consumers; the prices will go up considerably
for small plants.

WATER SUPPLY AND PURIFICATION

133. Boiler feed. Boilers must be fed with fresh water of reasonable
quality; in general, if a water is not potable, it is not fit, as it stands, for
boiler feed. Wells, fresh-water lakes, rivers and ponds are the prime
sources.
134. Water analysis to determine the value of a water as boiler feed
should be performed by a chemist; but the ordinary tests for hardness, with
standard soap solution, hydrochloric acid and methylorange, may readily
be carried out in the plant in conjunctionwith water-softening apparatus.
136. The dangerous impurities are sulphuric acid (or other acids if
the water has been contaminated by factories), grease and oils in quantity,

Lucke, C. E., "Engineering Thermodynamics."

* McGraw-Hill Book Co.,
Inc., New York, 1913; Table CIV.
t Lucke, C. E., "Engineering Thermodynamics." McGraw-Hill Book Co..
Inc., New York, 1913, Table CIX.
t Lucke, C. E., "Engineering Thermodynamics." McGraw-Hill Book Co.,
Inc., New York, 1913, Table CX.
§ Lucke, C. E., "Engineering Thermodynamics." McGraw-Hill Book Co.,
,Inc., New York, 1913, Table CXIV.

733
Sec. 10-136 POWER PLANTS
and the natural scale-forming salts such as magnesium, iron and calciui
carbonates and sulphates.
136. The treatment of feed water has been outlined in Par. 49 to 61
137. The use of condensate returned from surface condensers i

usually a valuable way of eliminating most of the boiler encrustation. Th

only drawback lies in the presence of oil and grease in the condensate, i

the condenser serves a reciprocating engine. Quantities of oil in excea

of 0.4 to 0.5 g. per gal. are objectionable, as they collect whateve
soft scale may be present in the boiler and form a brown mass which bake
on the tubes and has the same effect as hard scale.
138. Oil and grease extractors, designed on the same general lines a
steam separators are employed between
the engine and condenser, in order to
keep down the amount of oil passing into
the condensate. As a matter of fact,
the bafHes placed in these devices are
really of very little luse; it is the reservoir
effect of the extractor in slowing down
the current of steam which really does
the work. Where turbines are the prime
movers, no grease or oil separators are
required. Fig. 20a shows a typical
separator.
COAL AND ASH HANDLING
139. Coal is delivered to the power
plant of any size, either by barge,
schooner or railroad car. Handling coal
by truck is practically too expensive for
use in any but small isolated plants.
140. Unloading may be done by a
grab-bucket digger, or if delivered by
car, an elevated trestle may be employed,
dumping from the car bottoms. For
most of the large plants, a coal tower
Drip
with a 1-ton or 1.5-ton clam-shell digger
is employed to unload and hoist the coal Fio. 20a. —
Horizontal steam
high enough to pass by gravity through separator.
crushers and weighing scales, and finally
to conveyors or coal cars. In smaller plants, a locomotive crane, or mono
rail telpher, may perform the same work and also serve the storage yard
Towers may be either steam or electric driven; the former is generally th
cheaper and more rugged construction.
141. Crushers are heavy rolls of cast iron, studded with teeth, geare
together in such fashion as to crush the coal to small size; some spring c
relief device must be fitted to allow harder materials to pass through, sue
as link chains, sprags and occasionally a car coupler. Crushers are nc
needed for anthracite.
142. Conveyors are of five principal types; scraper, reciprocating, bel
bucket and suction. The scraper conveyor consists of flights or paddh
rigidly fastened upon a special bar-link chain, and dragged along in a troug
shaped to the flights. The reciprocating conveyor is very similar, bi
only moves a few feet forward and backward. The flights are so hingf
that on the backward .stroke they lift out of the coal and trail over the to
digging in again when the chain reverses.
143. Belt conveyors consist of wide rubber or textile belts travellii
continuously over idlers spaced from 2 ft. to 4 ft. apart, and with the out
pulleys tilted up to trough the belt. The belt conveyor is not suitable for h
ashea.
144. The bucket conveyor has separate buckets from 24 in. to 48 i
square, either fixed rigidly to long-pitch side links, or pivoted in the cent*
so as to remain vertical. In the latter case, all of the conveyor is mallcah
iron except the rails and framing. It ia exceptionally suited to handli
ashes.

734
 POWER PLANTS Sec. 10-145

145. The suction conveyors are used only for ashes; coal is too heavy
and packs too readily to be handled in this manner. The auction is usually
provided by a high-speed centrifugal blower, attached to the outlet, or a
Bteam jet eductor. The rest of the equipment consists merely of Wn. to
12-in. cast-iron pipe lines with swing-door openings at which the ashes are
admitted. The drawback to this system is the deterioration of the fan
from grit, and all turns and elbows from abrasion. If the ashes are too wet,
the blocking of the pipes is practically certain to give trouble.
146. Comparisons of conveyors. The belt conveyor is very satisfac-
tory on "carry" of coal, but not so good on "lift;" the bucket conveyor
is probably the most satisfactory aU-around conveyor, handling coal or
hot ashes equally well in lift or carry; it is, however, the most expensive.
The steam jet conveyor has been successful chiefly in small or moderate
size plants.
Another method of conveying is by cable cars; where possible
147.
this givesthe cheapest and most satisfactory means of carry.
148. Storage of coal outdoors for power-plant purposes requires less
care and handling than for coal companies, as the material is turned over
fast enough to avoid much loss by weathering. The storage yard may be
served by: (a) a locomotive crane, (6) a gantry crane, (f) a Dodge girder
unloader, (d) a telpher grab bucket operating on an overhead structure,
(e) or if the storage is in a pit, by a conveyor in a tunnel. Usually the
capacity should equal at least two weeks supply, or better, one month.
One company having trouble from spontaneous combustion of bituminous
coal, uses a concrete pit flooded with water; but this is generally unnecessary,
the excessive wetting of the coal being a drawback.
149. Bunkers placed under the roof of the boiler house are almost always
provided, to feed coal by gravity to the fires. Where external storage
is available, two to four days supply in the building is all that is necessary;
but in city plants where external storage is impossible, ten days to two weeks
supply must be provided.
160. Bunker construction. Steel framing with concrete or cinder-
concrete lining, faced with granolithic or other hard finish, is the best con-
struction for large work; for smallef work, the suspended type, catenary
shape, of plate steel with concrete lining, or simply of reinforced concrete,
bas been much used.
161. Hoppers. Ash hoppers of structural material with brick lining
ire the standard practice, but reinforced concrete is also being used to some
sxtent. The coal hoppers should always be of sheet steel, i\ in. being
_^
;heusual thickness; it is good practice to reinforce the hoppers with renewable
'^: Tearing plates where the abrasion is severest.
ji. ,162. Weighing is done at the hoisting tower (just after crushing) in
loppers carried in knife-edge supports which operate standard beam scales;
wo sets are required, one hopper receiving the continuous flow of coal from
* he crusher while the other is being weighed. Reversing gates for the supply,
>''.nd trip gates for the weighing hoppers are under the control of the weigh-
*aa8ter.
163. Automatic scales of the hopper type are in use for anthracite,
nd are fairly accurate, as the angle of repose and slip of anthracite in the
belfnaall sizes is very little affected by moisture, and the small size allows
iiiifci;ady control of the flow; with bituminous coals they are somewhat less
iiiftccurate over short runs, as the highly variable angle of repose affects the
Spillage when closing the feeder gates, making the "dribble" a variable
::f fuantity: but over longer periods, say a month, the error averages and they
usiork very well. Conveyor scales of several makes arc on the market, but
ot widely used.
^jiij 164. There is also a coal meter for use in pipe downtakes, acting on
,jt£«e principle of a propeller driven by the moving coal, which is very simple
;[b.'>id quite accurate for small sizes of coal. It is not yet fully satisfactory
r lump coal and run of mine.

,si 1'5. Spouting of coal in closed pipes must always ^e done at an angle
oilf.
^^ !^68- or steeper to be satisfactory, if the spout is a closed pipe; 8-in.
,^> l^j^' P'P^^ ™*y ^^ ^^^^ ^"itl^ anthracite; but nothing less than 12 in.
^.j;|Ould be used for bituminous crushed coal. In designing hoppers and
outs should be remembered that the intersection of two sides each at
it
' from the horizontal, is much less than 45 deg., so that the coal will
deg.
ways hang at such a junction.
736
Sec. 10-156 POWER PLANTS
166. The power required by belt conveyors is given by the foUowii
formula:
H.P.^S^+JH (2(
1,000 '
1,000
where C = power constant, !r = load in tons per hour, I, = length of conveyc
in feet, // = liftof conveyor in feet, and JS = width in inches.
Values of C for material weighing 25 lb. to 75 lb. per cu. ft.

B (in.)
 POWER PLANTS Sec. 10-159

169. Ash handling is very frequently done by trolley locomotive and

side dump cars, in large plants; these allow for thorough quenching before
delivering to conveyors for elevation. Of the conveyors, the malleable-
bucket type lasts the best in ash service. A
skip hoist may be substituted
for conveyors, for elevation; and where it can be used, is a most satisfactory
means of disposal. Ash bunkers are almost always provided for storage
purposes, as in many plants the ash removal from the individual boiler ash
hoppers is done on night shift, when cars or boats are not readily available.
160. Helical or screw conveyors. The power required is

where W'= capacity in lb. per min., L = length in feet and C = 0.67 for
coal, 1.00 for ashes.
161. Typical combinations are: low-hoist grab-bucket tower, con-
taining crusher and scales; belt .conveyors, horizontal, to power station;
V-bucket or pivoted-bucket elevator, belt distribution at top of building to
bunkers. Inchned belts may be used for "lift," but are not too satisfactory.
Belts are very good on "carry," however. If the tower is close to the build-
ing, bucket elevators may be used both for lift and carry. very good A
arrangement is: high towers, performing the whole lift at once, delivery
through crusher and scales to cable car for distribution over bunkers. For
small or moderate size plants telpher grab buckets offer a satisfactory
solution, serving storage yard, cars or boats, and bunkers on overhead mono-
rail structure. The usual system for ash disposal consists of collection from
ash hoppers by industrial railway and trolley locomotive, and delivery to
skip hoist or bucket elevator for lifting to ash storage pockets, for which
the ashes are spouted to cars or barges. The vacuum system is useful for
small and moderate size plants; or a single hand car may be enough. Belt
conveyors should never be employed for ash handUng.
162. The cost of conveyors is exceedingly variable and is dictated
^hiefly by structural conditions. It is almost impossible, therefore, to give
unit costs. Belt conveyors of the lengths usual in power station work cost
rem $2.00 to $3.00 per inch of belt width, per foot of conveyor; bucket
, levators and conveyors, roughly $0.40 to $0.50 per ton capacity per hour,
*i per foot of conveyor.

d. STEAM ENaiNES
163. Source of energy. The steam engine must obtain its energy
IS Irom the heat drop available by adiabatic expansion between any two pres-
ures. For adiabatic expansion, there must be no heat interchange with
he surroundings while the mass of steam in the cylinder undergoes the
xpansion; therefore a non-conducting cylinder is required. This is com-
lercially unattainable, and consequently the expansion is never truly adia-
atic. The heat drop obtainable is always less, if the expansion is not
diabatic.
164. The thermal efficiency of a perfect engine working on the
lankine cycle (Par. 166) is given as

jhere ffi = total heat of steam at initial condition (pressure and quality or
Biperheat), i/2 = total heat of steam at final pre-ssure after an adiabatic
' hpansion (constant entropy), and hi = heat of the liquid, at final pressure.
'>r modern steam pressures, superheats and vacua, this possible efficiency
les not exceed 40 per cent, for turbines. The usual steam pressures and
ouum for reciprocating engines would not give a higher efficiency than
per cent.
166. The efficiency ratio for good compound engines seldom reaches 60
r cent.,giving an actual thermal efficiency of 18 per cent., 13 per cent, and
per cent, are more commonly reached in large size reciprocating engines.
166. The Bankine cycle upon which these comparisons are based
3-3upposes a non-conducting cylinder, no leakage and no clearance;
mission at constant pressure, instantaneous cut-off; expansion adiabat-
lly to the back pressure; exhaust at constant pressure; and since there

737
 Sec. 10-167 POWER PLANTfi

is no clearance, no Compression is required. In the real engine, conductioi

of heat, leakage, wire-drawing, friction, incomplete expansion, and clearanci
all tend to reduce the efficiency ratio by adding losses.

167. A single-expansion engine is one in which the complete expan

sion from initial to back pressure takes place in one cylinder; a compoun(
engine is one in which the expansion is from the initial pressure to an inter
mediate pressure in one cylinder, and from this intermediate pressure to th
back pressure in a second cylinder. A triple or quadruple expansioi
engine performs the expansion similarly in three or four stages, respectively
All engines using more than one cylinder to complete the expansion ar
termed multiple expansion, in general.
Cut-oS usually takes place at J to i stroke in simple non
168.
condensing engines, i to J in condensing. The number of expansion
is the ratio of final cylinder volume to volume contained at cut-off; fo
simple non-condensing engines the ratio is 3 to 4; simple condensing, 5 i
8; compound and triple, etc., 8 to about 50. For power station purposes li
to 20 is common, with compound condensing units.
169. Non-condensing engines exhaust freely to atmosphere, or to
system in which the pressure is atmospheric or a few lb. per sq. in. above
condensing engines exhaust to a condenser in which a partial vacuum i
maintained, below atmospheric pressure.
170. High-speed engines operate at 350 to 250 rev. per. min., in size
from 5 h.p. to 500 h.p. Medium-speed engines operate at 260 to 150 rev
per min. in sizes from 2.50 h.p. to 1,000 h.p. Low speed engines (generall
Corliss types) operate from 100 to 70 rev. per min., in sizes from 400 h.f
to 8,000 h.p.
171. Single-acting engines take steam on one side of the piston onlj
they may be simple, compound or triple expansion; and are always higl
speed engines, usually with vertical cylinders.
172. The slide valve in the original D-valve form is unbalanced, mo\
ing on flat faces; it is unsuitable for large sizes and heavy pressure. Balance
forms of the slide valve, such as the Ball, Skinner, Mackintosh & Seymon
grid, etc., overcome some of these objections. The piston valve, shape
like a piston, is inherently balanced; it can be made tight, but requirt
large clearance percentage, on account of length of the ports.
173. The Corliss valve is of general cylindrical shape, oscillating ov<
ports parallel to the axis of the valve and crosswise of the cylinder; it ca
take care of but one function, therefore four are required per cylinder, tw
for admission and two for exhaust. The preceding types, except the gric
take care of all four functions with one valve. The Corliss valve is alwaj
used with a trip or releasing gear to vary the cut-off without changing an
other event in the steam admission or exhaust. In all fixed valve gear
it is usually impossible to vary the cut-off without varying other functior
at the same time.
174. Poppet valvesare those in familiar use on automobile engine
but for steam use are generally made double-seated so as to be balancei
They have met with great success in Germany, and are undoubtedly tl
best type for superheat. They may be used with releasing gears, and r
quire four valves per cylinder, as with the Corliss type.
176. Jackets for keeping the cylinder hot with live steam, to rodu'
condensation in the cylinder, have been used with some success for pumpii
engines; but have not been successful in many other applications.
176. Receivers are u.sed to eliminate variations of pressure between hi
pressure and low-pressure cylinders in multiple-expansion engines, due
intermittent exhaust and admission: they must be of large capacity to

> effective. Reheating coils are sometimes employed to dry the steam pi
ing through these receivers, to improve conditions in the succeeding cylind
They arc of practically no value in engines for power-station service.
177. Governors for steam engines are of two principal types: fly]
and shaft governors. The flyball type consists of two or more weight
balls supported by movable arms, the whole rotated around a shaft so i

centrifugal force tends to throw the balls outward; this tendency is resi^
by weights or springs, and the relative movement of the arms made to opr

738
 r

POWER PLANTS Sec. 10-178

the engine valve gear. In the shaft governor the weights are arranged
to rotate vertically around the main crank shaft, and attached direct to the
eccentrics without the intervention of other mechanism. It cannot be
used with slow-speed engines, nor with any form of trip or releasing gear.
Inertia effects are introduced in the Rites type of shaft governor.
178. Either centrifugal or inertia types of governor can be made
isochronous, but are generally only approximately so; isochronism, or com-
plete instability of the governor at all speeds except the correct speed, is
undesirable, causing hunting. ^

179. Engine frames are usually made entirely of cast iron, for stationary'
work; the vertical engines are of the A-frame type in large and small sizes
and of the enclosed type, with automatic oiling, for small and moderate size,
only. Horizontal engines of small and moderate sizes, may be enclosed,
with automatic or splash oiling.
180. Girder frames. The large horizontal Corliss type engines are
made with girder frames connecting the cylinders and the main bearings, for
the standard type in the heavy-duty type, the girders are completely
;

surrounded by the frame, which is carried down to the sole plate all the way
from cylinder to main bearing.
181. Mean pressure is the average pressure which if exerted
efifective
during the full stroke would equal the work done by the varying pressures
really existing during the course of the stroke. The mean effective pressure
(m.e.p.) is obtained from the indicator card as follows:
-- ... = card X scale of spring
area in sq. in.,„„,
M.e.p. in lb. per sq. in.
.

^^.
card length in inches
, ,(30) .
—
The shorter the cut-off, the lower the m.e.p. for any given steam pressure
and back pressure; consequently the larger the cylinder dimensions become
for a given horse-power, other things being constant.
182. Cylinders are usually so proportioned as to divide the total work
equally between high- and low-pressure cylinders; roughly, for compound
engines, the cylinder ratio is given by

i2c=(^^')^ and P2=(PiP3)* (31)

'
where Re = cylinder or ratio of low-pressure displacement to high-
ratio,
pressure displacement. Pi = initial pressure in lb. per sq. in. absolute, P2 =
receiver pressure in lb. per sq. in. absolute, and P3 = back pressure in lb.
iper sq. in. absolute.
H .This is based on no clearance, no cornpression, equal cut-off in both
« icylinders, logarithmic expansion, and receivers of infinite capacity. It is
n varied in practice by the clearance of both cylinders; by finite receivers and
by the effects of wire-drawing.
183. The speeds usually employed in America are given in Par. 170«
[i'Snell gives a table of usual English practice, which is slightly higher than
I
American usage.*
f
tor sizes above 1,760 k.w., the speed is from 75 to 60 rev. per min., for
ICorliss engines. Piston speeds range from 350 to 600 ft. per min. in the
illigh-speed engines, and from 600 to 750 ft. per min. in the low-speed, long-
|stroke Corliss types.
184. Indicated horse-power is given by the indicator, and is the
|imountof power actually developed in the cylinder by the steam. Brake
inrse-power is the actual output at the shaft.
T , PLAN ,„„,
33,000
Inhere
P = mean effective pressure, lb. per sq. in.;
_ L = length of stroke, ft.;
! A = piston area, sq. in.;
^ =« number of strokes per min.

• Snell, "Power House Design," p. 146. Table XLVII.

739 .
Sec. 10-185 POWER PLANTS
185. The mechanical efficiency is given by the formula

'
i.h.p. (33)
where Bm = mechanical efficiency, b.h.p.=brake horse-power, and i.h.p. =
indicated horse-power.
Friction li. p. = i.h.p. —b.h.p. (34)
Lucke gives the formula
£„.= l-f'.--^l (35)
(m.e.p.)
where Xi =0.02 to 0.05, average 0.04; and ^2= 1.3 to 2.0, average 1.6.
186. Mechanical design of the steam engine is limited by first cost,
effi-
ciency and reliability: these three factors exert influences in varying direc-
tions. Low cost per h.p. capacity indicates high rotative speed and sim-
plicity of mechanism. High economy indicates lower speeds, complicated
valve gear, multiple cylinders, reheaters and large receivers. Reliability
dictates heavily built parts, elimination of small parts, and especially the
elimination of small bearings. The
outcome is that for small powers, mod-
erate speeds and low steam pressures, the simple non-condensing slide-valve
engine, throttle governed, is Under steady load and speed it has fail
used.
economy, and is very reliable. For small electric isolated plant service, the
high-speed automatic engine, with shaft governors and piston-valves or
balanced slide valves, is used. For higher powers the low-speed condensing
engine, either simple or compound, is adopted. The higher economy de-
manded justifies the increased cost due to low .speed and Corliss valve gears;
reliability is also provided, since the complex gear is now large enough not to
be fragile.

187. Friction loss, which causes the difference between brake and indi-
cated power, is made up of bearing friction; piston, valve and rod friction;
and windage. The principal bearing friction occurs in the main bearings,
crank pins and crosshead slippers, the remainder occurs in the valve gear.
Suitable lubrication greatly reduces this kind of friction. Piston, valve
and rod friction occur in a steam atmosphere where lubrication is at best un-
certain. The latter depends upon the type of valve, whether balanced or
not; upon the kind and number of piston rings; and upon the condition of
the rod packing.
188. Lubrication of all bearings is accomplished with engine or machine
oil;or prepared grease. In small engines, sight-feed oil cups are commonly
used; for large units, a central gravity oiling system piped to all bearings is
considered the best practice. In the latter case, the oil is caught after use
and returned to filters, whence it is again pumped to the elevated supply
tank. In this way copious supplies of oil may be given without great expense
and the friction is very much reduced. Splash oiling in closed crank-case
engines is employed for high speeds and small or moderate sizes. Grease
can only be fed by individual compression cups at each bearing.
189. Cylinders are oiled with heavier lubricants, whose lubricating
qualities in the steam become the same as ordinary engine oil at room tem-
peratures. Cylinder oil is fed into the steam pipe just above the throttle, oi
into the steam chest: a hydrostatic sight-feed lubricator, or a force pump
may be employed. The latter is considered the better method. Oraphiti
has been used with much success in assisting cylinder lubrication; th(
chief difficulty lies in getting it into the cylinder.
190. The total losses occurring in a steam engine can be classifie<
as follows: cylinder condensation; leakage; clearance; incomplete expaii
sion; wire-drawing; radiation; mechanical friction.
191. Cylinder condensation is caused by the conduction of heat awaj
from the steam through the cylinder walls; the cylinder assumes an avcragi
temperature about half-way between steam admission and exhaust teiniit'ra
tures. Consequently the hot in-coming steam gives up heat to the uoli i

walls; some of this is returned, too late to be of use, during the exhaiis
stroke. Moisture in the entering steam makes this effect worse bu ;

superheat much improves it, by increasing the surface resistance to hea

transmission.

740
 POWER PLANTS Sec. 10-192

192. Leakage occurs past all sliding joints—;-the joint behaves like an
elongated capillary orifice for steam flow; such joints occur at the piston, the
piston rod, the valve seat and the valve rod. The means of reducing leakage
are generally snap and spring-rings for pistons and piston valves, pressure
plates insuring a close fit for flat balanced valves, and sectional metallic or
soft packing compressed by a gland, for all rods.
193. Clearance is any space left between the valve and the piston, when
the latter is at the end of the stroke. It varies from 3 to 4 per cent, of the
displacement in well-designed Corliss engines; from 8 to 14 per cent, on
high-speed and medium-speed engines; from 15 to 30 per cent, in badly
designed or low-price slide-valve and piston-valve engines.
194. Zero clearance is not possible in any commercial construction, since
piston must have some clearance from the cylinder head, and the steam and the
sihaust passages must always have some volume. Clearance necessitatoa
compression, in order to bring the volume of steam trapped in the clearance
jpace to approximately the initial pressure; this has the double effect of
cushioning the engine and avoiding loss due to filling the clearance space with
resh steam at each stroke.
196. Incomplete expansion is due to the limitations in size of cylinders,
rtfhichcommercially cannot be made large enough to handle the high vol-
imes at low pressure.
196. Wire drawing is the term applied to pressure drop between steam
rhest and cylinder due to insufficient area in the valves and ports, or slow
)pening of the valve; it reduces the effective pressure and therefore causes a
08S.
197. Radiation is the heat loss which occurs when the cylinder tempera-
ure is higher than that of the surrounding air. Not only the cylinder, but
Iso those parts of the engine which become hot by conduction, radiate heat.
''he cylinder is heavily lagged (or even jacketed in a few cases) to reduce the
D9S. This loss amounts to 1 or 2 per cent, of the total heat of steam used by
he engine.
198. Indicated horse-power is obtained from the indicator card (Par
84) and was the basis of most guarantees up to a few years ago. Brake
orse-power, which is the useful power delivered at the shaft, is now more
ommon.
199. Non-condensing single-cylinder engines are usually rated at
or i cut-off and 100 lb. gage steam pressure; compound non-condensing
ngines at ^ to i cut-off in the high-pressure cylinder and 150 lb. gage pres-
ire; simple condensing engines at i or J cut-off and 125 to 150 lb. gage
.ressure. The guarantees should always state steam pressures, back pres-
iires and actual cut-off, instead of the above figures.
'
200. The locomobile type of engine developed abroad and lately
itroduced in this country is a combination consisting of a tandem compound
igine mounted directly on an internally fired boiler. The high-pressure
.•Under is in the smoke flue, and the low-pressure cylinder is jacketed by
le steam dome. A superheater is also fitted in the smoke box. The
ivantage of maximum jacketing effect, high superheat, and practically no
ping losses, make the fuel economy high. This type of unit is now manu-
otured in this country, but the advantages of the turbine, coupled with the
iiiparative inflexibility of a single boiler-engine unit, will prevent extensive (
of the locomobile in America.
>

201. Exhaust steam heating makes use of the heat wasted by the en-
ne; it may amount to 80 or 90 per cent, of the heat originally in the steam.
)n.-<equently,the power is obtained at very low cost for fuel, since most of
e ordinary- inherent losses are recovered as heat in the heating system.
•nee in many industrial plants serving buildings with lighting and power
-vice, non-condensing engines are used. Generally the expense of a con-
nser to be used during the summer months will not be justified, as the small
(
in in economy for the year will not offset the fixed charges on the condenser
uipment.
202. Average steam-engine performance is best represented by a
nibination of the efficiency ratio and heat drop available from the steam
iiditions existing, since the efficiency ratio is the least affected variable
: solved.

741
t
Sec. 10-203 POWER PLANTS
The efficiency ratio is defined as the steam consumption of the Rankine
cycle, divided by the actual steam consumption (per i.h.p.-hr., per brake
h.p.-hr., orperkw.h., as the case may be); or, the ratio of the actual efficiency
to the Rankine efficiency. The Rankine cycle efficiency is found as follows:
on the Mollier diagram. Fig. 22, select the point corresponding to the initial
steam condition, and read off total heat, //i; follow down the vertical line
(constant entropy), to the back pressure in the case, and read off total heat,
Hi, in the final condition. The available heg.t-drop is Hi-Hi:
Efficiency of Rankine cycle, Et = ——jz
Hi
2545
Steam-consumption of cycle, WT = -r, — rr> per i.h.p.-hr., or brake h.p.-hr.
til H2
= 773413JJ-, per kw.h.
, .

Hi — Hi
Heat drop actually obtained, Hz = —sf . Per i.h.p.-hr., or per brake

h.p.-hr. = --- per kw.h.

W ,

where W
the actual steam consumption for the above units.
is
Thermal efficiency of the actual engine,

^-Hl
Efficiency ratio = _ ot-j^,ot^^
^^ ^^^
Having obtained the available heat drop, select the efficiency ratio for the
and type of engine, and multiply the two to get Hi, then
size

W — -.,'- per i.h.p.-hr., or per

Hi
brake h.p.-hr. (3

= —,f— per kw.h. (a

Hi
SOS. Water rates vary grreatly with steam pressure, superheat or mo8
ture, and back-pressure. No comparison of water rate alone can be fa"
unless the steam conditions are known. The efficiency ratio is the best mea
of comparison for varying steam conditions. For small non-condensia
engines, the efficiency ratio varies from 0.50 to 0.65: condensing lowers tW
ratio about 0.10 to 0.15. The reason is that in condensing single engine!)
the toe of the diagram is cut off and expansion is very incomplete. Tfci
same is true of compound engines. Another reason is that the shorter cuti
off employed with condensing engines induce a greater amount of cylinde'
condensation. Of course, the greater thermal efficiency of the cycle, du
to dropping the backpressure, more than offsets this reduction in efficienc;
of utilization of the cycle. The efficiency ratio is a measure of efficiency r
utilizatio7i.
204. The thermal equivalent of a horse-power hour is 2545 B.t.ii
Large high-grade engines actually develop a hor.se-power on 15,600 to 17,00
B.t.u. small engines, 25,000 to 34,000 B.t.u.
; The thermal equivalent of
kw.h. is 3415 b.t.u. The b.t.u. per kw.h. will vary from 13,500in a 30,000-kv
turbine to 38,000 in a small steam-engine driven generator.
206. The effect of raising the back-pressure upon an engine canreadm
be seen from the Mollier diagram the available adiabatic heat drop is reduS
;

and consequently, although the efficiency ratio may not change, the therM(|
efficiency qf the Rankine cycle is reduced, and therefore the thermal efficient 1
of the actual engine. In other words, the water rate increases. Since th
heat drop is less, there will be somewhat more heat per lb. in the exhaust.
206. Exhaust steam turbines are of valuable use in connection with npil
condensing engines used intermittently. The economy of such engines (j»:f
for rolling mill service) is low, and large quantities of steam are exbaiui»|
to the air one moment, and almost none the next.

742
 POWER PLANTS Sec. 10-206

IL 743
 Sec. 10-206 POWER rj.ANTfi

EUitMT Vdoeltf
Ft. lbs. B.T-U. n. per
of Work second

-
 POWER PLAXTS Sec. 10-206

'oilier diagram.

745
 Sec. 10-207 POWER PLANTS
207. Regenerators. The exhaust of several such engines (Par. 206) is
Eiped to regenerators, which are simply heat reservoirs containing a large
ody of hot water in contact with the exhaust steam. The effect of the regen-
erator is to absorb heat, when delivered in excess, by condensation of steam;
and to release it upon shortage, by evaporation of some of the water. The
slight pressure variations between full delivery and shortage are sufficient to
accomplish this.
208. A low-pressure turbine served by the regenerator will operate on
about double the water rate of high-pressure machine of the same size.
The resulting overall water rate for the output of both engines and turbines
may be from 20 to 50 per cent, less than with the original engines alone.
209. Low-pressure turbines may sometimes be used in connection with
high-grade engines as a convenient means of increasing capacity. The effi-
ciency ratio of non-condensing engines is always much higher than that of
condensing engines of the same size (Par. 202); this is due mainly to the
low-pressure cylinder, which has a very low efficiency. The low-pressure
turbine has a better efficiency ratio than the high-pressure machine, because
the friction of the steam is always less at the lower densities, and the fric-
tion is again reduced by the removal of the moisture in the steam before
reaching the turbine.
210. The largest installation of low-pressure turbines is at the Inter-
borough Rapid Transit Company's 59th-Street Station, New York. Five
Curtis turbines of 7,500 kw. maximum rating are individually connected to
five compound Corliss engines of 7,500 kw. maximum rating. The steam
pressure is 190 lb. gage; vacuum, 28.5 in.; moisture in steam, 1.5 per
cent. The net results are: increase of economical capacity, 146 per cent.,
increase of maximum capacity, 100 per cent, reduction of water rate, 25 per
cent. (Stott and Pigott; A. S. M. E. Trans.; Mar. 1910.)
211. When exhaust turbines are applied to an engine of poor econ-
omy, the saving is even greater. However, there is a limitation to the use of
the low-pressure turbine, in that the engines must be able to withstand the
extra pressures which result from changing to non-condensing service, and
must be in good enough condition to be reliable. It is very bad policy to
make such an installation in connection with an old and unreliable engine.
212. Engine specifications should cover the following points; (a)
Number and location; character of building, (b) Type, service, and man-
ner of connection to load, (c) Principal dimensions, (d) Steam and back
pressures, normal and overload capacity, (e) Speed regulation under all
kinds of load variation; variation of angular velocity, (f) Satisfactory
operation, noise, vibration, etc. (g) Tests and inspection, (h) Con.struc-
—
tion details cylinder, piston-rods, crosshead, connecting-rod, pins and bear-
ings, shaft and flywheel, governor, valves, frame, foundation, lubricators,
and receivers, piping, engine-stop, erection, (i) General: arrangements for
delivery into plant.
213. The only large-size engines in use in electric power plants arc
of the Corliss type, and the grid-valve type. The moderate-size, medium-
speed or high-speed engine may be of the following types: Corliss, automatic
piston valve, or Lentz type poppet valve. The high-speed small engine for
exciter service or small direct-current generation is practically always a shaft-
governor automatic slide-valve or piston-valve engine, generally simple.

) No new power plants are now built using reciprocating engines in large sizes:
See Par. 218.
214. The medium-power and high-power engines are practice
always compound. Wherever possible, the vertical compound, or at lea
the angle compound (horizontal-vertical) should be used on account of 1'
saving in floor space, and the more satisfactory wear of the parts. The he
zontal engine is used only where the headroom is restricted.
216. Automatic stops consist of some form of flyball governor, belt ]_
chain driven from the engine shaft: the governor is so set as to rcleaae.j
trigger or close an electric circuit when the predetermined speed is exceeda
This trigger, or a magnet in the electric circuit, releases a weight arranged i

close the throttle. The usual connection consists of a steel wire rope arouj
a drum on the throttle valve stem. In another form of automatic stop ;'
operation of the magnet or trigger releases the presaure of steam on a pih

74G
 POWER PLANTS Sec. 10-216

pipe line this in turn releasing the pressure behind a piston in the specially
;

designed throttle valve, which then closes. Both the systems are arranged
OT additional operation by hand.
216. The operation of steam engines, after correct adjustment of
moving parts has been made, is chiefly a matter of lubrication. In Starting,
;he usual procedure is to "crack" the throttle in order to admit a little steam
X) warm up the engine all over without allowing it to turn. After the pre-
iminary warm-up, standing, the engine is allowed to turn over slowly for a
ew minutes to all warm
jarts thoroughly; it is then
eady for full speed and load.
<^ve minutes may be long
nough for "warming up"
.n engine of 300 h.p. or
3ss; 15 or 20 min. are re-
uired for large machines,
ust before starting, a few
trokes of the hand oil pump
usually attached) should be
iven, to insure thorough
ibrication. All automatic
i
should be started
iling rigs
( few minutes before turning
ver. Drips should be wide 2 4 6 8 101214161820^24262830
pen while warming up, and Htoadred Brake H.P. Normal Rating "
•bile
osed when the engine is
—
turning slowly, but Fig. 23. Cost of large reciprocating engines,
u. .._ . J ox..-..
fought
,

up to speed. Shut- ^
ng down only requires the 4000
osing of the throttle, shutting
;>i automatic feeds, and the „3600-
Itjening of drips. All bolts is 3200
[jid nuts should be gone over 32800-
[jjriodically, say once a month, P 2400
id a thorough overhauling ..i-2000 -

ven the piston, cyhnder,bear- Sl600

gs, etc., once a year.
'

O 1200
217. Engine costs. Figs. 800
I and 2i give the usual costs
400
large and small engines.
he cost per lb. of engine varies 20 40 60 80 100 120 140 IM
3mS0.10to$0.15. Brake Borse Power Normal Katiug
218. The present status
the reciprocating engine ^ '" ^'*- —^°^^ . r
°'
n reciprocating engines,
small
•

revealed by a progressively
niinishing percentage of the total h.p. of prime movers sold. The large steam
rbine has totally displaced it in central stations and recently the develop-
;

ent of fairly economical small turbines is cutting down the field in all direc-
jns. The immense advantages of the turbine are great enough to overcome
slight inferiority in water rate in the small sizes. Ultra-conservatism and
lorance of the real cost of power, of which coal and water are only fractional
rts, account for the purchase of reciprocating engines where
turbines ought
be installed. The oil engine and the gas engine, for small and moderate
'! plants, are also giving the steam engine
competition, in localities where
St of oil, or producer gas, will permit.

STEAM TUBBINES
219.
-ory
bine
The thermodynamics of the steam turbine is a simpler matter in
than the steam engine. The energy of the adiabatic expansion in the
is converted into kinetic energy by producing motion of the
i
steam
nicies, which issue from the nozzles as jets.
220. Resisted and free expansion. The expansion in the engine is
'ned "iserfectly resisted;" in the turbine it is "free."
k 13 done upon the steam itself during the expansion,Therefore all the
producing high

747
Sec. 10-221 POWER PLANTS
velocity of the steam particles; these particles in turn impinge upon curved
vanea or buckets, which change the direction of flow of the jets in such a man-
ner as to produce a force in the direction of rotation of the wheel.
221. The losses are wholly different from those in the engine; there is nc
initialcondensation, because the parts assume the temperatures of the mov-
ing steam, instead of being alternately heated and cooled, and radiation is sc
sUght as to be negUgible (0.1 per cent, or less).
222. Friction. The only true mechanical friction is in the bearings and
governor mechanism and is usually under 2.5 per cent, in small turbines
and under 1 per cent, for larger sizes. The principal loss is steam friction
which is made up of (a) nozzle friction, (b) blade friction, (c) eddies in th«
flow and (d) windage of the discs or drums revolving in steam. There ii
some leakage, 'but generally less than in the engine. The velocity of tht
exhaust steam is also a source of direct loss.
223. The flow of gas or vapor through a nozzle is a phenomenon divis
Sble into two classes —
(a) above, and (b) below, the critical pressure. Whei
difference of pressure is maintained across an orifice, steam will flow witl
increasing velocity and in increasing quantity as the pressure different
increases up to that point at which
Pi
p =0.58, for steam, (38

where Pi = initialpressure in lb. per sq. in. absolute and P2 = back pressure ii

lb. per sq. in. absolute.

824. The critical pressure is,
P2 = 0.58Pi. (39
This is true for all initial pressures. The corresponding velocity vari«
from 1,300 to 1,500 ft. per sec, and is found practically to coincide with tt|
velocity of sound in steam at the pressure P2 = 0.58Pi. -i

225. Eflect of reducing back-pressure. Up to this point (Par. ili

the stream issues from the orifice in parallel lines; but if the value of PiT
reduced below 0.58Pi, no further increase in velocity or quantity can I
obtained, at the orifice, but there is further acceleration beyond the orift
and the stream flows out laterally as well as forward. Heavy accoui*
vibrations occur, and the efficiency of conversion decreases. To corr
this, a conical or conoidal section is added to the orifice, diverging in the dill
tion of flow, and the further pressure drop is permitted to take place in tj
flaring or trumpet-like exit. The De Laval nozzle was the original divergj
type.
j
226. The exit area should be that suited to the velocity and volui
resulting from the total heat drop from the pressure Pi to Pa; but the th«
always remains of that size required for a pressure of O.68P1, and a velow
of about 1,300 to 1,500 ft. per sec. The theoretical velocities are not realise
due to friction of the steam in the nozzle.
227. The velocity efficiency of a convergent nozzle (orifices wij
rounded entrance) varies from 98 per cent, at low velocities down to 95 p
cent, at 1,300 to 1,400 ft. per sec. The velocity efficiency of a diverge)
nozzle, for expansion beyond the critical pressure, ranges from 94 per oe'
at 1,500 ft. per sec. to 90 per cent, or 85 per cent, at 3,000 ft. per sec.
228. The velocity efficiency of the buckets varies from .about 96 ,

cent, to 98 per cent., for the low velocities used in reaction turbines
than 1,000 ft. per sec), to 84 per cent, or 86 per cent, in impulse turbinesj
velocities of about 2,500 ft. per sec. The second and succeeding rowil
buckets or guides in velocity-compounded turbines have even lower p
ciencies, reaching 84 per cent, at about 1,500 ft. per sec.
229. The velocity obtainable by expansion is expressible by I

where y = velocity at exit of nozzle in ft. per sec, //i = total heat contentll
steam at initial condition, and lit = total heat contents of steam at at
condition. If Ih denotes the heat contents after an adiabatic expansiolv
follows that V is the theoretical value; but //j is always higher than M
because internal friction reduces the quantity of heat removed from the ste^
by the work done.
748
 POWER PLANTS Sec. 10-230

230. Pressure drop. In the impulse turbine, all pressure drop occurs in
stationary nozzles, and there is no difference of pressure across the moving
blades. In the reaction type, about half the pressure drop takes place in the
stationary blades, and the remainder in the running blades; and the latter,
therefore, act also as nozzles. There is an unbalanced force due to this differ-
ence of pressure across the moving blades that must be cared for by balanc-
ing devices.
231. There are two basic types of turbines: impulse and reaction.
Neither of the two is really pure impulse or pure reaction, but the work done
by impulse predominates in the impulse type, and the work by reaction in the
reaction type. The simple impulse wheel is only employed in the single-stage
de Laval type; velocity compounding and pressure compounding are
employed in all other impulse types. Compounding becomes a necessity,
to secure reasonable rotative speeds.

Fia. 25. —Elemental turbine types. •

232. Ttie steam velocity in a single expansion from 150 lb. gage
a 28-in. vacuum would be about 3,100 ft. per sec. For best efficiency the
lade velocity should be a little less than half the steam velocity, or in this
I
ase 1,500 ft. per sec, which results in centrifugal stresses in the disc much in
xcess of suitable stresses for commercial materials. If the wheel is run
ower, the exit velocity of the issuing steam is increased, reducing the
Bciency.
233. In velocity compounding the exit velocity from the first wheel is
ceived in a series of guide blades and redirected to a second wheel, so that
1
ore of the energy is removed, without unreasonable wheel velocities (300 to
!5 ft. per sec).
' 234. Pressure compounding is the division of the pressure drop into
ivo or more stages, which are essentially de Laval single-stage nozzles and
heels in series. Fig. 25 shows these types with characteristic figures.
236. The reaction turbine for best efficiency runs at V2 or 1.414 times
•c peripheral speed of the impulse turbine for the same pressure drop. It
never built single-stage, but always pressure-stage compound.
236. Principal types. The de Laval is the original single-stage impulse
(
pf; the velocity-compounded type (generally also combined with few-stage
essure compounding as well) is usually known as the Curtis; the pressure-
i'-re type (pure), as the Rateau; and the reaction type, as the Parsons.

From " The Steam Turbine " by J. A. Moyer.

749
Sec. 10-237 POWER PLANTfi
2S7. The bladinsr of the three principal types. Parsons, Curtis an<
Rateau, is shown in Figs. 26, 27, and 28.
238. Hybrid types have lately proved the most efficient, or cheaper t(
build. In moderate sizoa the Parsons turbine is built with a Curtis 2-whee
velocity stage for the high-pressure stage; the advantage is a large pressun
drop in a small nozzle chamber, avoiding high pressure in the casing, shorten

FiQ. 27. —Curtis turbine.

ing and cheapening the construction, and eliminating the short high-pre
reaction blading, which is the least efficient.
339. The Curtis-Rateau type consists of a 2-wheel Curtis element {<
the high-pressure stage, followed by 6 to 12 Uateau pressure stages. Itjk<
the same advantage with regard to keeping the high-pressure out of tl
casing.

750
POWER PLAXTS
Sec. 10-240 POWER plants
240. Velocity staging is the least efficient method of compounding, but is
chiefly used for small turbines, as it lowers the cost. More than two wheels
per stage are very seldom used except in marine turbines.
241. Vertical and horizontal types. There is very little difference in
principal features between vertical and horizontal turbines. The only com-
panies that have built large vertical machines are the AUgemeine Elek-
tricitats Gesellschaft and the General Electric Company. Small vertical
turbines, in small sizes, are sometimes built for use all with vertical fans and
pumps, using a ball step bearing for support. The large machines are all
provided with oil or water high-pressure step bearings, requiring from 050 to
1,000 lb. per sq. in. pressure, and special pumps. The A. E. G. Co., has dis-
continued building this type for several years, and since the recent increase
in rotative speeds, the G. E. Co. has also discontinued it. The Parsons
turbine has never been built in anything but the horizontal type.
242. Pressure types. High-pressure turbines are those which operate
on full boiler pressure and exhaust to atmosphere or vacuum. Low-pres-
sure turbines are those operating on atmospheric pressure, or a few lb. above
it, and exhausting into a vacuum. They are usually connected to the
exhaust of non-condensing reciprocating engines, or other source of low-pres-
sure steam (except direct from boilers). Mixed-pressure turbines are
those designed to run normally on low-pressure steam, but equipped with
high-pressure stages which may receive steam from the boilers direct, if the
low-pressure supply fails to equal the demands of the turbine load. This
type is characterized by a low-pressure end designed to handle a much larger
quantity of steam than the high-pressure end.
243. Bleeder turbines are those in which provision is made for taking
steam from a stage of the machine normally at atmospheric pressure, or a
few lb. above, to be used for heating, or industrial service. The remainder
not sb used continues through the low-pressure section to the condenser.
This type is characterized by a large high-pressure section, as compared to the
low-pressure end.
244. The principal features of turbine design relate to balance, leak-
age, and resistance to high centrifugal stresses. Wheels for small impulse
turbines are normally operated at peripheral speeds of 250 to 350 ft. per sec,
and 400 to 550 ft. per sec. for large machines, using ordinary high-grade
open-hearth steels. For higher speeds up to 725 ft. per sec. chrome-nickel
forged steels are used. Reaction turbines are usually designed for much
lower speeds, 150 to 350 ft. per sec, or 400 ft. for very large units, and are
generally of drum construction, of open-hearth steel.
245. Speed limitations of open-hearth steel. Theoretically, a
properly designed disc can be run at from 125 to 160 per cent, of the safe
speed of a drum with corresponding blading. In practice, however, tht
difference due to computable tensile stresses from blades and centrifuga
force is less important than the unknown harmonic stresses duo to blad(
and disc vibration, and the drum type is better than the disc type in thi;
respect.
246. Casings for superheated steam above the 50-lb. pressure scctiot
of the turbine are made of cast steel; below this, of cast iron; and for al
pressures in saturated steam, of cast iron. The casings of most horizonta
turbines are split, so that lifting the upper half exposes the whole interior
With one more lift, the whole rotor may be removed, facilitating repair
to all parts. The vertical turbines must be opened in several sections am
taken apart wheel by wheel.
247. Olands to prevent leakage from stage to stage, or from tin in
terior of the turbine to the outside air, are nearly always some for mm
labyrinth, with no actual contacts, or at most very light contact on l!oa;
ing rings. The high speeds and lack of lubrication forbid any form-i <

soft packing except for very small units. The function of the labyrinth i

to interpose a large number of constricted passages to the flow of atfnn j

The Parsons turbine uses a water-sealed gland between the end of the i'a>in f

and the outer air. These constrictions usually measure from 0.003 in
''

<

0.035 in., depending on the size of shaft or dummy ring, and the i)res-iut
difference. The clearance is selected according to the vibration at the poii
of application and is often made a function of the diameter.

752
 POWER PLANTS Sec. 10-248

S48. The principal bl&de f asteningra consist of the dovetail for impulse
elements, in all sorts of forms from square T-heads to bulb heads with all
corners eliminated; the reaction blading of Parsons make is a caulked type,
depending upon some distortion and friction for the grip. Riveted blading
is used to some extent in small impulse turbines, but has been a failure in
large discs. Fig. 29 shows three sucessful types. • Blade heights vary
from 0.5 in. to 18 in., depending on the size of the machine, and the stage.
Widths range from 0.25 in. to 2 in.

Fig. 29. —Four types of blade fastenings.

549. Pressure stages. In high-pressure Curtis turbines, the usual num-
ber of pressure stages is five to' seven, with two velocity stages in each
pressure stage. In Rateau types, there are about thirteen to twenty-two
pressure stages, with one wheel in each; or one Curtis stage of two velocity
stages may take the place of two or three high-pressure stages. The Parsons
tjrpe has from forty to seventy pressure stages.
550. Turbine rating. Impulse turbines are rated on a basis of cal-
culated flow through the nozzles and known efficiencies of different types of
wheels. Thus a wheel of given size may be of widely varying horse-power
ander different areas of nozzles; the efficiencies also are altered. Reaction
turbines must be designed for the load, and can only be altered in best load
capacity by increasing the initial pressure. Overload is provided for in the
. mpulse types by adding extra nozzles; in the reaction type by by-passing
lome of the high-pressure stages.
251. Measurement of shaft output. The output of the turbine
Tiust be obtained by brake, or electrically; no indicated horse-power exists;
;
n small turbines, throttle governed, the steam-chest pressure bears an ac-
curate relation to the horse-power delivered at any speed, and if the turbine
3 calibrated, it may be used as an indication of the output thereafter. This
3 true because the pressure is a measure of the steam flow, and the steam
low is a measure of the output, for any given turbine efficiency.
252. Lubrication is exceedingly simple. No internal oiling whatever
8 employed; gravity or force feed with copious supply at 15 to 25 lb. pressure
3 general for large units. The speed of rotation causes a dragging of oil
mder the journal, by means of viscosity, so that the journal never rides on
netal. Some turbines actually rise a few thousandths of an inch after
!oming to speed due to increase in the oil film under the journal. Small
urbines are ring-oiled like motors.
253. The actual Ranklne-cycle efficiency ratios obtained in small
ion-condensing turbines vary from 45 per cent, to 50 per cent. for large
iiiitH, from 55 to 65 per cent, for
;

the great majority, up to 80 per cent, as

{
.bout the highest. These figures assume condensing service in each case.
This table gives efficiency ratios and B.t.u. per kw-hr. The latter figure
» obtained from the water rate and the steam conditions.

t B.t.u. per kw-hr. = irx(fli-qj) (41)

753
Sec. 10-254 POWER PLANTS

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754
 POWER PLAXTS Sec. 10-254

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Sec. 10-255 POWER PLANTS
Where Hi = heat contents of steam supplied to turbine, q = heat of the liquid
in condensate and W= water rate in lb. per kw-hr.
The thermal efficiency is the product of the efficiency ratio and the thermal
efficiency of the llankine cycle (adiabatic expansion).

266. Eflaciency ratios. Figs. 30, 31, and 32 give characteristic efficiency
ratios for small and large units. It is found that the Willans line (total

40

*.30
•s
(3 20

WlO
 POWER PLANTS Sec. 10-258

258. The efficiency losses may be subdivided into (a) nozzle friction,
6 to 2S per cent.; (b) blade friction, 6 to 30 per cent, (c) windage, 3 to 15
per cent.; (d) unused exit velocity, 3 to 5 per cent.; (e) leakage 2 to 10

Ratio Condensing Turjaines

—Efficiency
G-100°Fahr-Superheat
175 lb.
Higher
28.5
'

Max.
— Min::
Efficiencies 5 ^
"]
Includes Gen. Losses
4 a Lower

— Upjto 60000 iCw. UnitsrGain

Approx. 2^'from 20000
is

6 8 10 12 14 16 18 20
Thousand Kw. Max. Rating
Fig. 32.

)er cent. (f ) mechanical losses, 1 per

;
cent. As all the steam losses in the
ligh-pressure stages reappear in the steam as unused heat, the available heat
irop is increased by translation of the expansion lines to higher entropies,
;s shown by the Mollier diagram, * given in Fig. 22, and hence the whole

1.16
1.14 ,

1.12
1.10
l.(

1.06
1.M
1.02
LOO
.98
.96

.94
.92
.90
Sec. 10-260 POWER PLANTS
The shaft horse-power or brake horse-power is from 3 to 15 per cent, less
than the calculated diagram horse-power (corresponding to i.h.p. in the
engine). The usual friction losses are generally less than one-half those of
steam engines of the same rating. Mechanical friction in the turbine is
confined to bearings and governor drive; it is usually under 2 per cent., and
in large machines is less than 1.0 per cent. Internal or steam friction ij
caused by imperfect shape of blades, and windage of the discs or drums.
260. Pressure correction, for variations in steam pressure from guar-
anteed or desired conditions, is given in Fig. 33 and 34 for high-pressure
and low-pressure turbines. The correction is the same for all types.
261. Governors for turbine speed regulation are always of the cen-
trifugal type; the inertia governor cannot be employed, because there car
be no sudden angular accelerations. The centrifugal governor can be made
nearly isochronous; generally, however, there is a slight decrease in speed as
load increases.
262. Throttling governors. For all smallturbines (impulse type) and
some large makes, the plain throttling governor is employed, simply controll-
ing the admission pressure at the steam chest or first stage. The old Parsons
governor for reaction turbines admitted steam at full pressure, in shorl
pufTs, lengthening the period the valve was open as the load increased
Many of the Curtis types are governed by multiple-nozzle control, openind
and closing individual nozzles, from to 16 in number, and thus controlling
the quantity of steam to the first stage only.
263. Parsons governor. In the Parsons machine, the governor not onlj
controls the primary throttle, but also a secondary valve admitting live
steam in one-sixth to one-fourth the total number of stages, further down the
turbine. This virtually cuts out of service the by-passed rows, and converts
the turbine into one of fewer stages, but in eflfect having larger blade dimen-
sions, and not as economical. The best load for this type is that carried just
before the opening of the secondary valve.
264. Reduction gears have recently come into greater use, than wsf
formerly made of them. The de Laval turbine has used them successfully
for 20 years, at enormous relative speeds. The type developed by the
Westinghouse Machine Company from the Melville- IMacalpine gear has £
floating hydraulic frame for aligning the gears. All the other types, includinf
the Falk, Fawcus, Parsons, etc., use solid bearings and connections. All types
employ the double helical gear. By this means the turbine speed may be
kept high, for economy both in cost and steam, and the driven apparatus
may be operated at comparatively low speed. Direct-current generators
fans, and centrifugal pumps for large volume and low speed, may thus be
successfully combineel with the turbine with good economy.
266. Turbine specifications should cover the following items: (a]
Number of units and location; character of building, (b) Service, and at
tachment to-driven apparatus (direct, flexible coupling, reductjon gear, etc.]
(c) Speed, steam anel back pressure conditions, (d) Capacity, overload
electric system data, (e) Regulation, variation of speed under change ol
load, (f) Noise, vibration, (g) Tests and inspection, (h) Mechanica
details of connection to driven apparatus, (i) Type and steam system, H. P.

L. P., bleeder mixeel pressure, giving quantities for L. P., or bleeeiing steam
(j) Materials —
casing, wheels, nozzles, blades, shaft,
(m) Foundations, (n) Oiling, (o)
(k) Piping con-
Auxiliary appa
nections. (1) Bearings,
ratus — pumps, relays, step-bearing pumps (for vertical turbines.) (p]
oil
(q) Gages and miscellaneous equipment.
Painting and lagging,
266. Turbine supports should always be carefully designed to preven'
distortion of the parts; stiffness of the supports is usually very desiirable
but great mass is unnecessary; many reaction turbines of large size Mi
running on foundations entirely of steelwork, which is low in mass for tin
strength and stififness.

267. auxiliaries required for horizontal turbines consist only o

The
an oil pump for large self-contained units: no auxiliaries are needed lo
small units.
268. The auxiliaries for vertical units include in addition to the <>

pump, step-bearing pumps for oil or water, capable of handling pressuri

758
 JPOWER PLANTS Sec. 10-269

f 500 to 1,000 lb. per sq. in. (varying with the size of the main unit). These
tep-bearing pumps, with the piping, are generally in duplicate. I order
steady the oil supply, a frictional resistance called a bafiSer is employed
etween pump and step bearing; and to remove pulsations of pressure and
rovide a small reservoir, accumulators of the elevator type are also
jquired.

80 400
76 380
72 360
68 340
64 £320
S 60 =3 300
^56-3 280
5 52 Q 260
fi48o240
fe44g220
w 40-^200
7,36 -g 180
§.32 o 160
"28<-' 140
§24 "3120
O2O0IOO
16H 80
12 60
8
4
40
20
'- '* lyj t,^ X4
Maximum Hating,
iU iO
1000
AW
Kw,
—Steam
IV

j^ta. 35. turbines. Cost per kw. vs capacity. Total cost vs.
[1 capacity (1920).
) Cycles, maximum
24 hr. rating, 50 deg. Cent, rise; power factor, 80 "per
cent.; pressure 175 lb.; superheat, 100 deg. Fahr.; vacuum, 28.5 in.

4800

4000

33200

C
H a2400

O1600

800

400
Sec. 10-270 POWER PLANTS
270. The operation of the steam turbine is remarkable for its 8iinpli(
ity; one oiler can attend to two or three units (on the engine-room flooi
aggregating as much as 50,000 or 80,000 kw. But with engines, onl
3,000 or 4,000 kw. can be cared for by one man; and in many cases muc
less. The turbine has a maintenance cost but one-fifth as great as that (

the reciprocating engine approximately. There are very few articulate

parts in the turbine; its continuous operation is therefore much more reliabl
and periods of two to four weeks continuous operation are common. Inspec
tions made once a year frequently show no repairs or adjustments to h
necessary, and the turbine is continued in service. With large recipr<
eating engines, both inspections and adjustments are sometimes necessar
every 24 hr.
271. The general method of starting turbines with steam-seale
glands is to establish a vacuum on the condenser with the dry-vacuui
pump, start the circulating water, and "crack" the throttle in order to sen
steam through the turbine for warming, without turning the spindle. Aft«
the proper time allowance (5 to 15 min.) the turbine may be brought t
speed and placed under load.
272. In starting a turbine with water-sealed glands, it is usu:
practice to start the turbine non-condensing until up to sufficient speed t
seal the glands, then establish the vacuum on the condenser and apply th
load.
273. At the present time the turbine is practically supreme in larg
central stations, as a heat-operated prime mover. The hydraulic static
islimited to certain localities, while the large gas-engine plant is so unreliabl
as to be out of the question. For small and moderate-sized plants th
internal-combustion engine is on a competing basis, although its reliabilit
has never equalled that of the turbine.
. 274. The field for small steam turbines is readily increasing, particu
larly since centrifugal boiler-feed pumps, circulating-water pumps, fani
blowers, etc., are successfully designed for turbine speeds, with good effi
ciencies. The small amount of attention required by the turbine, its reliabilit
and low maintenance are generally more than sufficient to overbalance
slight inferiority to the steam engine in economy. Since the item of fue
economy is only one of the factors in operating cost, this resul t is naturf
and the use of the turbine is bound to increase. There is yet much to im
prove in the turbine, whereas the reciprocating engine has been at a virtue
standstill in development for 10 years past.

CONDENSING EQUIPMENT
276. Thermodynamics of condensers. The heat given up by tb
condensing steam must equal the heat received by the circulating water
In jet or barometric condensers, the steam and water mix; no differenc
between the temperature corresponding to the vacuum and the temperatui
of the discharge water need exist. The surface condenser requires son
difference of temperature between the steam and the circulating water ;

all times, or no heat flow from steam to water can take place.

276. Removal of air. The air present in the condensate is chief

drawn in by leakagfe at the joints. This air, being non-condensible, must
_
1

removed by segregation and pumping.

277. The volume of condensate water is practically negligible con
pared with the steam volume at the same pressure. The work in ft-ll
made available by the condenser is the steam volume multiplied l>v t!
pressure difference in lb. per sq. ft. existing between the atmosphere -au-I tl
interior of the condenser; the work required to produce this effect, is mire
the product of the number of cu. ft. of condensate and the same piis8U
difference. At 28 in. vacuum the ratio of these two is 21,000 to 1. To t!
condensate pump work must be added the work of the circulatini
water pump (chiefly a friction loss) and the work of the dry-vacuui
pump which removes the air.
278. The principal condenser types are: (a) jet; (b) barometric; (

eductor or siphon; (d) rotary jet; and (e) surface. These are described
Par. 279 to 283.

760
 POWER PLANTS Sec. 10-279

279. The jet condenser consists of a cast-iron shell into which the
thaust pipe is led, having the circulating water sprayed through the cham-
er in jets. The steam condenses and mingles with the jets, and is pumped
ut of the bottom of the shell. The baxometric condenser is a jet
con-
enser set higher than 34 ft. above the level of the discharge well or tunnel;
le water therefore runs away by gravity, but must be pumped in, due to
slight friction loss and velocity head, the vacuum assisting the circulating
,ump.
880. In the eductor or siphon type, the injection water is pumped in
nder 25 to 30 lb. pressure, and requires sufficient velocity to carry out not
aly its own mass but the condensed steam and entrained air as well, by
linetic energy. No vacuum pumps are required.
'
281. The rotaxy jet types —
originally developed by Le Blanc— consist
i' a centrifugal impeller throwing segments of water into a nozile, in such
shion as to form water pistons, which trap and condense the steam, and
fash before them the air. This type is also used as a dry- vacuum pump.
11 the above types (Par. 279 to 281) are derivatives of
the true jet condenser.
The surface condenser consists of a cast-iron shell with two heads
282.
water boxes into one of which the circulating water passes. These two
)xes are connected by a large number of small brass tubes, which allow the
rculating water to traverse the main shell without contact with the steam;
le latter is fed into the shell around the tubes. The circulating water passes
I
the second box, which may lead to the discharge or redirect the water
ick to another section of the first box by way of another nest of tubes.
the first type is used it is called single pass if the second, two pass ;
;

id so on, with three or four passes in some few cases. The cold water
issing through the tubes condenses the steam by conduction, and the con-
nsate trickles down to the bottom of the shell, there to be pumped out.
tie air, which is always heavier than steam at the same temperature, also
Uects at the bottom and must be pumped out, preferably by another pump.
283. Atmospheric condensers consist of a form of surface condenser in
liich the coohng medium is a mixture of air blast and water spray. The air
kes up some of the spray, becoming cooled thereby, and acts as a cooling
edium for the steam. High vacuum is not to be obtained with this type,
he chief feature is economy of circulating water, which may be in the ratio
1 lb. of water per lb. of steam, or sUghtly less, since the whole latent heat
evaporation (of the water spray) as well as the heat of the liquid is avail-
le for cooling.
284. Quantity of circulating water required. In the jet or ordinary
rface types, the circulating water must be at least 25 to 30 times the
dght of the steam condensed. In the jet condenser, the condensate mixes
th the circulating water, and, if the latter is dirty, is necessarily lost. The
irface condenser keeps the condensate separate from the circulating water,
" that it is available for re-use in the boilers, a pure distilled water (Par.
17 and 138).

186. The proportions of jet condensers are relatively unimportant, the

ign merely providing for adequate mixture of water and steam. The
therefore need only be large enough to take the exhaust and water
lell

nnections. The volume of a jet condenser varies from 0.5 to 2.5 tirnes the
llume of the low-pressure cylinder volume of a reciprocating engine; in
*Ie eductor types, the volume is somewhat less.
286. Surface condensers are limited in capacity by the rate of heat
msfer. For average practice, 300 to 350 B.t.u. per sq. ft. per degree mean
nperature difference per hour can be allowed. It follows from this as-
rnption that

A=PrX^-f3^ (42)

lere A = area
in sq. ft. of tube surface,W => lb. of steam per hour from
laust, 7^2 = total heat per lb. of exhaust, q% = heat of'' the liquid per lb.
condensate temperature). Hi — qz = 1,000 to 1,050 for most cases,
= transmission coefficient = 300 to 350 B.t.u. per hour, per sq. ft., per
i;ree mean temp, difference (Fig. 37), and tm = mean temperature differ-

761
Sec. i6-2$7 POWEii PLAjYTS

tn is:
 POWER PLANTf^ Sec. 10-291

matter is contained, the work of the dry air pump will be greatly increased.
Dirty water in surface condensers causes slime deposits on the tubes, if
containing grease and sewage; or it incrusts the tubes with scale, if very
hard. In either case, periodic cleaning is necessary, as both deposits lower
the efficiency of heat transmission.
291. Screens are usually made of iron mesh or bars, with openings the
same size as condenser tubes or J in. smaller; these screens are set in frames,
and operate in slides for cleaning purposes. Small metal screens enclosed in
cast-iron boxes in the suction pipe are employed for small sizes and are then
usually called "fish-traps." A later development is the use of moving self-
cleaning screens, either arranged drum fasliion like a stone screen, or like
a chain grate set on edge. The velocity through screens should not
exceed 4 to 5 ft. per sec.
292. Pumps. Circulating-water pumps in modern plants are always
centrifugal or propeller types, especially since the advance of the small
steam turbine. Wet vacuum pumps handle both condensate and non-
icondensible gases. They are not used to any extent at present. Dry
Evacuum pumps handle non-condensible gases only. Condensate or hot-
iwell pumps handle the condensate only. The separate pumps are much
more efficient than the combined wet-vacuum pump. The hot well-pump
Jis usually a one-stage or two-stage centrifugal. The dry-vacuum pump may
be a reciprocating compressor specially designed for tightness and small
r-learance, or a hydraulic device using a form of centrifugal pump and water
liets to entrain the air, such as the Le Blanc pump.

293. Power required for auxiliaries. The circulating pump, if a

"eciprocating dry-vacuum pump is used, requires 85 per cfent. to 90 per cent.
jf the total h.p. for condenser auxiliaries; the condensate and dry-vacuum
oumps, 5 to 7 per cent. each. The total h.p. at 27 in. to 28 in. vacuum is
, ibout 2 to 2 J per cent, of the main unit, for reciprocating main engine; 3 to
;
J.5 per cent, at 28 to 29 in. vacuum for turbine plants.

I 294. The steam demand

of all condenser auxiliaries, using engine-
iriven circulator,3 to 5 per cent, of the total; for direct turbine-driven
is
c'irculator, 5 to for latest type geared turbine-driven circulator,
9 per cent. ;

to 6 per cent.
I
The water rate of turbines used for hot-well pumps is 50 to
iO lb. per b.h.p.-hr.; for low-speed direct-connected turbines for circu-
lators, 35 to 45 lb. for geared high-speed turbines, 29 to 35 lb.
;

i 296. Recent High Vacuum Results with Large Surface Condensers

Plant
Sec. 10-296 POWER PLANTfi

296. Hydraulic dry-vacuum pumps take from 6 to 1 2 times as much

power as the reciprocating types; but this is relatively unimportant if the
exhaust steam is usable in the feed-water heaters.
 POWER PLANTS Sec. 10-298

598. Cooling towers are employed where condensing water cannot be

ibtained in sufficient quantity for complete rejection of discharge. The
irculating water is broken up into spray or thin sheets and falls through a
urrent of air. The air in becoming warmer, takes up heat from the water;
aporation also takes place and tends to saturate the air. This evapora-
lon is from 0.80 to 0.95 lb. per lb. of steam exhaust to the Condensers, ex-
lusive of the spray loss in water actually carried away mechanically in the
ir current. The distance between spray outlets and tank under the tower
I usually about 25 ft. so that this head, plus friction in additional piping,
lust be added to the total pump head. The towers are 50 ft. to 80 ft. high
jr natural draft; but may be snorter if a forced draft fan is used, provided
he rain from the tower is not objectionable. The ground area required is
sq. ft. per 20 lb. steam condensed per hr. approximately The circulating
ater required is 60 gal. per sq. ft. of ground area, cooled from 95 deg. to
5 deg., which is average performance. The heat transmission to air per
1. ft. of cooling surface in the lattice work or screens runs from 350 to 850
.t.u. per hr. The circulating water required is 25 to 30 lb. per sq. ft. per
r. The work of the circulating water pump is practically double that of the
_

rdinary installation without towers, or 6 to 8 per cent, of the h.p. of the main
nit. If forced draft is used, the fan requires 0.3 per cent, to 0.5 per cent.
'
the h.p. of the main unit.
599. The operation of condensing equipment becomes very simple
ith turbine-driven auxiliaries, as these requirealmost no attention. De-
snding on the water, condenser tubes should be cleaned from once a week
once a month; brushing the tubes may be necessary. All joints should
very carefully made and maintained tight; shellacing or painting is of
eat assistance in this respect. The ferrules of the tube ends need taking
} from time to time, as the packing shrinks, or as the vibration loosens
le ferrules.
800. Starting. The circulator should always be started first, so as to
»p the tubes cool at all times when steam may come in contact with
Lem; as soon as the circulator is running, the main unit may be started,
id the hot-well pump. Whenever the vacuum is desired, the vacuum
eaker valve may be closed and the dry-vacuum pump started.
SOI. Shutting down: shut oS the main unit, break the vacuum with
e breaker-valve, shut down the dry air-pump, then the hot-well pump,
d lastly, the circulating water pump.
801; The piping should be so arranged that air can be removed from
a highest point of the circulating water system; otherwise, air might
cumulate and prevent water from entering part of the tubes, besides
making the siphon. The discharge pipe should be submerged in the
roharge tunnel or well, so as to have an inverted siphon, not to exceed 25
head; this reduces the circulating pump head to friction and velocity
ly.

808. The cost of condensing equipment complete, including pumps,

rometric type is from $0.35 to $0.55 per lb., average $0.45; cost per kw.
main unit, $1.95 to $4.00, average $2.30 for moderate and large size units.
ir.very small units the cost may go up to $8.00 or $10.00 per kw. Jet
ndensers cost from $2.70 to $4.00 per kw., average $3.45, for moderate
d large sizes; $6.00 to $9.00 for small units. The figures assume 26 in.
27 in. vacuum and are based on normal kw. rating. Surface condensers,
in. to 29 in. vacuum, cost per kw. of main unit from $4.80 to $8.90 average
50; this is based on maximum rating of units and applies to large size?.
lall surface condensers cost from $7.50 to $20.00 per kw. Cooling towers,
50 to $12.00, average $9.00 per kw. rating of units attached (1920).

FEED- WATER HEATERS

104. The heat transfer in closed feed-water heaters is exactly the
ne as in surface condensers; that in open heaters, the same as in jet
idensers, as covered in Par. 286 to 289. The feed-water heater is merely
i
jondenser operated at atmospheric pressure, with boiler feed-water for
idensing water.
108. The open heater is much like a jet condenser in general arrange-
tnt, but is usually a rectangular box, or cylindrical tank large enough to

765
 8 . C
((

Sec. 10-306 POWER PLAXTS

provide a little storage capacity for feed water, aa the boiler feed pumps
usually draw
direct from the heater.
306. The
closed heater is usually built much like a surface condcnsei
and is then known as the straight-tube type. In some makes the tubes
are corrugated, in others coiled, or with a single U-bend; or an expansion
joint is placed in the shell; in these cases the tubes are expanded fast in the
tube sheets. In a few types, a floating head is used with straight tubes.
307. The water velocities employed in closed feed-water heaters
are usually slower than for surface condenser practice, so that the value of
the transmission coefficient is reduced. An average figure is 300 B.t.u.
per deg. mean temp, difference per sq. ft. per hr.
308. The mean temperature difference given by the arithmetic formula
is close enough.

where <« = temperature of exhaust steam at exhaust pressure (usually 212

to 214 deg.), <2 = temperature of heater discharge water, and <i = temperature
of heater inlet water.
309. Temperature rise. If a given quantity of exhaust steam is avail-
able, the resulting temperature rise in a closed heater may be found as
follows:

(<2 - <i) = z-^ (49)

where Tr = feed water in per hr., u). = exhaust steam in lb. per hr.,
lb.
/?. = total heat of exhaust steam per lb. (usually 1,150 B.t.u.), 93 = heat of the
liquid (condensed steam), at the temperature leaving the heater (tz), usually
212 deg., h = temperature of feed water at heater inlet, and (2 = temperature
of feed water at heater discharge. For all ordinary cases, //» — q3 = 970
tt cannot be higher than 208 deg. fahr., if exhaust steam at 212 deg. is em-
ployed. If the value of h, as found above, exceeds this, it indicates that then
is excess exhaust steam. Eq. 56 can be transposed to solve for w,, if th(
amount of exhaust steam to heat the feed water to 208 deg. is desired.
310. Temperatures Obtainable in Open Feed Water Heater
(Temperature of steam, 212 degrees F.)
Initial Temperature of Feed Water, Degrees F.

40 50 60 70 ! 80 90 100 110 120 130

60, 69.9 89. 5 94, 4 109 2 119, 138.7

128.8 '
148.5
69. 79.6 90 1 108, 8118 6 128, 3 138.0 147.8 157.5
79. 89.1 108, 51118. 1 127 8 137, 4 147.1 156.7 166.4
89. 98 5 108. 117 7ll27, 2 136 8;i46, 4 155.9 165.5 175.1
98. 3 107 .'71117 126, 71136, 2 145 7 155, 2 164.7 174.2 183.6
107. 4 116.8:126 135, 6 145, 154 4:163, 8 173.2 182.5 192.1
116. 4: 125. 7i 135 144 4 153, 7 163 0172 4181. 191.0 200.. 3
125. 2: 134. 5 143 153 21171 5 180
162, 7 190.0 199.2 208. S
101133 3;143.ljl52 161 4|170,6!l79 8!189 198.1 207 3 . 212.
U 142 51151. 6il60 169 7 178 91188 21197 0,206.2 212.0* 212.
12 150 91159.9 168 177 9'l87 196 205 0212.0* 212.0* 212.

311. The surface required in closed heaters is given by

where f/ = 300 and A =area of tube surface in sq. ft.; the other symbols
as given in Par. 309.
312. Heaters are rated in h.p. One h.p. equals 30 lb. of exhaust stc
per hr. This unit ought to be abandoned and million B.t.u. transfer capai
used instead.
* All of the steam not condensed.

766
J
 POWER PLANTS Sec. 10-313

313. The volume required in open heaters is given by

F = :^ (51)
a
where V = volume in cu. ft., a = 2.15 for muddy water, a = 6 for slightly muddy
water, and o = 8 for clean water.
314. Operation. The operation of closed heaters is somewhat more
expensive than open heaters; the tube packings require attention and the
tubes must be cleaned of scale, if this forms. In heaters with corrugated
or bent tubes, cleaning is practically impossible. The advantage of the closed
heater is the elimination of oil from the feed water, but with the use of tur-
bine-driven auxiUaries, this advantage disappears, as there is no oil in the
exhaust steam. In open heaters, the cast-iron trays over which the feed
water spills, are readily removable for cleaning. If an open heater is used
on oily exhaust, some means of oil elimination must be used, sometimes
supplemented by a filter in the body of the heater.

2400

2200

2000

1800

1 1600
^1400
P
^-1200

^1000
800

600
400

200
Sec. 10-320 POWER PLANTS
320. The temperature rise is given by
y{Ti-h)
X= -

5w+ GCv (52)

9.1 + 2GC ~

where X = rise in temperature of feed (deg. Fahr.) Ti = temperature fiue gasea

,

entering economizer, ti = temperature feed water entering economizer,

to= Ib. of feed water per boiler h.p. per hr., G = lb. flue gas per lb. of combus-
C = lb. of coal per boiler h.p. per hr., and y = sq. ft. of econo-
tible (average, 20),
mizer surface per boiler h.p. A rough method, if the temperature drop of
flue gases is known, is to take 0.5 deg. rise in feed water for every deg. drop
in flue gases.
321. The feed waterenters the bottom headers by a connecting main
and is from the top headers by another main, placed at the op-
collected
posite end form equal parallel paths.
of the headers, so that the tubes
322. The draft loss through economizers varies with the velocity of the
gases, as in the boiler. At normal full load on the connected boilers the
loss is from 0.25 in. to 0.40 in. (of water), increasing to 0.6 in. or 0.7 in. at
heavy overloads. In fact, as normally designed and installed, forcing
the boilers beyond 300 per cent, of rating is impossible without by-passing
the economizer. Induced draft must be employed if the economizer is to
be used at high ratings, because the draft losses limit the maximum capacity
of the boilers obtainable with natural draft. If the temperature of gases is
reduced from 550 deg. to 350 deg., the loss of draft is approximately 25 per
cent.
323. The capacity rating of economizers is based on circulating
6.25 gal. of feed water per hr. per tube, and upon a heat transmission coefiB-
cient of 2.7 to 3 B.t.u.

324. Economizer Dimensions and Capacities

No. of
tubes
 POWER PLANTS SeC. 10-327

bottom of the economizer chamber. The first item is small, as the drive is
usually by motor and the mechanism is very slow moving; the second
depends on the feed water and should occur with less frequency than in the
boilers; the last depends on the rate of driving and the coal, varying from
once a month to once in four months.
327. The cost of economizers averages about $15.00 per tube, installed.
The tubes are usually 4 J in. by 10 f t. cast iron is employed throughout, since
;

at the low rate of heat interchange, any other material would be too ex-
pensive. From the point of view of increased economy and the cost of
securing it, the economizer is the least desirable of all auxiliaries. In many
cases it cannot be made to pay; this is generally true if it saves less than
5 per cent. If it saves over 10 per cent., there is reason to conclude that the
rest of the plant is being very badly operated.

PUMPS
The work done by a pump is given by
328.
W = wh (53)
where TF = ft.-lb. of work per min. performed in lifting the water, to = lb.
jf water pumped per min. and h = sum of suction lift, discharge head and
Velocity head gained in the pump inlet and outlet, in ft. The water h.p.
•8 equal to wh divided by 33,000. The water pressure, or suction, in lb.
iper sq. in. divided by 0.434 equals the head in ft. at the discharge, or
!;he suction, respectively, for water at 62 deg. fahr. The velocity head is
=-
r2
A. (54)
^0
»here » = velocity of water in ft. per sec. and 2(? = 64.35. For most cases,
.he velocity head in suction and discharge pipes may be disregarded, as it
8 not over 8 ft. per sec.

829. The duty is expressed

_ /ft .-lb.
-lb. of work done on water
wate r \\
D t
,

\^ weight of dry steam / '

/ft.-lb. of work done on water n

The
""^ - (
°-
To J".Tu.^;—- 9 '°°°^°°°
latter definition of duty is more satisfactory than the first; duty
<=<»

always includes the efficiency of the steam end, as well as the water end.
830. Pumps are broadly classed in four types— reciprocating, cen-
rifugal and turbine, rotary, and jet pumps. The reciprocating type can
e subdivided into direct-acting, flywheel and power pumps. The dlrect-
i^cting type has steam and water cylinders on a common piston rod, and no
ly wheel; the valve mechanism for the steam cylinder is actuated direct
rom the rod by tappets. This type may be single-cylinder, or duplex,
;.nd the steam cylinders may be simple, compound or triple expansion.
I'he duplex simple pump is the most rugged and reliable of all. Out-
ide-packed plungers are the most desirable, as the packing on the plunger
adjustable while running and the amount of leakage can be seen.
?
Fly-
''heel pumps are similar to the direct-acting type, except that a flywheel
? added and the steam valve is gear driven from the shaft as in a steam engine,
r
umping engines are a development of this type. Power pumps are fitted
."ith one or more cylinders, driven from a crank shaft
and belted or geared
When three cyUnders with cianks at 120 deg. are
o the source of power.
the pump is known as a triplex; this type is very frequently gear-driven
.ised,
Jrom a motor or an internal combustion engine.
'
V Centrifugal pumps are those in which pressure and flow is pro-
uced by a rotating impeller, which gives the water entering it an increase
velocity; this velocity is converted into pressure by a suitable whirlpool
a
hamber or diffuser. The obtainable head is proportional to the square of
;ae peripheral velocity of the impeller; this velocity is
i
subject to practical
•
mitations, so that 150 to 200 ft. head is about the upper limit desirable in
,^
single impeller. For higher heads, such as boiler feeding, the pumps are
''^* j*^°' *^'"®® °'' niore stages, consisting merely of single impellers con-
.
ected in series in a single casing.

769
Sec. 10-332 POWER PLANTS
338. Rotary pumps are very little used in power-station service; the
commonest types are the bi-lobular type, and the gear pump. Neither
has very good efficiency.
333. Screw or propeller pumps, while not strictly centrifugal, create
pressure in the same manner, and arc usually considered in the same class.
334. Jet pum.p8 are covered in Par. 345 to 353.
336. The characteristic curve of a centrifugal pump is necessary
for determining its behavior. The capacity of a reciprocating or a rotary
pump varies directly with the speed and is substantially independent of
the pressure. The usual graphs are between capacity and efficiency, and
capacity and head. Fig. 40 gives results for a 6-in. single-stage pump.
Pumps for similar service, but different sizes, will have about the same
characteristics, the efficiency increasing slightly with the size.

60

CapacllJ In G.P.5I.
 POWER PLANTS Sec. 10-339

(water h.p./indicated h.p.) varies from 0.50 in small pumps to 0.85. The
water rates are very high, both on account of the low speed and the absence
jf expansion.

339. Performance test of boiler feed pump. The following test of

!Conomy of Marsh pumps was made at Armour Institute of Technology;
ize 12X7iX12 in.; steam actuated valve gear; initial pressure 100 lb. gage;
)ack pressure 2 lb. gage.

Number
of strokes
Sec. 10-344 POWER PLANTS
344. Operation. The direct-acting simplex or duplex steam pumj
requires almost no attention except occasional packing of glands and lubri
eating. When controlled by a pressure governor, the delivery is suitec
to the demand. It will run on water as well as steam, and little care need b(
taken to supply it with dry steam. The geared triplex type requires mor(
careful attention on account of the additional parts to be lubricated; i
motor-driven, it must be provided with a suitable speed control, or it cannol
be used on variable load. Piston and rotary pumps must always be provided
with relief valves in the discharge, as they are positive in action and wil
produce excessive pressures if the discharge is restricted.
Centrifugal pumps cannot discharge under a higher head than that corre-
sponding to the speed, therefore no relief is needed the reason for using pres-
;

sure governors with turbine-driven centrifugal boiler feed pumps is to reduce

the speed in proportion to the delivery in order to keep up the efficiency
Centrifugal pumps are generally ring oiled and therefore require very littli
attention. The packing of the glands where the shaft leaves the pump casing
is usually water-sealed; for this purpose a clean cool water should be pro-
vided. All centrifugal pumps must be primed before they will operate, and
if no vacuum apparatus is provided, a foot-valve on the suction pipe must bf
used to prevent the water draining out of the pump on shutting down. A
discharge valve must be provided, to be closed when priming, until th«
pump develops pressure.
JBT PUMPS
846. Jet pumps operate by means of the kinetic energy of a rapidly
moving stream of fluid. In those operated by steam, a jet of the high-pres-
sure steam issues into a chamber at approximately atmospheric pressure oi
a little below, and there strikes the supply of water to be pumped. Th«
impact of the steam transfers momentum to the water, which, together with the
condensed steam, is hurled into a second nozzle which converts the kinetic
energy of the mass into pressure and the stream enters the pressure chambei
through a check valve. Since the water pumped must condense the stean
used, it has a limitation in temperature, or the injector will fail to work.
346. Injectors are used for boiler feeding. For low and moderate pres-
sures a single steam tube is used, both for lifting the water and forcing i'
into the boiler. But for heavier pressures and greater flexibiUty in handlini
variable quantities of water, and with wider range of pressure, the double
tube injector is employed. The first jet lifts the water to the second, o
forcing jet.
347. Capacity of Schiitte &
Koerting double-tube boiler-feed In
jectors, in gal. per minute.

Size Steam pressure Size Steam pressure

Si«e
No.
pipe ~ bize
No.
pipe
(in.) 50 1b. 1
100 lb.! 150 lb. (in.) 50 lb. 1
100 lb. 150|b

00 33 48 60
83 101 112 1}
1 112 143 180 li
2 172 210 232 2
278 338 397 10 2
il 398 472 547 11 2-2 i
4 533 622 720 12 2i
5 675 802 922

The weight ranges from 3 to 108 lb.; No. 2 weighs 10 lb. and I*j|'
weighs 20 lb. ;"
348. Ejectors are either single-tube jet pumps, or direct-pressure pi
in which steam, or air, is admitted directly into a chamber filled by grtt^j
with the Uquid to be pumped. The pressure closes the inlet check valve Ju
forces the water or other liquid out; when the chamber is emptied, a ^ fl^
therein drops and relieves the pressure, allowing the chamber to fill I
As the liquid reaches the top, the float rises and readmits pressure.
Shone and Albany traps are examples.
 POWER PLANTS Sec. 10-349

849. Inspirators are injectors of the double-tube type (Par. 346).

360. Siphons, so called, are single-tube jet pumps used for lifting only.
in, steam, or high-pressure water may be the motive force. They are not
ised for forcing against more than a few feet head.
851. Pulsometers comprise another form of direct-pressure pump like
and operate in much the same manner. The operating steam is
'he ejector,
jOndensed by the cold-water chamber and, in collapsing to water, draws .

he chamber full of water and operates a ball valve to admit steam again,
f'here are always two chambers, one filling and one discharging, operated by
single ball valve. The pulsometer, therefore, can Uf t water by suction,
She
/hereas the pressure-type ejector must be primed by gravity.
852. Efficiency. If the mechanical eflBciency alone is considered, all
lit pumps are very inefficient, being more wasteful of steam than the direct-
cting steam pump. But thermally considered, the steam injector is nearly
00 per cent, efficient, since the heat of the exhaust steam is returned in the
';ed water. The siphon and the pulsometer are convenient for temporary
.se and for drainage of pits under conditions adverse to the use of machinery.
363. The cost of these classes varies so widely that representative figures
;

.Mi hardly be given, $3.00 to $8.00 per 100 g.p.m. capacity covers most cases.

PIPING
The requirements of piping are: (a) tightness against leakage;
364.
3) reasonably small pressure loss through friction; (c) suitable provision
for
lange of length through change of temperature of the fluid contained-
,1) reasonably small loss of heat by radiation if the fluid is hot, and
intended
be kept so.
) Most of these requirements increase the first cost; a balance
lust therefore be found beyond which it does not pay to carry
refinements.
355. The flow of steam is expressed by Unwin as

P = 0.0001306 --,«i
/ I (58)
\ yd^
here TF = lb. steam flowing per min., I, = pipe length in
I
ft., d = inside
anieter of pipe in in., 7 = mean density of steam at pressures
in the pipe
id I = pressure drop lb. per sq. in.
in. Babcock's formula differs only in
e con.stant (87.0). Carpenter's is the same as Un win's.
356. Steam flow chart, based on Unwin's formula.
This chart
ig. 41a) gives accurate results of the formula,
and was prepared by Prof
L. Durand.
. An example will illustrate its use: 100 lb. steam pressure'
n 1 lu PoP*^ i?"^' ^ '^- *?,*^' pressure-drop. The drop per hundred feet
.^t'^rting at 100 lb. mark, drop down vertically to
irkeda\4 in.
I
diagonal Une
traverse horizontally to left to the diagonal marked 0.5 and
* °^ ^^^ minute vertically, 73 lb. in this case. It will be
i. .]°.uT'^u P*^"".
tea that the range of pipe sizes is not consecutive on the chart-
this is
• cause the chart "repeats," and the lines for each of the four
scales lie
pr the same area.
357. The flow of water in long pipes is given
by Church as

||
(3 = 3.1o \~ (59)

f'^!lffi"'''i
ft. per sec, d= diameter pipe in ft., = head /i of water in ft.,
1
1' coelfacient of friction and I = length of pipe in ft.
[|For pipe under 500 diameters in length,

^ ^= ^-^^oToS^ (««)
i
'
i888. The loss of head due to friction is given by Weisbach as
i/=('0.0144+-^l^)_^"-- ,.,.
\
VF ' 5.367di (61)

773
 Sec. 10-359 POWER PLANTS
where H^ friction head in ft., F = velocity of water in ft.
d'= diameter of pipe in in.
sdij JO aztg
g

869. EquiTalent length of valves and elbows. The above formtilas f

steam and water (Par. 367 and 368) apply to straight pipes. Valves a:
elbows may be figured as equivalent to lengths of straight pipe as follov

> for steam,

L = ^^-^^ f -— for each 90 deg. ell (f

9 ^5d
L«a for each globe and angle valve, ((

( +")
774
 POWER PLANTS Sec. 10-360

where L = equivalent length of straight pipe in ft., and d= diain. of pipe

in in. Gate valves are not considered. For water,
H=^C(£) (64)

where C = coefficient,
0.182 for 45 deg. ells, 0.98 for 90 deg. ells, 0.182 for gate
jvalves, 1.91 for globe valves, and 2.94 for angle globe valves.
j 360. The principal piping systems are: high-pressure steam; exhaust
or low-pressure steam; hot, cold and circulating water piping; and oil piping.
'

361. Higrh-pressure steam piping^ is made chiefly of steel pipe with cast-
ron fittings, if saturated steam is ased; if superheat is employed, cast-steel
ittings and valves must be used, as cast-iron will not stand the temperature,
or any pressure up to 125 lb. per sq. in. standard fittings are used; above
25 lb. extra heavy fittings. Screwed fittings should not be used above
i-in. pipe sizes; all larger material should be flanged.

362. On exhaust lines, standard weight pipe and fittings are usually
mployed; for very large sizes, however, special light-weight fittings may be
ised to save weight and first cost. Screwed pipe may be used up to 8-in.
ipe sizes, but flanged fittings are preferable for everything over 4 in. Spiral
iveted galvanized pipe may be used in place of standard pipe, as it is very
luch lighter and perfectly suitable for moderate pressures. It cannot be
sed on vacuum work.
363. Hot and cold water mains are made up the same as live steam
nes; except that in some cases cast-iron pipe as well as fittings are employed
iroughout on high-pressure hot- water service, to minimize corrosion effects.
10 cast-steel fittings are necessary. For circulating water lines, galvanized
)iral riveted pipe is useful for fresh water, but cast-iron pipe is generally
3ed throughout for salt water and is preferable even for fresh water.
;

364. Oil systems were generally installed in brass pipe and fittings on
le supply to engines; but it has been found that steel pipe, if well cleaned,
i

1perfectly satisfactory for the service. There is little excuse for the use
brass piping except for appearance, on gage fittings, or for some special
I

rvice where corrosion would be fatal.

860. There are four principal systems of piping arrangements:
dividual supply; ring; header; and unit (Fig. 42). The individual
ipply is really not a system, but the lack of it, and should not be employed.
366. The ring system is a development of the duplicate header; all
; pply lines tap in on one side of the ring, all demand lines on the other; by
i
eans of sectionalizing valves in the main, any section may be isolated witb-
t interfering with the rest of the plant.

367. In the header system, all supply and demand Unea tap to one
ge main; so that if any section is cut out, it must interfere to some extent
th the operation of the plant. This feature may not be serious; but for
ge power stations it is undesirable.
Unit system. The modern tendency is to revert to the unit system.
368.
is the individual supply system
lis —
each group of boilers supplying its
n turbine, but the units are tied together by equalizer pipes; so that there
ireally a header of diminished capacity between the units. Fig. 42 gives
•ypical example.
J69. Expansion in steel and cast-iron pipe may be taken as 0.9 in. per
5 deg. temperature difference from atmosphere, per 100 ft. of pipe under
israge conditions. Expansion joints should be provided every 50 ft. of
faight steam main; every 75 or 100 ft. will do for water or exhaust steam.
s!
h Sec. 4, for coefficients of expansion of piping materials.
'-'
170. The slip expansion joint is useful for water service and exhaust
tam at atmospheric pressure. It should never be used for high-pressure
6am or vacuum; its capacity can be anything up to 9 in. or 10 in. of move-
tnt.
171. The copper bellows joint is very successful for low-pressure steam
tl vacuum work, particularly the type having only one corrugation. Its
tiacity^ however is never over 0.5 to 1 in. of expansion, and preferably not
' r 0.25 in. This type of joint is sometimes made up of boiler plate for
L h-pressure steam service.

775
 :

Sec. 10-372 POWER PLANTS

372. The pipe bend the simplest and safest joint for high-pressu
is
steam and is usually made of as large radius as can conveniently be mac
taking care of from 1.5 to 2 in. of expansion per bend.
373. Avoidance of strains in fittings. Piping should always be la
out so that expansion will not bring strains upon cast-iron fittings, but up*
the expansion joints, or at least upon the more flexible steel pipe.

^^^^s^^^^^^^^^^^^^^^^\^^^^^''^^^s\^^^\^^x^^^^^ ^^^^y;^S^^^^^s^^^s''^^'- .s-sss';^

Fig. 42. —Piping systems.

374. Condensation in steam pipes is due to radiation; it occurs only
saturated steam mains, when running. All low points in the pipiun !sy.stc
and all dead ends or pockets where water can collect, must be drained. Tl
usual method for high-pressure steam is to connect a steam trap at eai
point to be drained and can be returned direct to the boilers, or to tlie fci
tanks. Low-pressure steam mains are usually drained by gravity throu/
an inverted siphon leg, to act as a steam seal.
376. Steam traps are of four principal types: bucket, float, tilting a
expansion. The bucket and tilting traps are probably the most rehab
376. Separators are employed to remove nioi.?ture from the stoani befi
it is supplied to an engine. In every instance short and sudden turns i

employed to throw out the moLsture by centrifugal force, and a large chaml
is then provided to reduce the velocity of the steam and act as a reservoir
collect and retain the water. (See Fig. 20a.)
377. Controlling: valves are of three types: gate, globe and angle. 7
globe valve is always used for stop or throttle work. The angle valve

> really a globe valve with the outlet turned through 90 deg. and is used a
globe valve, usually for the stop valve on boilers. For all othi-r steam w<
the gate valve should be used on account of offering practically no obatr
tion to steam flow. All exhaust valves should be of the gate type. J

water service, gate valves should be used wherever possible. Check v»l'
may be horizontal, vertical, and swing. The horizontal and vertical ch'
valves ordinarily are built much like a globe valve, but the valve disc has
stem and wheel for closing it.

776
 POWER PLANTS Sec. 10-378

378. Relief and back-pressure valves are developed from the check
valve, with a spring or lever and weight loading device, so that a definite
pressure under the valve disc will lift the valve and let off pressure. Relief
valves are used on the discharge of reciprocating pumps to prevent excessive
pressures; also on cylinders and receivers of steam engines. Back pressure
and atmospheric relief valves are used on exhaust steam systems and con-
densers respectively. All of these types are emergency valves, to prevent
damage under unusual conditions.
879. Reducing valves are usually double-seated, or balanced, valves,
with a pressure diaphragm substituted for the spring of the relief valves.
This diaphragm is connected to the discharge side of the valve, and operates
to close the valve only when the pressure on the discharge side rises above the
predetermined amount. They are used to feed high-pressure steam into
'low-pressure systems

I 380. The three principal types of pipe joint used are; screwed, flanged,
land bell and spigot. The screwed joint is used for all pressures and ser-
vice up to 3-in. diameter of pipe, and up to 12 in. for low-pressure service.
Above 3 in. in high-pressure service and 12-in low-pressure service the
langed joint in one of its forms is used.
381. The principal methods of attaching flanges to steel pipe are:
icrewed flanges, peened flanges and, lately, machine expanded flanges, welded
langes and lap flanges. Of these, screwed flanges are in common use for
ow-pressure work, and high-pressure work up to 100 lb. in size up to 24 in.
lia., or up to 150 lb. in sizes not larger than 6-in. or 8-in. diameter. It is a
:heap and satisfactory joint when well made.
I 382. A much better joint for high pressures is the lap joint, in
vhich the pipe is lapped over on the flange and then faced off. The
velded jointis also satisfactory but more expensive. The new machine-
izpanded joint, in which the pipe is rolled into a recess in the flange,
iromises well and is cheap to make it has been used for years in marine work.
:

383. Gaskets for low-pressure work may be of rubber compounds or

sbestos. For high-pressure steam, asbestos, and the metallic gaskets, such
3 corrugated copper, are better.
384. Bursting pressure of standard mild steel pipe. Tests made at
he Armour Institute of Technology on o-ft. random specimens capped at
oth ends gave average results as follows: 1-in., 7,730 lb. per sq. in.; 2-in
,080 lb.; 4-in., 1,750 lb.; 5-in., 2,550 lb.; 6-in., 3,200 1b.; 10-in., 1,800 lb.;
--in., 2,500 lb. On the 4-in., 5-in., 6-in., 10-in. and 12-in. sizea failure
:curred at the threaded end.

I
385. Pipe covering
is practically always justified for high-pressure steam,
.ad for exhaust also, if used for heating feed water. Hot feed-water pipes
'lould also be covered. The standard coverings are principally magnesia,
sbestos and the fossil meal compounds. Moulded sectional covering can be
Jtained for pipes up to 12-in. diameter in single (1-in.) and double (2-in. to
in.) thickness. All exhaust lines should be covered with single thickness;
1 steam lines, with double thickness. Usually the covering is bought
ready canvassed. For larger size pipe than 12 in., sectional blocks, about
in. X 3 in. X 18 in. are used, and wired on; then the joints
are pasted
th asbestos cement and the whole is canvassed and painted.
Moulded
vpring can be bought in shapes to fit standard fittings, such as tees and
ells,
It is frequently made up from blocking and
asbestos cement.
386. The radiation losses from uncovered pipe are given by

Q = A{Ti-T2)U (65)
re A = sq. ft. of radiating surface, 7*1 = temperature of steam within the
^
To= temperature of air outside, and f/ = transmission coefficient —
l>.t.u. per sq. ft. per hr. per degree of temperature difference.
r 1-in. magnesia, 85 per cent., 17 = 0.4 — 0.5 (66)
r 1..5-in. magnesia, 85 per cent., 17 = 0.25 — 0.3 (67)
In a modern plant, with properly covered piping the actual radiation loss
m pipe alone should not exceed 1 per cent, of the total heat of steam
pass-
'
:
through at full load.

777
 . '

Sec. 10-387 POWER PLANTS

387. Tests of Relative Efficiencies of Steam-pipe Coverings
B.t.u.per
Size of Thickness sq. ft.
Kind Per cent,
of covering pipe of cover- per deg. Authority
heat lost
inches ing, in. difT. of
temp.

Bare pipe 2.7 100

Hair felt 2 0.96 0.387 14.3 Jacobus
Remant 2 0.88 0.434 16.1 Jacobus
Solid cork 2 1.20 0.427 15.8 Stott
Magnesia 2 1.16 0.439 16.3 Stott
Magnesia 4 1.12 0.465 17.2 N orton
Asbestos sponge felted. 10 1.63 0.280 10.4 Barrus
Asbestos sponge felted. 2 1.21 0.490 18.1 Barrus
Manville sectional. . . . 4 1.25 0.453 16.8 Norton
Manville sectional. . . 2 1.31 0.572 21.2 Paulding
Asbestos air cell 4 1.12 0.525 19.4 Norton
Asbestos air cell 2 0.96 0.716 26.5 Jacobus
Asbestos fire felt 1.30 0.502 18.6 Brill
Asbestos fire felt 1.00 0.721 26.7 Paulding

{.Abstracted from "Book of Standards," National Tube Co., Pittsburg!

Pa.)
388. Exhaust heads comprise a form of separator in which the entraine
moisture in atmospheiic exhaust is removed so that the issuing steam may m
be a nuisance to the neighborhood, or an injury to the roof. They operai
on the same centrifugal principle as separators.
889. Blow-ofl valves and piping, being subject to rapid variation fro:
low to high temperature, must be carefully designed for expansion. As soli
scale and rust flakes must be passed, the turns should be easy, and all coi
nections between individual boilers and mains should be by 45-deg. latera
instead of tees.
390. The installation of piping should be done with great care to pr(
vide good alignment. Pipe joints can be made when piping is considerabl
out of line, as the lines are more or less flexible, but satisfactory joints ar
service cannot be expected. For high-pressure work, it is unsafe to strai
the pipe in order to joint it. It is therefore good practice to arrange conns
tions for flexibility, in case of variation from drawing dimensions; or bette
to leave certain pieces of pipe called fillers, to be cut to field dimension
This entails a slight delay in erection but is safe and eminently satisfactor;
All steam piping, and most water and oil piping, should be carefully cleane
of internal scale (by brushing or hammering), as this may dislodge durir
operation and cause trouble in the cylinders of engines or other apparatu
Steam and water piping should be tested at the working pressure before beir
put in service.
391. Hangers. Careful provision for hangers at suitable points must 1,

made in order to support the pipe properly. The interval between hange
should not exceed 12 ft. except for small pipe, which may be supported i

centers as much as 18 ft. apart.

392. Costs. Valves cost, in cast-iron body, approximately $0.20 to $0.
per lb; straight cast-iron pipe, 12-ft. lengths, $34.00 to $50.00 per to
straight pipe, shorter than i2-ft. lengths, $52.00 to $60.00 per ton; standa
fittings, $60.00 to $7.5.00; special fittings, $73.00 to $113.00 per t(

> Wrought-iron and steel pipe, 1-in. to 6-in. sizes,

cents per lb.; 7-in. and 8-in. 4.3 to 5 cents; 10-in. to 12-in., 5 to
per lb. All the recent evidence seems to show that wrought-iron pi
18 no better than steel for practically all purposes; and as the steel pipe
costs
cei
from 3.4 to

lower in price and more readily available, it is satisfactory to use it (l',tl4)

PLANT ENSEMBLE
393. The best combination of plant equipment is seldom if ever c
in which each piece of apparatus is chosen by reason of its best water rate,

778
 .

POWER PLANTS Sec. 10-394

highest efficiency. The characteristic under variable load and the heat
relation to the rest of the plant are most important.
394. The question of first cost versus economy is discussed under
power-plant economics (Par. 884 to 931). The following paragraphs coyer
the beat capacity and grouping of units for the best overall economy, with
given efficiencies in the individual apparatus.
396. The heat analysis in B.t.u. is valuable for the purpose of proving
the espected economies of any given combination of apparatus. Starting
with the coal supplied, the boiler-room distribution of all the heat contents
13 followed through, including the B.t.u. delivered to steam, flues, unburned
eomi)U8tible, radiation, leakage, stoker, fan, and boiler feed-pump drives,
other auxiliaries and miscellaneous steam such as boiler blow-down, ft-ee drip,
dusting tubes, etc. In the engine room, the B.t.u. supplied in the steam is
separated into pipe and engine radiation, exhaust drips, condenser auxilia-
-ies, oil pumps, exciters, friction, electrical losses and energy delivered to bus
bars. Heat returned by feed-water heaters and economizers is credited.
396. The average conditions in large stations (100,000 kw. and
more) with steam driven auxiliaries, will give the heat distribution stated
Delow. For a 12,000 kw. station, the useful heat in the coal appearing in
let output, is approximately 12.5 per cent., with a coal factor of about 2.10
bs. The coal factor of the station using 30,000 kw. units would be about
1.40 lbs.

Coal
'Loss in ashes*
Stack *
Incomplete combustion*
'Radiation and leakage, boiler.
iReturned by feed-water heater
Returned by economizer
!pipe radiation and leakage. . . .

Condenser auxiliaries
.Boiler-room auxiharies
Heating
Slectrical losses, gen. etc
H^ouse service
<iipcted to condenser
\i t output, switchboard

397. In choosing the number and capacity of prime movers, the

rillans line of total steam consumption with load is plotted. The arrange-
lent which gives the least area under the curve is the most economical. Fig.
i shows this curve for 42-in. X 86-in. X 60-in. double compound Corhss
igines, 7,500 kw. maximum continuous rating on 190 lb. dry steam, 28 in.
icuum. If the auxiharies were not considered, the Willans line for engines
one would show the proper points for cutting engines in and out. It is
und, however, that the mos. economical method is to carry up the load on
vmits until the Willans line for n units intersects the Willans line for n 1 +
'ts; and vice versa. The maximum capacity of individual machines may
the outting-in point somewhat when only one or two engines are run-
'

.;. but as the number in aer\'ice increases, the loads on each engine before
vl after cutting in another unit become nearer alike.

398. Effect of auxiliaries on Willans line. The condensers and other

txiliaries using steam necessitate the addition of their demand to the main-
(
lit demand, and the resulting Willans lines will give the steam demand
of
e engine room for any load. This supposes the units to be all alike and
ually loaded when on the line; however, for units of unequal capacities,
nous loadings should be tried and plotted in order to determine the most
onomical operating conditions (Fig. 43).

* -\verage boiler efficiency, including banking, 71.5 per cent,

779
Sec. 10-399 POWER PLANTS
 POWER PLANTS Sec. 10-404

turbine-driven centrifugal types. The steam for forced-draft fans on under-

feed stokers varies from 1 to 2 per cent, of main-unit steam; coal-conveying
systems require 1.7 to 3 per cent., or the equivalent in electrical energy.
The total varies therefore from 8 to 18 per cent.
404. The power taJEen by the auxiliaries of a 6,000-kw. turbine
tested by the Edison Illuminating Co. of Boston was as follows:
Sec. 10-411 POWER PLANTS
dissimilar units, the reserve should be equal to the largest unit in the plant,
either as one large unit, or the equivalent load capacity in smaller units.
411. Unit costs of equipment may be taken as given in Par. 67, 88, etc,
But on a basis of plant output, the relations will be different. Lyford and
Stovel give the following central station costs, high and low, for steam
turbo-electric generating stations of 2,000 to 20,000 kw. capacity, based oe
maximum continuous capacity of generators as 50 deg. Cent. temp. rise.
Prices are exceedingly variable at the present time, but they may reason-
ably be taken at twice the figures in 1913 to 1915, for all items. Some
individual apparatus, such as boilers, is more than twice as costly, othei
apparatus less. The net result in May, 1920, is that the total cost is almost
exactly double that of 1913.

Dollars per kw.

Costs in 1913
High Low
Preparing Site: Clearing structures from site, construction $0.25
roads, tracks, etc.
Yard Work: Flumes for condensing water, siding, grading, 2.50
fencing, sidewalks, etc.
Foundations: Foundations for building, stacks and ma- 6.00
chinery, excavation, piling, waterproofing, etc. 6.00
Building: Frame, walls, floors, roofs, windows, doors, coal 12.00
bunker, etc., exclusive of foundations, heating, plumb-
ing and lighting.
Boiler-room Equipments: Boilers, stokers, flues, stacks,
feed pumps, feed-water heater, economizers, mechanical
draft, piping and covering, except condenser water
piping.
Turbine Room Equipment: Steam turbines and gener- 22.00
ators, condensers, condenser auxiliaries, condenser
water piping, oiling system, etc.
Electrical Switching Equipment: Exciters, masonry
switch structure, switchboards, switches, instruments,
etc., all wiring except for lighting.
Service Equipment: Cranes, lighting, heating, plumbing,
fire protection, compressed air, furniture, permanent
tools, coal- and ash-handling machinery, etc.
Starting Up: Labor, fuel and supplies for getting plant
ready to carry useful load.
General Charges: Engineering, purchasing, supervision,
clerical work, construction plant and supplies, watch-
men, cleaning up, etc.

Total cost of plant, except land and interest during

Construction.
 POWER PLANTS Sec. 10-414

414. Operating and maintenance costs, for 1915, taken from the
port of the Committee on Power Generation, A.E.R.A., 1916, are as follows,
a yearly basis.

et output, million kw.-hr. 130.08 111.08 172.90 91.40

ne hr. peak 42,000 33,240 46,100 23,900
oad factor, 1 hr. peak .... 0.35 0.38 0.428 0.437
apacity, 2 hr. peak 45,000 37,000 65,700 44,700
lant load factor 0.33 0.34 0.30 0.234
bs. coal per kw.-hr 1.75 1.97 2.48 2.78
.t.u. coal as rec'd 14,450 14,250 13,400 13,000
osts per kw^.-hr. mills:
5. Buildings 0.0130 0.0096 0.05 0.0039
7. Maintenance 0.1237 0.2593 0.65 0.2167
2. Labor, op 0.2780 .2594 1.02 4469
.

3. Fuel 2.6710 3.0030 3.71 2 0750

.

4. Water .0243 0.03 0.00001

Lubricants. 0.0055 6! 0220 0.06 0.0226
3. Miscellaneous supplies 0.0425 0.0279 0.24 0.0980

otal 3.1580 3.5812 5.78 2 8632

.

er cent, of total: i

3. Buildings 0.41 0.26 1.00 0.13

7. Maintenance 3.93 7.24 11.30 7.57
2. Labor 8.79 7.24 17.60 15.62
B. Fuel 84.57 83.86 64.30 72.47
i. Water I
0.78 0.62
1. Lubricants 0.18 0.62 1.10 '6!79
j. Miscellaneous 1 34
. 0.78 4.07 3.42
0. 1045 0.1116
I

ost of coal, per million B.t.u 0.1071 0.0574

t.u. per net kw.-hr 25,300 28,100 33,232 36,200

TESTING
416. Boiler- testing requires the following essential data: (a) Weight
water fed per hr.; (b) weight of coal fed per hr.; (c) quality of steam;
I pressure and superheat; (e) feed- water temperature; (f) proximate
alysis of coal including moisture and B.t.u. per lb. Additional desirable
ta includes: (g) Flue temperature, including furnace and pass tempera-
res; (h) flue gas analysis, and analyses of gas at various points in boiler;
weight of refuse; (k) proximate analysis of refuse, moisture and B.t.u.
r lb.; (1) siftings, if stoker fired; (m) soot and dust passing through boiler;
' steam flow by meters. Boiler testing is always interwoven with stoker
i'Ang; the fire and the heating surface are tested together. The duration
test should never be less than 24 hr., for the most accurate results.
tl6. Summary of overall results.
Total Quantities
1. Date of trial
2. Duration of trial hr.
3. Weight of coal as fired lb.
4. Percentage of moisture in coal per cent.
5. Total weight of dry coal consumed lb.
6. Total ash and refuse lb.
7. Percentage of ash and refuse in dry coal. per cent.. . .

8. Total weight of water fed to the boiler lb.

9. Water actually evaporated, corrected for lb.
moisture or superheat in steam.
10. Equivalent water evaporated into dry steam lb.
from and at 212°.
|?<Jr M. E.
further details, see the standard code of the A. S. i
17. Especial care should be taken to isolate the boiler tested so
lit leakage can be eliminated or measured. No single valve may be con-
' ered absolutely tight. Where lines cannot be completely disconnected,
re should be two closed valves with a half-inch open bleeder between them
;
indicate leakage. Variations of water level must be corrected for.

783
 X

Sec. 10-418 POWER PLANTS

418. For weighing feed water, tanks on platform scales are best:
lacking these, a calibrated recording Venturi meter is satisfactory and a<
rate within 1 per cent, on reasonably steady flow.
419. For full details as to methods of firing, calorimetry, etc.,
standard rules of the .\. S. M. E.
420. Heat Balance, or Distribution of the Heating Value of 1

Combustible
The heat value of 1 lb. of combustible B.t.u.

B.tiU. Per ce

1. Heat absorbed by the boiler = evaporation from and at

212° per lb. of combustible X 970.4.
2. Loss due to moisture in coal = per cent, of moisture re-
f erred to combustible-M00XK212-<) +970.4+0.6
(T — 212)] (< = temperature of air in the boiler-room,
T = that of the flue gases).
3. Loss due to moisture formed by the burning of hydro-
gen = per cent, of hvdrogen to combustible-;- 100X9
((212-0 +970.4 + 0:6(T-212)].
4.* Loss due to heat carried away in the dry chimney
gases = weight of gas per pound of combustible X 0.24 X
(T-0
5.t Loss due to incomplete combustion of carbon =
CO ^ , per cent. C in combustible , ,„,.„
COi + CCX 100
77,^ X 10,loO.

6. Loss due to unconsumed hydrogen and hydro-carbons,

to heating the moisture in the air, to radiation, and un-
accounted for. (Some of these losses may be separately
itemized if data are obtained from which they may be
calculated )

Totals 100

421. Quality of steam. The percentage of moisture in the St

should be determined by the use of either a throttling or a separating f
calorimeter. The sampling nozzle should be placed in the vertical st
pipe rising from the boiler. It should be made of O.o-in. pipe, and shou!
extended across the diameter of the steam pipe to within half an inch oi
opposite side, being closed at the end and perforated with not less ;

twenty 0.125-in. holes equally distributed along and around its cylind;
surface, but none of these holes should be nearer than 0.5 in. to the ii
side of the steam pipe. The calorimeter and the pipe leading to it shoul-
well covered u-ith felting.
422. Superheating should be determined by means of a thcrmom
placed in a mercury-well inserted in the steam pipe. The degree of su
• The weight of gas per lb. of carbon burned may be calculated from
gas analyses, as follows:
t CO2 and CO are respectively the percentages by volume of carb
acid and carbonic oxide in the flue gases. The quantity 10,150 = numb
heat units generated by burning to carbonic acid 1 lb. of carbon conta
in carbonic oxide.
^ llCO, + 80+7(CO + Xi
Dry gas per ,^
lb. carbon
3(C0j + C0) '

) in which CO2, CO, O and

gases.
N
are the percentages by volume of

art are liable to considerable errors, the result of this

only an approximate one.
th.
As the sampling and analyses of the gases in the preserit .sta- m
calculation i-

The heat balance itself is also only api'' m'

1-;
-•
'

'

'

dptern' "
for this reason, as well as for the fact that it is not possible to :

^
rately the percentage of unburned hydrogen or hydrocarbons in tho f!u.- p
The weight of dry gas per lb. of combustible is found by muHipHi
the dry gas per lb. of combustible by the percentage of carbon in the »
bustible, and dividing by 100.

784
 I

POWER PLANTS Sec. 10-423

^sating should be taken as the difference between the reading of the ther-
>ometer for superheated steam and the reading of the same thermometer
r saturated steam at the same pressure, as determined by a special ex-
rjriment, and not by reference to steam tables.
'
4A3. SampUng the coal and (jetermining its moisture. As each
Urrow-load or fresh portion of coal is taken from the coal-pile a representa-
ve shove f ul is selected from it and placed in a barrel or box in a cool place
>d kept until the end of the trial. The samples are then mixed and broken
to pieces not exceeding 1 in. in diameter, and reduced by the process of
peated quatering and crushing until a fine sample weighing about 5 lb.
obtained and the size of the larger pieces is such that they will pass through
I

meve with 0.2o-in. meshes. From this sample two 1-qt., air-tight
ass preserving jars, or other air-tight vessels which will prevent the escape
moisture from the sample, are to be promptly filled, and these samples
e to be kept for subsequent determinations of moisture and of heating
lue and for chemical analyses. For further details, see the standard code
the A. S. M. E.
424. Calorific tests and analysis of coal. The quality of the coal
ould be determined either by heat test or by analysis, or by both. The
tional method of determining the total heat of combustion is to burn the
mple of coal in an atmosphere of oxygen gas, the coal to be sampled as
-ected in Article XV of the code. The chemical analysis of the coal
ould be made only by an expert chemist. The total heat of combustion
mputed from the results of the ultimate analysis may be obtained by the
of Dulong's formula (with constants modified by recent determinations),
f;

14,600C-|-62,000(H )-t-4,0O0S, (68)

8
•rhich C, H, O, and S hydrogen, oxygen
refer to the proportions of carbon,
i sulphur, respectively, as determined by the ultimate analysis. It is
Hirable that a proximate analysis should be made, thereby determining
nelative proportions of volatile matter and fixed carbon.
: These pro-
rtions furnish an indication of the leading characteristics of the fuel, and
re to fix the class to which it belongs. As an additional indication of the
fincteristics of the fuel the specific gravity should be determined.
Treatment of ashes and refuse. The ashes and refuse are to be
••

l^ybud in a dr>' state. If it is found desirable to show the principal char-

'cfilistics of the ash, a sample should be subjected to a proximate analysis
tithe actual amount of incombustible material determined. For elaborate
fJs a complete analysis of the ash and refuse should be made.

IM. A throttling or a Thomas electric calorimeter should be used

I'M* possible, in preference to separating or other types. Thermometers
! more satisfactory as indicators of saturated steam pressure than spring
im.
Engine testing requires essentially: (a) Weight of steam used;
|11T.
kw. output of generator, or brake h.p.; (c) i.h.p., from indicator cards;
rev. per min.
, (e) steam pressure, receiver pressure and back pressure
;

vacuum; (f) quality of steam. Desirable additional data include: (g)

[Wver and exhaust temperatures; (h) weight of condensation from receiver
;e4>ewhere; (j) reheater steam, if used.
iM. The steam consumption is best obtained by weighing the discharge
f 'm a surface condenser; but if jet condensers are used or the engine is non-
idensing, the feed water must be measured as it enters the boilers, the boiler
'

kage determined, and the boilers isolated from all other steam piping and
1

laratus.
i
If the condensate is weighed, the condenser leakage must be
iertained. The test should continue not less than 1 to 3 hr., with surface
'idensers and 8 hr. when using the feed-water method.
M. Turbine testing involves the following essential data: (a) Steam
ght per hr.; (b) initial and exhaust pressures; (c) superheat, or wetness
*?team; (d) rev. per min.; (e) b.h.p. or kw. output of generators;
iim chest pressure. There is a general similarity to engine testing,
' real difference lying in the absence
of indicator cards. In measuring
'riden.sate,pro\'ision must be made for measuring also the gland-wat«r,
-team for sealing purposes, which is not strictly chargeable to the turbine,
"

:e all the water, or all the heat is recovered.

I

&^ii 785
 t;
!

Sec. 10-430 POWER plants

430. For full data on turbine testing see the standard rules of i

A. S. M. E.
431. Condenser testing. The condenser is the chief auxiliary requir {
test: generally it is convenient to combine the condenser test with the engs
or turbine test on the attached prime mover. The essential readings a:
(a) vacuum at exhaust entry referred to standard barometer; (b) confiens
weight per hr.; (c) circulating water temperatures at inlet and dischar
(d) hot well temperature. Additional desirable data include: (e) vacu
at hot well; (f) vacuum at dry vacuum pump; (g) temperatures, top and b
torn of condenser; (h) temperature of dry air at pump; (j) Pitot or Vent
meter readings on circulating water; (k) temperature of circulating wsi
at beginning and end of each pass; (1) volume of dry air removed per n .

A separate test for leakage should be made before the operating test, and te i

for salt may be made on the condensate during the operation, if salt wate i

employed as cooling water.

432. Tests of boiler feed pumps and circulating water or hot-v
pumps, of the centrifugal type, require the following readings, for turbi -

driven units: (a) weight of steam used per hr.; (b) steam and exha
pressures; (c) quality of steam, or superheat; (d) suction and discharge hea
(e) weight of water pumped —
by scales, tank or Pitot or Venturi tube re
ings, which are close enough for this work (weirs may be used for la
-
:

>

pumps) (f) rev. per min.

;

433. In testing direct-acting steam pumps, indicator cards shot

also be taken. •

434. For tests of electric driven pumps, readings (a), (b), and,
in Par. 432 would be replaced by kilowatt readings on the motor. ™
436. Tests on turbine-driven fans for forced or induced draft requi
(a) Steam used per hr. (b) steam pressure and back pressure; (c) qiid
;

of steam or superheat; (d) Pitot static and dynamic readings on suita

fan outlet; (e) rev. per min. For motor drive, kilowatt readings will repl
(a), (b) and (c). |

436 Complete plants have what amounts to a continuous test

their regular recqrda, if proper y kept. Coal is bought and paid for I

weight and by analysis; and recording wattmeters give the output,

yearly figures the plant storage usually is not an important factor,
amount is small compared to the total consumption; but for monthly figuj
a survey of the coal stored is necessary. This is usually made by ta" '

readings at predetermined points over the bunkers or storage space an

culating the volume of coal, allowing generally 50 lb. per cu. ft. for bitui
coal and 54 lb. per cu. ft. for No. 1, No. 2 or No. 3 buckwheat anth
437. The apparatus required for weighing water is preferably mi
up of one or more .sets of tanks on platform scales; the accuracy may be kt
to 0.25 per cent, quite readily. Where less accuracy is required, 0.5 to ')

per cent., measurement by volume in a tank, or by Venturi meter, or V-no i

weir, is suitable.
For measuring the steam used, the best method is by surf;
438.
condensers (which may be made substantially tight), using scale tanks
weighing the condensate.
439. For measuring temperature up to 900 deg. Fahr., more
'

thermometers of 12 in. length are most convenient; they should be iiseri

iron or brass wells, with a little mercury in the bottom of the cup, nnd ,'

remainder filled with oil. For temperatures above 500 deg. Fahr., nitron •

filled mercury thermometers must be employed. Care should be taken)

ascertain the immersion for which the thermometer is calibrated. Res-
ance thermometers are now available, but are in general very niuch in

) expensive; their use is a convenience where there are several inacci-ssi)

readings to be taken, as all the resistance bulbs may be read from one c
vanometer and bridge. For higher temperatures than 900 deg. Fahr., res
ance thermometers or thermocouples should be used. For high furn
temperatures, radiation or optical pyrometers are best. (Sec. 3.)
440. For pressure measurements, the spring gage is convenient t
usually inaccurate; for pres-sures up to 15 lb., mercury columns are far bet..
For steam pressure, the thermometer is a valuable and accurate meant

780
 POWER PLANTS Sec. 10-441

getting results.If the steam is superheated, a thermometer in a pressure

chamber separated from the steam main by a condensing coil, and suitably
drained, will give correct readings of pressure. If gages are used, they
should be carefully checked at the operating pressure, in position if possible,
"against a standard gage tester.
! 441. Frequency of observations. Observations of temperatures,
pressures and speeds should occur once every 10 or 15 min. Water and coal
R-eighings should be made as often as needed by the capacity of the con-
iainers on the scales. Wattmeter readings and coal and water readings
hhould be balanced every hour, as a precautionary measure in checking the
Eiteadiness and reliability of the test. Calorimeter readings on boilers and
-urbines at steady load only need be taken at half-hourly or hourly intervals,
<is they vary but little. Barometer readings taken three times during a test
ire sufficient. For short tests, such as occur in motor-driven pumps and fans
vith Pitot tube or Venturi tube readings, instantaneous values taken once
.1 minute for 10 min. gives good enough results as a rule. Pitot readings
:or air should be taken at numerous points in the pipe (see Treat, Trans.
,V. S. M. E., 1912, and Rowse, Trans. A. S. M. E., 1913.

442. Duration of tests. Engine or turbine tests by the feed-water

•nethod should not be less than 8 hr., as the error introduced by variations of
[3vel in the boilers is too great on shorter tests; when weighing the condensate,
to 3 hr, will be sufficient, depending on reservoir capacity in the system.
jVhere flow meters can be employed with sufficient accuracy, instantaneous
ests of a few minutes duration may be run. The time taken for a boiler
est, start to stop, should never be less than 10 hr., 12 are better and 18 to 24
r. give much more consistent results. This length of time is needed on
ceount of the variable error introduced by the unknown amount of coal
:n the fire at start and finish.
443. Precision of tests.
'
Boiler tests of 10 hr. duration are seldom closer
3 per cent, either side of the average; 12-hr. tests, 2.5 per cent.; 24 hr.
:tian
per cent.
'
Engine tests of 8 hr. duration, will have a probable error of 2
ijr cent., either way; turbine tests of 3 hr., 2 per cent,
ft is therefore need-
fissto compute results closer than y\, of 1 per cent.

I GAS POWER PLANTS

BY REGINALD J. S. PIQOTT
PRODUCERS
444. Destructive distillation can occur only with fuels containing
Volatile matter; therefore anthracite and coke producers cannot be said to
"Derate by destructive distillation. Oas may
he produced from hard coal
.? follows: with air only, 2C + =
02 2CO; with steam only, H20-1-C = CO
I-H2; with both =
steam and air, 3C-t-Oj4-H20 3CO-|-H2. The first
ifocess is not often used; the second is used to make water gas, but since
. does not produce heat,
it is used intermittently with the process C + 62 =
O2, or simple combustion of the fuel in the producer to generate the necessary
.iat. This is called "blasting up." The third process is the one used in
aking producer gas from anthracite or coke.
446. With bituminous coals, the volatile matter is given off as tar and
/drocarbon gases of the methane series, chiefly. These are again broken
,3 by the heat in the producer to methane, carbon monoxide and hydrogen.
|i addition, the formation of CO and Hfrom the coke remaining, goes on
ibstantially as in the anthracite producer.' In the down-draft types of
oducers, the tar passes through the fuel bed and is broken down to com-
jstible gases aad lampblack, some of which are burned in the passage.

**6. Suction producers obtain a flow of air, steam and gas by means of
slight difference of pressure due to the pump action of the four-cycle
13 engine on the charging stroke, or by an exhauster.
(
**'• Pressure producers obtain a flow of gas, etc., by means of a
essure fan or blower for the air, or a boiler for the steam. A pressure
•oducer is independent of the engine, and does not affect the capacity of
..<! latter.
***• ^P-draft producers are arranged with the steam and air admitted
the bottom and gas removed from the top; tar passes off with the
-
gas and
ust be removed by scrubbers and purifiers.

b»
 Sec. 10-448 POWER PLANTS

)
 . .

POWER PLANTS Sec. 10-449

449. Gasification of Anthracite Coal (R.. D. Wood Co.)

Products
Process
Cu.
Anal, by
Lb. ft.
Vol.

80 lb. C burned to CO 186.66 2,529.24 33.4

5 lb. C burned to CO2 18.33 157.64 2.0
5 lb. vol. HC (distilled) 5.00 116.60 1.6
120 lb. Oxygen are required, of which
30 lb.from H2O liberate H 3.75 712.50. 9.4
90 lb. from air as associated with N 301.05 4,064.17 53.6

514.79 7,580.15 100.0

Energy in the above gas obtained from 100 lb. anthracite: 85 per cent.
'.C.; 5 per cent. V.M.; 10 per cent. ash.

186.66 lb. CO 807,304 B.t.u.

5.00 1b. CH4 117,500 B.t.u.
3.75 1b. H 235,500 B.t.u.

1,157,304 B.t.u.
Total energy in gas per lb 2,248 B.t.u.
Total energy in gas per cu. ft. 152.7 B.t.u.
Efficiency of conversion. . . . . . , 86 per cent.
460. Down-draft producers are ar-
ranged with and steam supply at the
air
top, and gas removal under the firebrick
grate at the bottom. The double-zone
producer has down draft in the upper
zone and up draft in the lower.
451. Suction producers have the ad-
vantage of not allowing gas to escape
into the operating room from the producer,
as the carbon monoxide is intensely poison-
ous; and poke openings, etc., can be con-
veniently operated. For small sizes, no
exhaust fan is used, the necessary draft
being provided by the engine suction. Most
of the down-draft producers are suction
types with exhaust fans. In this class
belong the Loomis-Pettibone, De La-
vergne, Korting, United Gas Machinery
Co., Westinghouse double-zone, Otto, and
Mond (small size).
452. Pressure producers require forced
drskft supplied by a fan or a steam jet
blower, the steam thus admitted being used
in the gasification. The tar formed is car-
ried over with the gas and requires more
extensive cleaning, but access to the grates
is better than with the down-draft and suc-
tion types and mechanical stoking or poking
may be employed either by mechanical
water-cooled pokers, or by rotating the ash
table and in some cases the producer shell.
Examples of this type are the Mond large
size, Taylor, and Chapman.
453. The capacity of a producer is
based on 0.065 to 0.075 sq. ft. of cross-sec-
tional area per brake h.p. of engine and
Tia. 45. —
Taylor or Mond about 0.105 to 0.118 cu. ft. of volume per
h.p. (SneU).
up-draft producer.
454. The continuous rate of gasifl-
vtion with high-grade coal will not exceed 23 lb. of coal per hr. per sq.
.of fuel bed; 12 lb. is a good average figure.
Sec. 10-455 POWER PLANTS
466. aasification of Bit. Coal, Low Volatile

Process
 . .. .

POWER PLANTS Sec. 10-458

The efficiency of large producers will vary from 70 per cent, to

468.
iOper cent, if the gases are used cold, and 80 to 90 per cent., if used hot
furnace work).
for The losses include: (a) Sensible heat in gases; (b)
)roducer radiation and conduction; (c) combustible in ash. The carbon
Q the ash of a properly operated large producer will be from 4 per cent.
12 per cent, for about 0.5 to 1.5 per cent, total heat loss, with a coal hav-
ag 10 per cent, to 12 per cent. ash. For small producers, suction type, the
arbon in the ash may be as much as 60 per cent, of the total refuse, and the
fiSciency of the whole producer from 44 to 75 per cent. The sensible heat
ithe gases varies from 4 to 19 per cent., usually about 15 per cent, average.
459. Heat balance. The following data on the test of a Loomis-
ettibone producer were taken from the N. E. L. A. report on gas engines,
908.
'otal heat in fuel 100 per cent.
'otal heat in gas at 60 deg. fahr 84 7 . per cent.
otal heat removed by scrubber 8.16 per cent.
otal heat removed by water cooled valves 1 56 per cent.
.

otal heat lost by radiation, etc 5 58 per cent.

.

100.00

460. Tests on a 60-h.p. Otto Suction Producer

Id. of test. 21 16 17 27 25

)uration, hr. 12 12 12 12 12

and of fuel. Lehigh chestnut Scranton pea

i,] roximate analysis.

, ixed carbon 80.11 73.59 77.39 75.54 78.45
I! olatile matter. . . 4.27 8.47 6.70 6.34 5.99
tjloisture 1.95 3.98 1.11 2.90 2.75
1 sh 13.67 13.96 14.81 15.22 12.81
Ir jlphur 1.08 1.41 0.63 1.71 1.10

( NLu. per lb., dry coal 12,750 12,780 12,680 12,540 13,040
}i .t.u. per lb., combustible. 15,570 15,550 15,700 15,700 15,700
{
I ry coal fired per hr. (lb.) 12.78 49.40 82.90 24.75 64.70
I
liter to producer per hr. (lb.) 22.2 30.40 42.05 16.30 28.50
ry air per hr. to producer (lb.) 58.8 202.5 386.0 87.5 259.2
)
ilorific value gas, b.t.u./cu. ft 104.8 111.8 103.4 120.0 137.3
I
t. dry gas per hr. (lb.) 69.0 248.6 456.0 105.0 326.0
]
as analysis, CO2 (per cent.) . . 9.17 6.46 6.94 5.90 4.20
CO 16.06 27.77 21.33 21.70 27.01
i
O2 0.53 0.49 0.37 0.40 0.23
[
H2 9.55 9.53 7.06 10.70 10.40
\
CH4 2.10 1.74 1.90 1.60 1.77
• N2 62.65 59.01 62.50 59.70 56.40
j
)!d gas efficiency (per oent.) 54.3 65.8 64.6 56.4 76.2

461. Tests of Westinghouse Double-zone Producer

Fuel Pocahontas Texas lignite

1 iration 96 hrs. 46 5 hrs..

I
tal coal fired 14.452 lb. 12,693 lb.
at value per lb •
13.983 B.t.u. 8.007 B.t.u.
iat value per cu. ft. (totial) •
126.9 B.t.u. 128.3 B.t.u.
[at value per cu. ft. (effective). 117.8 B.t.u. 117.1 B.t.u.
Uciency (total) 80% 77.3%
iiciency (effective) 74 5 %
. 70.5%

791
 . 1 5

Sec. 10-4G2 POWER PLANTS

Gas Analysis
Carbon dioxide 7.9% 12.4%
Oxygen (O) . . 0.5 0.9
Carbon monoxide (CO).. 18.1 13.3
Marsli gas (CHO. 2.6 3.6
Hydrogen (H)... 12.6 14.7
Nitrogen (N)... 58.3 55.1

In the above table all values are computed on the assumption that -i
gas is at a temperature of 62 deg. Fahr., and that the absolute pressuru
30 in. of mercury.
462. Tests of Wood Pressure Producer
—
(Gas plant test 24 days continuous running)

'COAL per cent. GAS: Average per cei

Moisture 14.68 Carbon dioxide COs= 9
Volatile combustible 30 98
. Oxygen O2 =
Fixed carbon 42 93
. Ethylene CjHi =
Ash 11.41 Carbon Monoxide CO = 20
Hydrogen H2 = 1
100 00 Methane
. CH4 = 1
Sulphur 1.33 Nitrogen N2 = 52
Calorific power 12,343 B.t.u. per lb. of dry coal.
Average heat value of gas for 24 days= 156. 1 B.t.u. per cu. ft

On
the average of the Government tests generally Prof. Fernald gives a

following:
463. Tests by Oeological Survey

Bituminous Lignites
Load 90 —100 Per cent.
30 to 50 hr. As Dry
fired

B.t.u. per lb. of fuel 12,280 13.150

Cu. ft. of gas per lb 60 5 64.7 . 35.8
B.t.u. per cu. ft. of standard 152. 1 158.4

Total lb. per b. h.p. hr 1 .36 1.26

464. Quantity of gas per lb. of fuel in up-draft pressure produce

given in Par. 462 (Fernald, Tech. Paper No. 9, Bur. Mines., 1912).
465. The addition of excess steam over that theoretically reqd
if not too large, has little or no effect on efficiency, but gives more coi
over clinker formation. The steam required at 30 to 60 lb. gage is
to 2.5 lb., averaging 0.7 to 1.0 lb., per b.h.p. The highest figure*
for by-product recovery plants.
466. Analyses of gas are given in Par. 128, 4S9, 460, and 463.
467. The operation of gas producers presents three main featt
(a) maintenance of uniform resistance of bed, which includes rcgula
of feed and poking; (b) removal of ash; (c) prevention of clinker. Il
case of up-draft producers coal is fed usually by an air-lock deviofli,
spreader; poking is done through holes in the top, to fill up holes or chai
which may have formed by clinkering and arching, or by localized (

Poking must be carefully done to avoid starting the evib

\ bustion.
intended to correct. A moderate rate of driving will tend to keep fm
better condition, as the producer cannot be forced to the same ezvB
a boiler and give satisfactory results. The down-draft producer tm
poked in the same manner as the suction producer. ;

468. The cost of producers (1920) complete wit'h auxiliaries rangesj

lows: Suction producers, up to 300 h.p., total cost =- 1600 -1-23.0 X (h.p»(
'
Prof. R. H. Fernald.
792
 POWER PLANTS Sec. 10-469

'ressure producers,up to 300 h.p., total cost - 1800+30X (h.p.) (70)

'ressure producers,above 300 h.p. Total cost = 4,000 28 X (h.p.) (71) +
Repairs and maintenance vary from $0.35 to $0.55 per h.p. per year,
juarantees on maintenance are usually 2 to 3 per cent, of first cost a year.
SUPERHEATERS AND CONDENSERS
469. The laws of heat transfer for superheaters have been covered in
'ar. 15 to 29, and for economizers in Par. 320, for vaporizers in Par.
, 3 and 4.

470. Superheaters are attached to the vaporizers of some types of

reducer, to superheat the steam fed to the fuel bed. They are usually of
le protected type, heated by the hot gas leaving the producer, and deliver-
ig superheated steam for use in the fuel bed. Some additional economy
*
gained by their use.
471. Wash boxes are water sealsof a check valve
and serve the purpose
prevent blowing back of gas.
)
They are made of cast iron generally, with
cross-section equal to about 25 times the delivery pipe. The submersion
the entering pipe is about 3 in.
472. Economizers are employed for preheating the air fed to the pro-
[icer and operate on the sensible heat of the gas leaving the producer.

I
473. Vaporizers or boilers are attached to nearly all producers, and
: rve to yield the necessary steam for gasification, abstracting sensible heat
om the hot gas. They are usually built much like a vertical fire-tube
)iler, or of cast-iron cooling chambers forming the top or side, of the
oducer.
474. Condensers are employed to remove the tar, and consist usually
chambers with iron baffles upon which the viscous tar impinges and
Uects; suitable drainage allows the tar to be recovered and removed. The
Qeral design is similar to an oil separator. Some are made with helical
ssages to secure centrifugal action. There are also one or two designs of
^chanical tar extractors built like centrifugal fans, to throw out the
by centrifugal force. They are generally made entirely of cast-iron.
475. Operation. The operation of superheaters requires practically
labor; vaporizers in this respect are the same as boilers; tar separators
luire periodic cleaning The tar is inclined to
and continuous drainage.
umulate and thicken with the dust in the gas. The standby period for
aite or bituminous producers is from 6 to 10 hr. a week for cleaning
rposes and repairs, on the average. Anthracite producers may be run
to 90 days continuously. (Latta, 1910.)
176. The
cost of these auxiliaries is included in the cost of the producer,
en in Par. 468, since they are essential to operation.
SCRUBBERS AND PURIFIERS
177. The impurities found in producer gas are duet, tar and ammonia.
i3t isblown over from the fuel bed, being usually the ash from the fines in
coal. In some cases, lampblack is also carried over in the down-draft and
ble-zone types. Tar is the result of partial decomposition and is a corn-
•tible material. Ammonia is produced by the union of H dissociated in
producer with N in the air supplied.
1 78. Two methods of cleaning are generally used: (a) wet scrubbing,
h stationary towers and water spray in sonae form, or mechanical scrubbers
re or less like fans with water injection; (b) dry scrubbing, with purifiers
filters made
with excelsior or shavings, which require periodic removal
: 1 cleaning.
''

i79. Wet scrubbers consist of steel towers filled with coke, wire netting
'
wood latticing, somewhat after the fashion of a cooling tower. Water is
I ayed down from the top, and divides into fine streams or spray, washing
;
.solid impurities and tar, dissolving out ammonia and sulphur gases.
3 amount required varies from 1.5 gal. to 2.5 gal. per b.h.p. per hr.
80. The m.echanical washers are chiefly heavy-built fans with water
i
-y devices, or Theisen washers. The simple fan washer consists of cen-
' ugal fans of heavy construction, usually with cast-iron casing, with a water
' .y device at the inlet to produce a spray curtain or fog through which the
t passes. The efficiency averages about 12 to 1, gas containing 1.75 to
'
' gr. per cu. ft. being cleaned to 0.15 to 0.22 gr. per cu. ft. The h.p.
 Sec. 10-481 POWER PLANTS
required per 1,000 cu. ft. per hr. ia 0.066. With two fans in series, the clea
ing is from 50 to l,.to 200 to 1 and the h.p. required is 0.184 to 0.2,
per 1,000 cu. ft. per hr. The water required per fan is 0.0125 to 0.0150 g
per cu. ft. cleaned per hr.
481. The Theiaen washer consists of three elements in one casing: (a.)
primary cleaning fan at the suction end; (b) an annular chamber betweer
drum fitted with helical vanes and a coarse mesh grating surrounding t
drum; (c) a discharge fan chamber. Water spray is fed in at the suoti
chamber and tangentially in the grating. The water consumption ia 0.02
gal. per 1,000 cu. ft. per hr.; the h.p. required ia 0.184 per 1,000 cu. ft. per 1

cleaned.
483. The by-products recovered from bituminous coal gasification f
ammonium sulphate and tar. , The recovery of ammonium sulphate reiiuii
the addition of an acid tower, through which dilute sulphuric acid is oin
lated as in a purifier. The acid removes the ammonia gas as ammonii
sulphate. Tar is removed by separators or condensers, and may be used a
fuel in certain oil engines; it usually contains considerable moisture —
up
20 per cent., on account of the water employed in washing the condeni
trays.
483. Purifiers or dry scrubbers consist of a steel tank or tower, fill
with shavings, excelsior, coke, or Laming composition. Laming compusiti
_

isa mixture of bog iron ore and shavings. It is used in 6-in. to 8-in. laye
on gratings, and absorbs cyanides and sulphur compounds. The Laming m
ture is removed and exposed to the air from time to time, which regencra
the materials for use again. Shavings and other mechanical dry purifyi
material must be removed and replaced by fresh material as often us tU
become clogged. Wet scrubbers are automatically cleaned by the wa
used to precipitate dust. The Smith tar extractor consists of a diaphrai
of glass wool, which causes the separation of tar without the use of wa
except for cooling.
484. Cost of the apparatus is included in the cost of producers, Par. 4

HOLDERS
485. Oas storage is required to provide reserve capacity for sudiien
crease of demand, and to absorb excess generation when sudden decnase
load occurs.
486. The holder is of the regular collapsing gasometer type, in no w
different from the ordinary illuminating- as tank. In some cases the wa
seal in the base is used as an additional wash-box for incoming producer g
487. The capacity required varies from 40 to. 25 cu. ft. up to 100 h.
20 to 15 cu. ft. up to 1,000 h.p. The larger the number of units the less .-^ton
usually requirea, as manipulation is more flexible.
488. The operation of gas holders requires only occasional painting
protect the tank, yearly cleaning of sediment from the water reservoir. H
suitable ateani-supply to the lift seals to prevent freezing in winter.
489. The cost of gas-holders varies from $1.40 to $0.75 per cu.
including foundations (1920).
P&OPEBTIES OF OAS
) —
490. Calorific
Lucko.)
Value of elementary gases. (From Gas Engine De^
J-

B.t.u. per lb.

Lb. B.t.u. per cu. ffcV
per cu. ft.
Fuel at 62 deg.
High Low fahr. High Low

H... 61,524.0 51,804.0 .00538 331.0

CO.. 4,395.6 4,395.6 .07498 329 58.

CH4. 24,021.0 21,592.8 .04308 1,037.22

C2H4 21,222.0 19,834.2 .07631 1,619.45

794
 POWER PLAMfS Sec. 10-491

Producer gas has a specific gravity, referred to air, of 0.97, average

i91.
0.25. 'It varies in composition, not only witlx the type of pro-
lecifio lieat,
icer,but from variations in operation of the same producer. The hydrogen
mtent, being usually high, limits the compression, usually from 100 to 160
i.
per sq. in., with 18 to 5 per cent, of hydrogen, average pressure 135 lb.
areful jacketing of valves and pistons for large engines raises the obtainable
)mpression.
492. Natural gas is the richest of the power gases, and is obtainable
liefly through the soft coal and oil regions. Ohio, Indiana, IlUnois, Pennsyl-
inia and Virginia are most favored in this way. The allowable compression
iries from 75 to 130 lb. The specific gravity referred to air is approxi-
ately 0.40 to 0.50; density, 0.043 to 0.049 lb. per cu. ft.
i93. Illuminating gases, either coal or water gas, are usually too ex-
nsive for use in any but the smallest engines, up to say 75 h.p. The allow-
le compression is 60 to 100 lb. average 80; specific gravity approximately
W to 0.43 for coal gas, 0.57 for water gas.
'494. Blast-furnace gas is the leanest of the gases and will stand compres-
^•n from 120 to 190 lb., averaging 155 lb.; this is on account of the dilution
I
th N, and-low hydrogen. It is used only in large gas engines at steel mills.

[
OAS ENGINES
Pl96. Oas-englne cycles. The thermodynamics of the gas engine is
nplicated by the fact that not only the change of state by expansion and
; npression occurs in the cylinder, but also the combustion. The order of
'ints in the usual Otto or four-stroke cycle is as follows: aspiration of a
fiirge into the cylinder (suction stroke) compression, approximately adia-
;

fic on the instroke; ignition and explosive combustion at constant volume,

ile the piston is on or near the dead centre; and approximately adiabatio
I
l^ansion on the second outstroke; partial expulsion of the burnt gases at
stant volume when on the outer dead center, further expulsion on the
Dnd instroke, at atmospheric pressure. The two-stroke cycle eliminates
auction and exhaust strokes, by admitting the incoming charge under a
pounds pressure while the piston is on or near the outer centre, after the
tial exhaust to atmospheric pressure and constant volume has just taken
;e. This incoming charge sweeps before it, by displacement, most of the
_

idning burnt gases.

S6. The standard reference diagram put forward by Lucke is useful
nvestigating the performance or design. This diagram is an assumed
cator card based on the assumption that the mixture in the cylinder will
ave the same as pure air. The general relations are as given below.
IT. Compression pressure.
/ro\1.41 /t)a\1.41 ,_„.
andJ h = t.{^)
^
Pb = P.(-) .

(72)

per sq. in., suction pressure; pb = final compression

p<i=14.7 lb.
'sure; cylinder volume in cu. ft. = displacement plus clearance;
t;a = total
jompression volume, or clearance, in cu. ft.; ta = absolute initial
jerature (deg. Fahr. + 461) and<i, = absolute compression temperature.
;

}«. The pressure rise on explosion depends on the amount of heat

1 !u. ft. of mixture.

Pe = + l) and =
P6(^^ «. <!,
+^ (73)

[•«pc = explosion pressure; Q = B.t.u. per lb. of mixture; C, = specific

at constant volume; tc = absolute explosion temperature; and the other
pcJs are as "above (Par. 497).

2. 2 Q ,. ,.
(in lb. per sq.
.
in.)
,

(P^)0 71t)a
\pb/
\i. B.t.u. per cu. ft.

-oT^an
n + a' + 1 <75)
Sec. 10-500 POWER PLANTS
where // = B.t.u. per cu. ft. of mixture, hot; a' = cu. ft. of air required
burn 1 cu. ft. gas; and n = cu. ft. of neutral added. 'The actual press-
ratio pc/pb obtained is from 40 per cent, to 65 per cent, of the air card rati
000. Expansion is taken according to the law
^»5\1.41
Pd=-pe(^ (

which the same as for compression

is

601. Efficiency.
/po\0.29
("-)"-"
E=i-*;=i-
th \pb/
where =
therrnal efficiency of the cycle; other symbols are as abc.
£!
The thermal efficiency of the ideal cycle is only dependent upon the r o
of compression to suction pressure.
602. Four-cycle engines are built in all sizes; the terms single and dove
acting have the same application as for steam engines. The majoritM?
engines of small and moderate size are single acthig. Large engines e
generally made double acting, to economize space, as the gas engine is e n
more bulky per h.p. than the steam engine.
603. Two-cycle engines are also used in all sizes, but are found to ic
greatest extent in large units, double acting. For small units they ari> m !r
built double acting, as separate pumps are then required to give the i>re3 e
for charging at the end of each stroke. In the small single-acting typos, le
mixture is compressed between the piston and the crank case.
604. Cylinder jackets are essential to practically all gas engine.s. ie
enormous heat developed during explosion would soon destroy the oyli sr
and piston if they were not protected by cooling. In most cases this is le (

by water jacketing; in a few small engines, air cooling is emplod.

Pistons smaller than 15 in. in diameter are not separately cooled by w?r
jacketing; but above this size, the area of piston head is too large to'
properly cooled by conduction to the jacketed cylinder walls, and the aii
the crank case; therefore water cooling becomes necessary.
606. The quantity of jacket water should be about 6.5 gal. per b4' '

hr. at 50 deg. Fahr., 7.75 gal. per b.h.p.-hr. at 60 deg. Fahr., 9.7a
per b.h.p.-hr. at 70 deg. Fahr., and 12 gal. per b.h.p.-hr. at 80]
Fahr., for large units. Most of this may be recovered and re- used if coi
If a cooling tower is used, for recooling the jacket water, about 8 per *[

is lost by evaporation. The heat loss to the jacket is from 25 to 50 per

generally the largest with small engines.
606. Mean effective pressure is computed from the indicator card
same manner as for a steam engine. The m.e.p. of the reference diai
given by
M.e.p.=-;^^\(l-(^")0.29}
or
M...p..«i(Ji-,){i-Qo.»}.c(4-i)
where the symbols have the same meaning as in Par. 497 to 600.
For constants to be used with these equations see Par. 607.
607. Constants used in Calculation of M.E.P. (Par. 606)

Compression Value of factor Compression Value of trnji

C = 5.41X C = 5.V
Atmos- Lb. pel Atmos- Lb. per
pheres sq. in. pheres sq. in. -(g)
44.1 1.474 8 117.6 2.44
58,8 1.787 9 132.3 2.511
73.5 2.014 10 147.0 2.(
88.2 2.187 11 161.7 2.71
102.9 2.327 12 176.4 2.771(1

796
 POWER PLANTS Sec. 10-508

B08. Observed mean effective pressvires obtained by test are given

Lucke:
 ' 3

Sec. 10-516 POWER PLANTS

m.e.p. for the fuel employed (Par. 608;, the required displacement per
divided into required i.h.p. gives total cylinder displacement per mini
Internal combustion engines are usually rated at 15 per cent, to 20 per ci
below the capacity of the cylinder as given above. Torrance and Ulbri
(.Power, 1912) give the following formulsB for builders' rating in Amer

Producer gas, b-h.p. = -g-g^-

Illuminating gas, b.h.p. = dHn -2.0

15,700

Natural gas, b.h.p. = dHn

15,200'

Blast-furnace gas, b.h.p. = dHn -5.0

21,000
where d = diameter of cylinder, inches; i = stroke in inches; and n—-
per. min.
616. The fuel consumption of gas engines on producers ranges f r

0.99 to 3 lb. per b.h.p.-hr. From 75 to 90 cu. ft. of gas i

b.h.p.-hr. are required, of approximately 150 B.t.u. per cu. ft.

617.Test of 300-h.p. lUmer 2-stroke cycle double acting horizoid
engine. (Power, May, 1913.) Duration of test, 33.5 hr.; coal, Wt-
moreland bituminous, 14,100 B.t.u. as fired; average b.h.p., 284; ave);e
B.t.u. per cu. ft. of gas, 144; Producer efficiency, 67 per cent.; B.t.u. 'i

h.p.-hr., 10,300; total eoal per b.h.p.-hr. 1.14.

618.Fuel consumption, Ulbricht and Torrance (Power, 1912) e
average fuel consumption as below: (B.t.u. and cu. ft. per h.p.-hr.)

50 b. h.p. 100 b.h.p. Over 100 b.h 1

B.t.u. cu.ft. Eft. B.t.u. cu. ft. Eff. B.t.u. cu

Water gas 10,690 35. 2123. 10,160

8j 33.4'25.0 10,160i 3:i
Carburet ted gas. 10,690 18.123.8 10,160 17.225.0 10,160! 17
Coal gas 10,690 17.6 23.8 10,160 16.7.25.0 10,160 10
Producer gas:
anthracite. .10,380 82.6 24.5 9,630
. . 76 6;26.4 9,600 70 .

bituminous. 10,380 83.0 24.5 9,630

. . 77, 026.4 9,600 7t> .7 15
coke 10,380 82.0 24.5 9,6301 76, 2i26.4 9,600 76 ,015
lignite 10,380 77.5 24.5 9,630] 71. 826.4 9,600 71.6 15
oil 10,380 68.7 24.5 9,630! 63. 7i26.4 9,600 63 .515
peat 10,380 73.6 24.5 9,630 3 26.4 9,600 (VS.OlS
wood 10,380 80.6 24.5 9,630 8|26.4 9,600 74 15 (•)

Blast-furnace gas 10,860 114.0 23.4 10,500 0124.2 9,860 104.0

Coke-oven gas. 10,690 22.0 23.8 10,160
. 9 25.0 10,1601 20.9 10
Natural gas avg.. 10,380 12.2 24.5 9,420 027.0 9,320 10.9 13

619. Test of a 310-h.p. engine, horizontal double-acting (Buck

running on coke-oven gas, 560 B.t.u. per cu. ft., gave the following ro:

Load B.h.p. B.t.u. per h.p. hr. Per cent, eflicipi

i 165 13,000 18.5

! 210 11,700 23.0
full 310 11,100 22.5

The B.t.u. per kw.-hr., with bla.st-furnace gas engines (Freyn, 19i:i). >

from 16,200 to 26,000, average 18,400; thermal efficiency 13.0 to HI

cent., average 18.5.
620. Test of a 600-h.p. engine of the Borsig-Oechelhauser 8-
type, on coke-oven gas (Junge, in Power) gave results as follows:

798
 POWER PLANTS Sec. 10-521

J , B.t.u. per
^•^•P- b.h.p
 «

Sec. 10-527 power plants

827. The maintenance and repair costs are approximately 42 per cent
to 55 per cent, of the net operating cost. For oil and supplies the cost ii
about double that of a steam plant.
028. Weight. The net weight of large tandem double acting typei
averages 680 to 740 lb. per kw. Moderate sizes of single-cylinder
single acting engines weigh from 200 to 300 lb. per b.h.p., the unii
weight going up with the brh.p.

PIPING
629. Oeneral requirements. As all pressures are light, standarc
pipe and fittings may be used throughout. Expansion must be providec
for in the same manner as steam piping (Par. 369 to 372).
630. Q as piping from producer to scrubbers and purifiers should b(
cast iron with standard flanged joints, asbestos or metallic packing. It
most oases it is advisable to line the piping between scrubber and producei
with fire-brick. Explosion doors should be installed at intervals, and if th<
gas is dusty, ells should be replaced by tees where possible, to provide fo:
raking and cleaning.
031. Water piping for supply to jackets, vaporizers and purifyinj
apparatus may be of ordinary galvanized standard pipe. The discharg'
from scrubbers and purifiers is preferably of cast iron, on account of corro
sive action.
632. Exhaust piping can be built of wrought-iron standard pipe, o
cast-iron standard pipe; light riveted pipe is not advisable as it may col
lapse on the return wave of a muffler or exhaust pipe explosion. Mufflers fo
small engines are usually cast-iron pots; for large plants, concrete tunnels
with water in the bottom to cool and silence the exhaust, are frequontl
used.
033. The cost of piping varies from $6.00 to $12.00 per kw. of maximui
rating of the plant, being much the same as for steam plants (1920).

PLANT ECONOMY AND DESIGN

034. The auxiliaries to be considered in the engine room are: comprcsso:
for starting; exciter units and cooling water pumps; station lighting. I
the producer room the auxiliaries are: the blowers or exhausters, as the ca:
may be; power for rotating ash table, producer body, or mechanical poker,
if these are used; coal and ash handling apparatus; mechanical washers ar
tar extractors; scrubber and washer water-supply pumps.
030. The heat losses in a producer plant will be indicated by tl
foUowiiig analysis. (Snell, "Power House Design.") Loss inproducir ai
auxiliaries, 20 per cent.; loss in jacket water, 19 per cent.; loss in exhau
gases, 30 per cent., loss in engine friction, 6.5 per cent., loss in generator
per cent., total losses, 76 per cent., converted to electrical energy, :

per cent.
036. The Willans line for the several main units should be plott;
with kw. output and cu. ft. of gas as ordinates. On this curve should
superposed the gas used by auxiliaries, or if these are electric driven, th(
requirements should be subtracted from the gross output of the generate
before plotting the Willans line. By taking the gas required at any lb:
from this curve, and plotting for the load curve of the plant, the gas demi^ir
of the engine room is obtained. Similarly, an input-output curve forj-t,
producer can be drawn, between coal fired and gas generated; on thidi
superposed the gas or power demands of producer room auxiliaries and't-
) standby coal. In conjunction with the engine-room gas demand cujf":
this gives the coal demand for the station under load.
037. Power for auxiliaries. The power required for the blower or
nauster will be from 1 to 2.5 per cent, of the total horse-power of the produc
The horse-power requirements of washers are given in Par. 480. The ci
and ash handling system will not usually require more than 0.2 to 0.4 j.
cent, of the total horsc-powor; compressor equipment, not over 0.1 J,

cent. The total power requirements of the auxiliaries will be about 5 ]

800
 POWER PLANTSi Sec. 10-538

cent. The standby losses of a producer bauked 14 hr. in 24 are about

1.5 to 2.0 per cent, of the total.

038. Water consumption per h.p., for the plant will run from 5 to
8 lb. per kw-hr., at the switchboard for non-recovery plants, and 40 lb.
per kw-hr. for recovery plants, using cooling towers in both cases.

639. Vertical vs. horizontal engines. Design practice in plants up

to 2,000 b.h.p. will allow vertical engines; these usually are not built
over 750 to 1,000 h.p. per unit. Above this size only horizontal engines
are used.

640. Ammonia
recovery. It is not worth while to attempt the recovery
of ammonia from bituminous plants of less than 2,000 b.h.p., and
then only when the load factor is above 25 per cent. Each ton of coal
produces approximately 100 lb. of sulphate of ammonia; the sulphuric acid
I'equired is about 1 to 1 in weight ratio to the sulphate of ammonia. In
nties, the recovery plant is practically out of the question on account
of space requirements. Extra labor, the acid tower, extra repairs and the
|308t of bagging the sulphate must be taken into account.

^ 641. The floor space required is from 5 to 8 sq. ft. per kw., or 3 to 4
jjmes the floor space for a turbine plant. The producer room requires from
,1.0to 4 sq. ft. per kw.

042. The load factor should be high for a successful gas plant. The
-jas engine is not well suited for heavily swinging loads partly on account
>it its lack of much overload capacity.

643. The subdivision

of generating units should be the same as for
i

j
I steam —
plant six to eight units if possible. For small units, up to 400
J).h.p. one reserve unit in 5 or 6 is sufficient; but for large units (which have
never been brilliantly successful), one in four is necessary for continuity of
if>I)eration. The reliability of the gas engine is still open to much question
ijn very large units, but the units of moderate and small size are as reliable
I'f steam engines, if given the same grade of attention.

! 044. Labor required is usually one man per engine above 7.50 h.p.
[nd one man to four or five producers of good size and equipped with me-
chanical apparatus for feed and stoking. About one man for 1,000 to
'F,200 h.p. of engine, and one man per 2,000 to 2,500 h.p. of producer,
Represent the average.

645. Total plant cost. The following data gives (1920) producer plant
.33ts: For plants up to 4,000 kw.,
'(ital cost= 3,000 -f- 259.5 (kw.) (86)
T" I plants larger than 4,000 kw.,
\ cost = 12,000 + 250 X (kw.). (87)
•
distribution of cost is given below for three cases, and is not much
id by size of plant.

Item
Sec. 10-546 power plants

TESTING
546. The essential mesurements for determining producer effl
—
ciency and capacity are: (a) weight of coal per hr.; (b) proximat.
analysis, B.t.u. per lb. and moisture in coal; (c) cu. ft. of gas made; (d
temperature of gas, humidity; (e) calorific value and analysis. Additiona
data required for full information include: (f) weight of dry ash per hr.
(g) proximate analysis and B.t.u.; (h) wt. of steam per hr.; (j)
wt. of vapor
izer and scrubber water per hr., and temperatures; (k) h.p. required fo
blowers or exhausters and tar extractors or washers; (1) grains of dust pe
cu. ft. in gas. -,/.•,• j
For most purposes, only the efficiency of the producer itself is desired
For full details of tests, see Gas Power Committee reports, A. S. M. E.
647. The testing of gas engines is very similar to that of steam enginet
The essential data are: (a) i.h.p.; (b) b.h.p. or kw. output and generate
efficiency; (c) r.p.m.; (d) explosions per min., if hit-or-miss governed
(e) cu. ft. of gas per min.; (f) calorific power of gas per cu. ft. Desirabl
additional data include: (g) jacket water per hr.; (h) inlet and outlet jacke
water temperatures; (i) gas, air and exhaust temperatures; (k) amount c
lubricant. All physical dimensions of the engine should of course be takei
648. The essential data for a plant test consist of kw.-hr. output b
switchboard and coal used in producers; or cu. ft. of gas and calorific powe
if coke oven, blast-furnace, natural, or illuminating gas is used.

649. For gas measurement the gas meter is chiefly used; the metho
of measuring the fall of a gas holder for volume should never be employe
as the change of temperature ordinarily possible, entirely vitiates tV
accuracy. The Venturi meter furnishes an accurate and inexpensive nieasu
ing device if properly handled and kept clean in the throat.
660. Indicated h.p. is obtained by the usual indicator, but equippi
with 0.5 in. area piston for this work.
651. The calorific value of gas can bo obtained by the Junkers or oth^
make of gas calorimeter. Grains of dust per cu. ft. are obtained 1
a special filter apparatus and test gas meter; the dust of a measured quantit
of gas is collected and weighed. Other measurements are simdar
those for steam engines (Par. 427).
552 The duration of test should be about the same a« for engine ar
boiler tests generally. For Venturi readings, a record is best, or very fr
quent readings, say once a minute. The producer test should preteraOu
not be less than 24 hr. except with small producers intended for intermit^
use; the longer the test the better.
663 For full calculation of results the heat balance is required.
Power Test Codes, A. S. M. E., furnish full data for the elaborate test

OIL POWER PLANTS

BY REGINALD J. S. PIGOTT
OIL ENGINES
564. The thermodynamics of the explosion cycle (O^to) typ«^
engine are exactly the .same as for gas engines (Par. 496 to 608).
"^
oil
constant-pressure cycle (Bray ton cycle), of which the Diesel is the^
cipal example, has slightly different events. For the four-cycle tJJ
the inspiration and compression strokes are the same, but are made upo%
only; at the end of compression, the oil fuel is injected, and burned,
inM
earlyj""
a way as to maintain a practically constant pressure during the
of the working stroke. Expansion and exhaust then follow as m tM
engine.
655. Thermodynamic equations. For the air card, or ideal
vb, t;, and vr, are obtained as for the Otto
cycle. Par 497 to 501., when
ing fuel at constant pressure:

Pc='Pi, (87) P'»='(P'w) J

802
 POWER PLANTS Sec. 10-556

(88) td = ta^ (92)

V Cp tb' Pa
(89) (93)

Q1-Q2
(90) E=- (94)
Mi
where pa, Pb, P<r> pj = inspiration, compression, combustion and release
pressures, respectively, in lb. per sq. ft.; Vn, Vh, Ve, r<i = volumes in cu. ft. at
beginning of compression, end of compression, end of combustion or begin-
ning of expansion, respectively; tn, h, tc, id = absolute temperatures, at the
same points in deg. Fahr.; Qi = heat added per lb. of gases, in B.t.u.; Q» =
heat abstracted per lb. of gases in exhaust, in B.t.u.; JS = thermal efficiency;
Cr = specific heat at constant pressure.
556. The thermal efficiency would be the same as for the Otto cycle,
if complete expansion occurred for the same compression pressures. But as
expansion is always incomplete, the efficiency is less; this is more than
offset by the much higher compression possible with the Diesel cycle.
657. Types. The types are the same as for gas engines; see Par. 502 and 60S.
668. Mean effective pressure of the Diesel type is given by

[Qi- •c»< „(r'-"-i)l

M.e.p=/
[Da"""!
1- — (95)
Pb 1

r= i+ (96)
Cpta
where / = JouIe's equivalent, 777.5; Cv and Cp = specific heat at constant
volume and constant pressure, respectively; ta, Va, pa, Pb are the same as
.in Par. 554.
Lucke gives the following usual m.e.p. for Otto types.

Kerosene Gasolene

Absolute compres-U^
sion pressure
"ov,» ^
,cv. ..i.c.^f.
Absolute compres-
sion pressure
Observed m.e.p

46 40 66 106
63 69 70 75
65 68 75 100
68 40 86 70
70 72 86 72
50 35 95 60
55 85

"869. Speed and power. The speed is the same as for gas engines of
the same power For indicated and b.h.p. see Par. 612.
(Par. 511).
MO. Kerosene engines of the Mietz and Weiss and Hornsby-Akroyd
i

jjypes are built in sizes up to 250 h.p. and operate in the same general manner
»8 gas engines, the fuel being pumped in and vaporized in a hot tube, hot
'
3ulb, or vaporizing chamber. The hot tube and the hot bulb are kept warm
)y being left unjacketed, and by the combustion of a portion of the charge in
he hot bulb chamber. Compression forces up the temperature of the charge
nough for ignition to take place. Kerosene engines are the least efficient
if the oil engines.
861. Gasolene engines are practically unused for power-station purposes,
>n account of expensive fuel, and low relative economy, except for IJ to .5
L'.v. house or farm lighting sets.
562. The crude oil engine is arranged like the kerosene engine, except
hat more careful arrangements must be made for preheating the oil for
'iiporization, andin most cases, the air also. Exhaust gas jackets are
;(nerally used for
the purpose of providing the necessary heat.

803
Sec. 10-563 POWER PLANTS
663. The Diesel engine ia now the most important of the oil engines
on account of its remarkable efficiencies. It is built in both two-cycle and
four-cycle types, and practically always vertical, single acting. It requires
separate compressed-air starting sets, at about 1,000 lb. per sq. in. pressure.
In the two-cycle type, separate air pumps (cylinders driven from the cro.ss-
head) are employed, as well as the fuel pump, which is always necessary.
664. Weights. The Diesel and the Junkers engines are the heaviest of
prime movers, running from 400 to COO lb. per b.h.p. The enormous
weight is due chiefly to the heavy pressures, 500 lb. per sq. in. being an
ordinary compression, with safe design allowance up to 1,000 lb. per sq. in.
to safeguard against breakage due to preignition.
666. The capacity of oil engines is based on cu. ft. of cylinder dis-
placement, as for gas engines (Par. 616).
666. Builders' rating. Ulbricht and Torrance (.Power, 1912) give
average practice in builders' rating (for oils and distillates), as

b.h.p.
dUn -0.75
(97)
'217875
where (i = cylinder diameter, in in; Z = stroke in in. n = r.p.m. The rating
is about 10 to 20 per cent, less than the ultimate capacity.

667. The fuel consumption is poorest for the gasolene and kerosene
engines, running from 13,000 to 15,600 B.t.u. per b.h.p.-hr. 9,400 to ;

10,000 B.t.u. per b.h.p. hr., for American Diesel engines. The German
Diesel and Junkers engines run as low as 7,100 to 8,500 B.t.u. per b.h.p.-
hr. All figures are for full load. These figures correspond to 0.65 to 0.78
lb. of gasolene or kerosene per b.h.p.-hr.; 0.48 to 0.52 lb. of oil for Ameri-
can Diesels; 0.37 to 0.44 for German Diesel and Junkers Engines. Fuel
consumption decreases with size.

668. Test of Falk kerosene oil engine (H. D. Wile, Elec. World, 1913)

Cooling water, per hr

lb. 632
Inlet temperature, deg. Fahr. . . 47.5
Outlet temperature, deg. Fahr. 106
Rev. per min 448
B.h.p 9.05
Indicated h.p 11.04
Mechanical efficiency, per cent. 82
Kerosene, lb. per b.h.p.-hr. . . . 1.14
Thermal efficiency 11.2
Angle ignition, deg. 34
Rev. per min
B. h.i
Indicated h.p
Mechanical efficiency
Kerosene, lb. per b.h.p.-hr.
Thermal efficiency
Mixed water-kerosene, per cent.
Rev. per min
B.h.
Indicated h.p
Mechanical efficiency
Kerosene, lb. per b.h.p.-hr.
Thermal efficiency
 POWER PLANTS Sec. 10-569

670. Tile efficiency of

gasolene engines at full load
O "H Tfi t> 10 CO C> t»r-( ca^ic^ varies from 18 per cent, at 10
COO'-iOO<N>C-H''5cOMt-OOtO b.h.p. per cylinder, to 20 per
cent, at 22 to 32 b.h.p. per
cylinder; kerosene engines, 1
to 2 per cent, less Americam
;

Diesel engines, from 26 per

cent, at 60 b.h.p. per cylinder
O tOOO t»tO CD-^Ci CO end, to 27 per cent, at 100
COOOONOSTtit^T-itoOOOO
CO'—1»0 05^cDCOCD»'5CD
O
CO
b.h.p. and over, per cylinder
end; Oerman Diesels, from
33 per cent, at 60 b.h.p. per
cylinder end, to 36 per cent,
at 100 h.p. All figures are at
O cot- t- ooS full-load.
0"5C510 ai'<*" OO CD-'ll-*

eOt-00»0(N-*0(MOOO»00«0 871. The overload capac-

ity of oil engines is not more
than 10 to 20 per. cent, above
the rated capacity.

872. Governing in on
engines is chiefly by throttling
0C<10>-i CO-* OiiO t-'*00 00
the oil supply to the cylinder.
COOOS-Hh-rtl— lOr-nCfflOOO t— The Mietz and Weiss kerosene
00 t- 00 >-i o r- to r-i lo (N
engine governs by the hit-or-
miss principle on the oil pump.

673. Ignition in some of

the kerosene engines, and all
• -H * Oi CO CM t- 00 of the gasolene engines, is by
eoi-coo"5-*a>t-Nt->Of-ioo t» electric spark, usually make-
CO COOO COCOCOCM-* i-H rt
and-break. Some of the kero-
sene engines operate with hot
bulb. The Diesel types and
most of the heavy oil types
ignite by means of the heat
(N^-H ooeo
due to high compression.
C<l»Ht-rtU5 0>
t- 00 CO -H CO
674. The operation of-the
kerosene and other low-com-
pression oil engines is practi-
cally the same as for as en-
gines. The hot-tube systems
require occasional removal for
cleaning of carbon deposit, and
clearing the oil holes. The
Diesel engine, however, re-
quires the highest class of op-
erating labor, on account of
• M-S ^^ .
0.=' the high pressures employed,
and the lubrication difficulties.
These objections are reflected
in the lower efficiency of
t. 3 s! ^^ aj"^
American engines compared
2-^ o
with English or German types,
J3.S C a i- >-iO because the compression pres-
.13 O sures have been reduced to
i£ relieve pressure and lubrica-
tion troubles, and thus obviate
(
the use of such highly skilled
labor.

§ -S a^ .2 ^ -73
.2
-g
^ '^ '° '3 '3 e S- 676. The cost of internal
combustion engines is given
as follows:

805
 , .

Sec. 10-576 POWER PLANTS

Gasolene, up to 75 h.p., throttle governed,
Total cost = 253.0 + 59.2 (b.h.p.) (dollars) (99)
Oil engines, up to 400 h.p.,
Total cost = 356 85X (b.h.p.)
+ (dollars) (100)
Diesel engines, from 100 to 1,000 h.p., approximately (price varies very
widely)
Total cost = 58.0 (b.h.p.) +2,000 (dollars) (101)
Stott, Pigott, and Gorsuch, A.I.E.E. Proceedings, June, 1914, give 95.00
per kw. for all sizes of Diesel engines complete with generators. This is due
to the fact that weight per kw. increases with size. The price in June, 1920,
was $150.00 per kw.
676. Test of a low-compression heavy oil engine. (A. A. Potter
and W. W. Carlson, Elec. World, 1913)

Cylinder diameter, in 16 ,'i

Length of stroke, in 24
Kind of fuel Solar oil
Specific gravity at 60 deg. Fahr. 0.8145
Deg. Beaum6 42 .

Lb. per gal 6.70

Heat units per lb., high 17,240
Heat unit per lb., low 16,322
Heat units per gal 117,100

Number of test
Data and results
1

Duration of heat, hotirs 3 1 1

Barometer, in 26. 26.94 2t).95

Speed of engine, rev. per min . 183. 201.2 202
Mean effective pressure 75. 37.1 27.50
Indicated h.p 85. 45.5 34.0
B.h.p: Average 73. 39 70 . 20.2
Mechanical efficiency, per cent 85. 87.4 59.4
Fuel used, total lb 222. 50.1 42.55
Fuel used per i.h.p. per hour, lb 0. 1.10 1.20
Fuel used per b.h.p. per hour, lb 1. 1.26 2.1
Heating value of fuel consumed:
Per b.h.p. per hour, b.t.u 17,400 21,750 36,200
Temperature of cooling water, deg. Fahr.
Inlet 82. 79.0 84.25
Outlet 164. 133.0 125.55
Rise 81. 54.0 41.2
Cooling water used per hour:
Total, lb 1,775 2,868 2,712
Perb.h.p., lb 24. 72.2 134.2
Thermal efficiency, per cent 14. 11.7 7.0

Heat distribution per lb. of Per

B.t.u. B.t.u. B.t.u.
fuel ^,. cent. •nt.

Converted into i.h.p 2,935 17.0 2,315 13.4 2,030 1 1 30 .

Converted into b.h.p 2,520 14.26 2,020 11.7 1,210 7.01

Friction and losses 415 2.40 295 1.7 82(1' 1.7(1

Losses in jacket water. 1,955 11.32 3,090'l7.9 2,03 .S l.-.^f-

Losses in exhaust, radiation, etc. 12,350 71.68 11,835 08.9' 12,50'.) 7:1.1::

677. The cost of piping for oil plants, per installed kw., ranges fror
$1.20 to $.3.85 (1920).
 POWER PLANTS Sec. 10-578

PLANT DESIGN
678. General. What has been given in Par. 394 to 414 can be applied
in principle to the oil plant. But inasmuch as the only auxiliaries are the
exciters, jacket pumps and air compressors for starting, the problem is much
simpler, and the economy of the plant is much more nearly that of the main
unit.

679. Plant costs. The oil storage tanks require approximately 0.06
to 0.08 gal. capacity per kw. All other auxiliaries, including crane, oil
pumps, air compressor and compressed air tanks, cost from $4.00 to $10.00
per kw. of rated capacity, installed. The total costs will range as follows,
per kw.:
 I

Sec. 10-r^m POWER PLANTS

686. Brickwork for power-station buildings varies about as given
below. May, 1920.
Heavy basement work, labor cost, only, $15.00 to $20.00 per M.
18 in. walls 17.00 to 21 .50 per M.
13 in. walls 20.00 to 23.50 per M.
18 in. wall, faced on one side with pressed brick 25.00 to 30.00
18 in. wall, faced on both sides with pressed brick 35.00 to 41.00
13 in. wall, faced on one side with pressed brick 30.00 to 36.50

This is for straight wall work. For work much cut up by windows and
corners, these prices must be increased. Common red brick costs about
$21.00 per M
delivered in or near cities.
587. Concrete. The following approximate cost for concrete applied in
1920.

Per cubic yard

Range Average

Mass foundations $7.20 to 10. 10 $12.50

Conduits and sewers 9.00 to 28.80 17.00
Tunnels, subways 10.80 to 75.00 27.00
Reinforced retaining walls i 21 50
. to 27 00
. 24 00
.

Reservoirs, filters i 10.80to41.00 19.00

Tanks, standpipes 7.20to36.00 21.50
Buildings, total structures 14 50 to 47 00
. . 25 00
.

Walls in building construction... ,5i.-.j.>s«j--,' 21.00 to 45.00 I 31.50

Encasing structural steel in concrete.'. .... I
25.00 to 37.00 33.00

688. Structural steel for building purposes costs from $105.00 to

$270 per ton, erected. For any amount over 200 tons, it should not
ordinarily exceed $125.00 per ton. May, 1920.
689. Building foundations are made almost exclusively of mass con-
crete (Par. 587).

690. The bearing power of soils for computing the proper spread ol
footings is given below.

Soil
 .

POWER PLAXTS Sec. 10-592

592. Loads on Foundation

(Chicago Building Ordinances)

Foundation
Tons per Foundation
[Tons per
sq. ft. ! sq. ft.

Concrete , 4.0 Iron rails in concrete 6.0

Foundation piers, dimension 5.0 Steel rails in concrete. 8.0
stone.
Brick piers in cement. . . ,
9-12.5 Piles. 12.0

693. Machinery foundations are generally of mass concrete, as for

buildings. But lately the demands for condenser and auxiliary space
under steam turbines have forced the use of structural steel foundations.
There is no objection objection to this, provided the turbine is properly
balanced and the maximum permissible deflection of about 0.02 in. is not
exceeded. Foundations should extend up to 1 in. or } in. below the bottom
line of the machine base to be set; and when the latter is lined up, the whole
should be grouted with cement grout, mixed 1:2, of cement and sand.
Foundation bolts are now seldom set from templates, but are accurately
located in the forms by drawing dimensions. Each bolt is mounted in a
pipe sleeve large enough to allow a play of at least one diameter for taking
care of inaccuracies in the casting and in the setting. With some turbines,
no bolts whatever are needed.
694. Drainage should if possible be arranged for by placing the whole
station above sewer or tide-water level, so that gravity flow from sumps and
traps is possible. Where this cannot be done, suitable reservoir sumps
must be provided, emptied by ejectors or pumps, float controlled. Gal-
vanized iron or cast-iron roof leaders may be employed, with cast-iron soil
l)ipe in the 'ground, or glazed clay tile pipe.
595. Lighting and ventilation. The use of all-glass monitors is the
most desirable way of lighting and ventilating plants. The rolled steel
section windows and monitors now produced have rendered easy the problem
of fireproof, permanent window and ventilator fixtures. The operating
devices should be arranged for quick opening and closure, to provide for
storm protection. The continuous sash for monitor use is the latest device
ia this line. Care should be taken to make windows rain- and snowproof,
and to allow opening for ventilation without letting in rain during ordinary
storms.
696. Lighting by daylight is accomplished by the monitors above
mentioned and by high side windows in some cases. The night illumination
in most cases is by incandescent lamp. The arc and Xernst lamps are gener-
ally undersirable; the mercury vapor lamp is very successful wher« used, and
is the least injurious to eyesight, but there is much general objection to the

color of the light. The usual demand for illumination in a power station
will take from 0.2 to 0.5 per cent, of the output.

697. Fire risks in well constructed plants are exceedingly low; in many
of the largest plants, no insurance against fire is carried. The use of wood
roofs or other inflammable structures, makes insurance imperative.
698. The cost of buildings for various types of power plant is given in
Par. 411, 646 and 679 per kw. of capacity. The cost per cu. ft. of contents
j.s less variable, and runs from $0.40 to $0.65. May, 1920.

HYDRAULIC POWER PLANTS

BY ARTHUR T. SAFFORD
\,<m»iUting Hydraulic Engineer, Member, American Society of Civil Engineers,
'I
Member, American Society of Mechanical Engineers
HYDRAULICS
699. Pressure and depth. Water is but sUghtly compressible, therefore
he pressure, P, is for all practical purposes directly proportional to the
I'.'pth, H, and can be represented by a diagram as shown in Figs. 46 to
49.

809
Sec. 10-600 POWER PLANTS
The total pressure on any submerged surface is equal to the area
of the pressure diagram Fig. 4C; decb. Figs. 47 and 48) and the centre of
(^abc,
pressure passes through centre of gravity, G, perpendicular to the sub-
its
merged surface. The moment of the pressure about c is (Fig. 49),
M = Py (ft-lb.) (102)
The pressure in lb. per sq. in. at any point is

p = 0.433 X Depth (103)

The pressure is always normal to the submerged surface. The total pres-
sure exerted on a submerged body is
P = Q2AHA (\h.) (104)
wherein H is the depth of water in feet over the geometrical centre of the
body and A is the area of the surface in sq. ft.

Caution: If % dun, and there Is lealcago

< under It there maj- be upward pressuto
,

90 the entire bottom

Fig. 46. Fig. 47. Fig. 48. FiQ. 49.

600. Possible upward pressure under dams. If the structure is a

dam and there is leakage under it there may be upward pressure over the
entire bottom. If there is no leakage then there will be no upward pressure.
The truth in any given case probably lies between these two extremes and
the foundations and underlying material must be carefully studied to make
a proper design.
601. The dynamic properties of water in motion are theoretically
the same as those of falling bodies i.e.:
V= V2gh = 8.02Vh (ft. per sec.) (105)
where ff
= 32.16.
Actually this formula is rarely exact and expressions based upon it mu-st
be modified by empirical coefficients.
602. Tb.% quantity of water passing a given point in a unit of time
is equal to the product of the net cross-sectional area taken perpendicular tc
the line of flow and the mean velocity in that time parallel to the line of flow
This may be expressed by the equation
Q = AF (sec-ft.) (106)
If A the area in square feet, V the velocity in feet per second, then (,
is
is the quantity in cu. ft. per sec, or, in its briefer form, second-feet. This
in the United States is now the common expression in water-power practiet
for flow of streams, capacity of canals and raceways and discharge of water-
wheels.
603. At every section of a continuous and steady stream the tot*,
energy is constant; whatever head is lost as pressure is gained as velocity
This is known h.m Bernoulli's theorem, and in terms of head can be expressec
as follows: Total head = velocity head +
pressure head -|- head due to ele
vation = constant; or in every stream section,

IlT'=hv+hp + h,=' -p +I +h. (ft.) (107:

where y the constant to reduce lb. per squaro inch to head in feet, or 0.433
is
In order to make this equation of practical application, a term represontim
the head lost in overcoming friction, h\, must bo added on the right-hand sidi
of the equation. This formula, properly modified to include the effect o

810
 ^

POWER PLANTS Sec. 10-604

frictional resistances, is the basis of all empirical formulas for the flow of
water.
604.Power and energy. The potential energy of water held in reserve
s its weight multiplied by the net available distance through which it can
'all performance of work. As power expresses the rate of doing the work,
in the
t is convenient to deal with the flow of water in cu. ft. per sec. falling through
I given vertical distance in feet. Power = 62. 4QH ft-lb. per sec, where
3 is the flow in cu. ft. per sec, and H
the vertical distance or "head" in feet
vnd 62.4 is the weight in pounds of 1 cu. ft. of water.

Horse-power = —&2AQH QH
(108)
550
This is the maximum horse-power that might be obtained from Q cubic
eet of water per second falling a distance H
feet, assuming an efficiency of
ransformation of energy of 100 per cent. This expression multiplied by
he known efficiency of a water wheel will give the power at the water-wheel
haft. Ordinarily QH/W or QH/\2 will give approximately the net water
lorse-power, corresponding respectively to eflSciencies of 80 per cent, and 73.3
>er cent.

FLOW FORMULAS
605. Orifices employed
as meters, are limited in use; experimentally
hey have given very consistent results, but in practice these results often
annot be reproduced with sufficient accuracy for precise work. Orifices of
slatively small sizes, of regular shapes (usually round or rectangular) with ,

arefuUy made edges, and used with

ill contraction of the jet, have been
arefully experimented upon and may
^e used with confidence provided there
' practically no velocity of approach
[ess than 0.5 ft. per sec).
, 606. The flow of water through an
rifice (Fig. 50) in a vertical wall ex-
ressed in cubic ft. per sec. is

= CAV = CAy/2^
(cu. ft. per sec.) (109)
here A
the area of the opening in
is
h the head in feet measured
[uare feet,
'rOm the surface of the water to the cen-
• r of the opening, and C is the coeffi-
.ent of discharge which depends on
iie form of the orifice. For sharp-edged
.ifices, 4 sq. ft. or less in area, with full
ntraction of the issuing stream (Fig.
,t), discharging under heads from about

:to 20 times the depth of the orifice

Tactically no velocity of approach), a
Hlue of C may be taken as 0.6. If the
•ince is large and the head acting is BtlUliiE Box

•lall, the exact or integral form of the

nation* must be used when C is taken —
Fig. 50. ^Circular orifice with
0.6. For high heads and relatively sharp edges, giving full contrac-
lall orifices this is not necessary. If tion.
iB contraction is even partly suppressed
le results are unreliable; if wholly suppressed the orifice becomes a short
be or nozzle and the coefficient varies greatly, depending on the shape
d proportions; but always more than 0.0 (see Par. 635). {
607. In treating head gates and sluice gates as orifices, the forms of
iss-soction, the channel of approacii and that leading away from the
!''<', and the velocity of approach are all very important; these factors
"lifv any computed discharge based upon the opening and observed head.
* Water Supply and Irrigation Paper No. 200.

811
 Sec, 10-608 POWER PLANTS
The coefficient of discharge for gates on the basis of their cross-sectional are
and the head measured above and below them may vary all the way from tha
of a standard sharp-edged orifice (0.6) to over 1.0 if there is much velocity o
approach. For these reasons, if head gates or sluice gates are to be used a
measuring devices they should be given their own rating by some independen
method of measurement.

608. Weisbach's Coefficients

Cin Q =
(109 /\

wherein C is a coefficient which depends on the form and head h acting oi

orifice, Q is given in cubic feet per sec. when h and d are measured in feet
h is head in feet above centre of orifice; and d is diameter of orifice in feet.

Thin plate ori-

fice and com-
0.3d)U^'>-^<i
plete contrac-
tion of stream
Larg« holes
M wid gTMt depth
C=
ill !i-8to5d»l • ^^
*•
0.M

S. deg. Inlet I
T-v J
slightly i.
Depend- Depend-
round '"^ "P°° ing on
smooth- the
0. 0.97 0.54 C = 0.90 ness length
5.75 0.95
11.25 0.92 Inlet
surface and 0.0144 0.68
22.5 0.90 0.55 very C = 0.96 velocity 0.0328 0.64
45. 0.75 0.58 round
to 0.99 C = 0.96 0.0656 0.63
to 1.5
67.5 0.68 0.60 C = 0.97 0.0984 0.62
90. 0.63 0.63 0.1312 0.6141

609. Weirs, * if properly constructed and used with faithful regard'

reproducing the exact conditions which obtained when the experimenl
derived his formula, should give good results. Some extraordinary resi|
have been obtained because the.se precautions were not observed; and
measurements unless standardized will gradually lose their hold. A ynf
installation in a power plant must necessarily cut down the available h^
by roughly 3 ft. For this reason the weir should be used only for testil
and not for operating. "
610. "The procedure to be followed in weir measurements con
prises :t
(a) Constructing and setting up the weir and the gage for measuring tl
head; reproducing, if possible, the experimental conditions of the formula i

be used.
(b) Measuring the length of the crest and determining its irregularis
if any.
(c) Taking a profile of the crest if not sharp-edged.
(d) Determimng by actual measurements the cross-sectional area of t
channel of approach.
(e) Establishing by leveling the relative elevations of the crest of the '

and the zero of the gage.

(/) When the desired regulation of flow is established, determining t
head by hook gage or other observations at intervals as frequent aS"
conditions require.
r
* For the most extended compilation and examination of existing wi
data Water Supply and Irrigation Paper No. 200 (Weir Experiments, Cq
cients, etc., by R. E. Horton) should be consulted.
t Hughes and Safford, "Hydraulics;" New York, MacMillan Co.,
page 196.

812
 »

POWER PLANTfS Sec. 10-611

(g) If possible, measure the ac-

;ual velocity in the channel of ap-
jroach by a current meter or some
)ther direct method; and
(A) Compute the discharge by
,he formula selected. Three of
hese operations require especial con-
ideration, viz.: construction and
etting, the measurement of the
lead, and the selection of the for-
nula."

^ +
II
a:
^ >

<\ <;l a u a
£'" o o
I 1

S S ^^ +> n
II

K^
II

Kd
I
^ o o
?°
O
in-q O «
71

•^ a <^
EC a
< <-i
^
lOrt —
&:!i:;

2
iJ CD « "a
cr o
a o
m"
a as

"S u
.a a
"I
I Fig. 52. —Weir with end con- 15, Si 1

tractions suppressed. 8 .

*
611. "Construction and set- +
ng of weirs.* In order to elimi- m n
ite as far as possible factors for M n
^lich precise allowance cannot be II II

ade, the construction and setting 13^

ould meet the following conditions:
('!) A sharp-crested weir with
rnplete crest contraction should
used. (
('') The crest should be level, and
i-nds vertical.

*
Hughes and Safford, "Hydrau-
;-;
'
New York, MacMillan Co.,
11.

813
Sec 10-613 POWER plants

(c) The end contractions should be complete, or, if suppressed, entire!

suppressed.
(5) The upstream face should be vortical; the downstream face so designt
that the nappe has free overfall.
(e) Free access for air under the nappe should be made certain.
(/) The weir should be set at right angles to the direction of flow.
Ig) The channel of approach should be straight for at least 25 ft. aboi
the weir, of pnactically uniform cross-section and of slight slope (preferab
none).
(h) Screens of coarse wire or baffles of wood should be set in the channe
if necessary, to equalize the velocities in different parts of the channel, bi
not nearer the crest than 25 ft.
(t) The channel of approach should have a large cross-sectional area i

order to keep the velocity of approach low."

A weir witli complete end contractions is shown in Fig. 51; suppressed er
contractions are shown in Fig. 52.
613. Francis formulas. The best known formulas are those of James 1

Francis and M. Bazin. The Francis formulas are strictly applicable only
vertical, sharp-crested weirs with free overfall and either with no end oo
tractions ("suppressed weir"), or with complete end contractions and: C
when the length of the weir is at least 5 ft.; (6) when the head (//) is n
greater than one-third the length (L) (c) when the head is not less than
;

ft. nor more than 2 ft.; (d) when the velocity of approach is 1 ft. p
second or less; (e) when the height of the weir crest above the bottom of t)
channel of approach is at least three times the head. For tabulation
standard formulas see Par. 612.
614. Smith's formulas. For short weirs (shorter than 5 ft.) t:

experiments and studies made by Hamilton Smith, Jr., afford the be

guide (See Smith's weir coefficients. Par. 620).
615. Bazin's formula. The beat weir experiments abroad are those
M. Bazin whose general formula is Q = mLh\/2gh for suppressed weirs onl
At about 1.0 ft. depth on the crest, with no velocity of approach, t
results from his standard 8.56-ft. (2-meter) weir are practically those
James B. Francis' standard 10-ft. weir (See Par. 621).

616. Fteley and Stearns' formula. For heads from 0.07 to 0.5 ft. t

Fteley and Stearns formula* Q = S.SlL\/ U'+0.007L is recommended.

617. Weir discharge tables. The following table of discharges for wc
without end contractions, and velocity head is given for heads from 0.00
2.98 ft. and includes figures from the Fteley and Stearns formula up to (

ft. and the Francis formula from 0.5 ft. to 2.98 ft. The quantity
water is given in cu. ft. per sec, per foot of weir, with complete cc
traction on the crest, and no end contractions. Q = 3. 312/V //'-[- 0.007L i

depths up to 0.5 ft. and Q = 3.33L\^/7^ for depths above_0.5 ft.; the vc
city due to the head is computed by formula, Vel. = v2gh.

•Fteley and Stearns, in "Sudbury River Experiments" (page 84) sfe

that this formula is based upon experiments in which the depths oi^
weir ranged from 0.07 to 1.63 ft. Trans. Amer. Soc. Civil Eng., Vol.

814
 POWER PLANTS Sec. 10-G18

„ Quan. Velo. Quan. Velo.

(ft. per (sec- (ft. per
^'*' sec.)
ft.) sec.) ft.)

1.18 5.67
.02 1.13 .25 5.78
.03 1.60 .32 5.89
.06 1.96 .39 6.00
.08 2.27 .47 6.11

0.11 2.54 1.55 6.21

.14 2.78 .63 6.32
.18 3.00 .70 6.42
.22 3.21 .79 6.52
.26 3.40 .87 6.61

0.30 3.59 1.95 6.71

.35 3.76 2.03 6.81
.40 3.93 .12 6.90
.45 4.09 .21 6.99
.60 4.24 .29 7.08

0.55 4.39 2.38 7.17

.61 4.54 .47 7.26
.66 4.68 .56 7.35
.72 4.81 .66 7.44
.78 4.94 .75 7.52

0.84 5.07 2.84 7.61

.91 5.20 .94 7.69
.97 5.32 3.03 7.78
1.04 5.44 .13 7.86
.11 5.56 .23 7.94

6.12 9.82 2.00 9.42

.24 9.89 .02 .56
.36 9.95 .04 .70
.49 10.02 .06 .85
.61 10.08 .08

6.74 10.14 2.10 10.13

.87 10.21 .12 .28
.99 10.27 .14 .42
7.12 10.33 .16 .57
.25 10.40 .18 .72

7.38 10.46 2.20 10.87

.51 10.52 .22 11.01
.64 10.58 .24 .16
.77 10.64 .26 .31
.91 10.70 .28 .46

8.04 10.76 2.30 11.61

.18 10.82 .32 .77
.31 10.88 .34
.45 10.94
.58 11.00

8.72 11.05
.86 11.11
9.00 11.17
.14 1 1 23 .

.28 11.29
 X

Sec. 10-019 POWER PLANTS

0.64 ft., compute the discharge (a) by the Francis, (b) by the Fteley am
Stearns, (c) by the Smith formula.
(o) Francis formula: Q = 3.33 (5-0.1X2X0.64)
.y'oTeS'^^. 33X4. 872>
0.512 = 8.31 cu. ft. per sec; not corrected for velocity of approach V
Area of channel of approach ^ = (4. 36 + 0. 641 10 = 50 sq. ft. Velocity
ofapproach F^ =QM =8.31/50 = 0.1662 ft. per sec. Velocity head h,=
(0.1662)2/64.32 = 0.0004; y/W
= V(0.64 + 0.0004)' - \/0.0004' = 0.5125 -
0.000008 = 0.5124; Q = 3. 33X4. 872X0.5124 = 8.313 cu. ft. per sec.
(6) Fteley and Stearns formula: Q = 3.31 (5-0.1X2X0.64) Vo.64»4
0.007X5 = 3.31X4.872X0.512 + 0.007X5 = 8.29 cu. ft^ per sec; ;», (a
above) =0.0004; H = 0.64 + 2.05X0.0004 =0.6408; \/H» = 0.513; Q = 3.31X
4.872X0.513 + 0.007X5 = 8.31 cu. ft. per sec.
(c) Hamilton Smith formula: Q =0.607 X!X5X8.02X\/o.64' = 8.30S
cu. ft. per sec; hv (as above) = 0.004 // = 0.64 + 1.4X0.0004 =0.6406
;

= =
\/W' 0.5127; Q 0.607X 1X5X8.02X0.5127 = 8.320 cu. ft. per sec
In the foregoing solutions it is seen that the effect of velocity of approacl
is negligible, as is usually the case when the velocity is less than half a foo'
per second.
619. Further examples of weir calculations. Given a suppressec
weir 7 ft. long, with crest 4.5 ft. above the bottom of the channel; th<
observed head is 1.36 ft. Compute the discharge by the Francis, Ftelej
and Stearns, and Bazin formulas: (a) not correcting for the velocity of ap
proach; (6) correcting for the velocity of approach.
(a) Francis formula: Q = 3.33 X 7 VlJfP = 36. 97 cu. ft. per sec
Fteley and Stearns formula: Q = 3.31 X7xVl.36»+0.007X7 -36.80 cu
ft. per sec
(6) Francis formula: A = 7 X 5.86 = 41.02 aq. ft.; V^ = Q/A '
36;97/41.02 -0.90 ft. per sec; ;i« = (0.90)764.32 = 0.0126 ft.; \/7f»'
\/(l-36 + b70126)'-\/0.0126'=1.610; Q = 3.33X7X1. 61 =37.50 cu. ft
per sec.
Fteley and Stearns formula: F^ =36.70/41^2 = 0.894; A, = (0.894)764.3
= 0.0124; // = 1.36+ 1.50X0.0124 = 1.379; \/H»=1.620; Q = 3.31X7X 1.62
+ 0.007X7 = 37.58 cu. ft. per sec.
Bazin formula: Bazin's coefficient (Par. 621) includes effect of veloeit
of approach; Q = 0.4266X7X 1.36 \/64.32 X 1.36 = 37.97 cu. ft. per sec.
620. Smith'
 POWER PLANTS Sec. 10-621

Ce = coeflBcient for weirs with complete contraction at two ends and com-
plete crest contraction.

Effective
 '

Sec. 10-623 POWER PLANTS

when the batter of the sides is 1 in 4 this aim i.s accomplished. The formulj
for any trapezoidal weir takes the usual form
Q = CLVh^ (cu. ft. per sec.) (110
in which C for the special form cited has been experimentally determine
as 3.367. Correction for velocity of approach may be made as for the Franci
weir. The advantage of this weir is tha
a constant length L may be used for a
heads so that for continuous measurt
ments with varying heads it saves muc
labor. This form has been much use
in irrigation projects in the Wester
United States. By adding 1 per cent, t
the value of Q found in the weir table i
Par. 617 the discharge for this weir ma
be computed.
623. Triangular (notch) weirs. Th
common triangular notch is right anglec
set with the apex down and the bisectc
of this angle vertical (Fig. 53). It ha
been found by experiment that the coeff
cient of such a triangular weir is remart
ably constant for all heads. The formal
Fia. 53. —Triangular weir.
for a right-angled notch set as describe
reduces to
Q = CVHS (cu. ft. per sec.) (Ill
in which C may be taken as 2.54 when H is measured to the apex of the angli
For measuring small quantities of water where the necessary head consume
is unimportant the V notch furnishes an accurate means and has been dt
veloped commercially as the Lea Recorder.
624. Flow of water in channels, whether open or closed, is subjoct t
the same fundamental laws, and the formulas in common use are based on tl
two primary conceptions stated in Par. 602 and 603. Head is required i

produce velocity, to overcome obstructions such as bends, sudden constri

tions or enlargements and head is required to overcome friction. Friction J.

turn depends on the velocity of flow and on the surface over which the vraXu
flows, its extent, and its character. In any formula for discharge the extm
of the rubbing surface in contact with the water may be cared for directly t'
a numerical factor known as the mean hydraulic radius, which is found V
dividing the cross-sectional area of the stream by its wetted perimeter; t:
latter is the linear dimension of that part of the boundary line of the cro.'^
section of a channel in contact with the water. The effect of the charact
of the surface must be cared for by empirical coeSicients. Head may 1

provided by natural topographical conditions as in the slope of a river bCj

or created artificially as in the case of an elevated reservoir feeding into a \
line. In the formulas mo.st commonly in use the head appears in the a
of the hydraulic grade line which is the fall 'in feet, per foot of dista
measured along the longitudinal axis. The hydrauUc grade hne is a lin
the plane of the longitudinal axis of the stream and at all points distant I
it an amount equal to the net effective head. In an open channel]
hydraulic grade line is coincident with the surface of the water. In the (

of a pipe or conduit flowing under pressure the hydraulic grade line is ab

the centre line of the pipe and distant from it as defined above.
625. The Chezy formula is probably the most satisfactory one tol'
certainly for open channels. It is usually stated as follows:

V = cVliS (ft. per sec.)

where C = coefficient increasing with the mean hydraulic radius, and fot
clean channels usually increasing with the mean velocity of flow, and
creasing with the roughness of the channel; /it = mean hydraulic radius/y*
S = sine of the slope of the hydraulic grade line. The common text-BB
formula which, as nearly as may be determined, was proposed by Weisbwl

is not uncommonly designated as Weisbach's, Darcy's, Weston's, or Che

818
 :

POWER PLANTS See. 10-626

idwhich is used only for pipes under pressure, is as follows (for steady
iform flow under pressure in circular pipes)

lere ft/ =
the head lost in friction, /=the
friction factor or coefficient of
-ction, decreasing with an increase in the diameter of the pipe and commonly
th an increase of velocity of flow; and increasing with the age and roughness
the surface in contact with the water (Par. 626). Z; = the length (in ft.)
the pipe measured on its axis; D = the internal diameter (in ft.) of the pipe;
= the mean velocity of flow in ft. per sec; g = the acceleration due to
ivity, taken here as 32.16. The above equations are merely different
)ressions for the same formula. Either may be used to suit convenience.
alues of C suggested for use in Eq. 112 are as follows: New cast-iron pipe
i carefully without abrupt changes in grade or alignment: sizes 6 in. to
in., velocities 3 to 8 ft. per sec., C = 102 to 108; sizes 12 in. to 20 in., velo-
es 1 to 5 ft. per sec, C = 105 to 115; sizes 20 in. to 60 in., velocities 1 to 6
per sec, C = 120 to 150. Riveted steel pipe (new) sizes 16 in. to 102 in.,
:

ocities 2 to 5 ft. per sec, C=

100 to 115. Tunnel or aqueduct with
30th cement or hard brick lining of relatively small cross-sectional areas
to 50 sq. ft.): velocities 1 to 5 ft. per sec, C = 115 to 140. Small
id, cross-sectional area about 100 sq. ft. in loose gravel or rock: velocities
=
5 ft. per sec, C 60 to 85. Large canal, wide and shallow, smooth
torn and sides: velocities 2 to 5 ft. per sec, C = 50 to 70. Large canal,
,e and deep, fairly smooth bottom and sides: velocities 2.5 to 3.5 ft. per

C = 75 to 90. Large river, tortuous channel: C = 40 to 80. Large river,

bends: C = 70 to 100. Where the carrying capacity of any pipe or chan-
18 very important about 30 per cent, depreciation should be figured in
ance.
36. Friction factors (/in Eq. 113, Par. 626) for pipes may be computed
Weston's formula. * This formula, which must only be applied to pipes
ing interior sides similar to lead and brass pipes, from one-half inch to
e and one-half inches in diameter is as follows:
.
f,„,„„, 00315- o.oed
/=0.0126-h — (114)
V V
vhich d = internal diameter of the pipe in feet; and r = the velocity in
per second.
or pipes with interior sides similar to new cast-iron pipes the following
I

aulas are used:

OOO1.Q6"«^0*0723+«:50002O81_6x
/= V0.017379+°-:50^+ ^— i ^ (115)

0198920 + «:0«1|«^3)1£ (116)

(°
formula (Eq. 115) is for velocities of flow less than 0.33 ft. per
first
the second for higher velocities.
VI, The Eutter formula though intended and largely used for pipes as
;
as for open channels, is not recommended for general use in either case.

41.66 +Mli-HM^
n
V= S
xVrS (117)
1 + (41.66 + °T'^\-^
iStimate directly a value of C (Par. 626) is simpler, and probably quite as
late as to estimate a value of n. The value of n depends on the value
i
Considering that in picking out the value of n a variation of 0.001 for
!l values of n and Rmay change the value of C as much as 17 per cent.,
'Tables showing Loss of Head due to Friction of Water in Pipes" by
^l^ld B. Weston, C. E., D. Van Nostrand Co., 3rd Edition, 1903.

819
 i

Sec. 10-628 power plants

and for moderate values as much as 5 to 8 per cent., it should be obvious tl:
hair-splitting calculations with the Kutter formula are a needless wai
of time, producing merely numerical accuracy instead of a high degree
Erecision. Though it seems evident that we shall never have one formula
t accurately all kinds of channels, it appears probable that we may hav(
small group of formulas each of which will fit some particular class of chann<
Values of n to be used in the Kutter formula for calculating values of C
be used in the Chezy formula are as follows:
7! =0.01: should never be used except for temporary work and then oi
for perfectly smooth, clean iron pipes under 8 in. diameter and for high
•

locities, or for temporary and new planed wooden stave pipes, at high veloc:
10 in. and under in diameter.
n = 0.011: for above pipes, and low velocity.
n = 0.012: for above pipes 3 ft. or more in dia.rneter and high velociti
old iron pipes 8 in. diameter or under, low velocities; old city water ma
above 8 in. diameter. Also for concrete tunnels having R = 2.5; wood flum
open, planed plank, long bends.
n = 0.013: for above pipes 36 in. to 120 in. diameter, old pipes and 1

velocities; l-to-2 cement-lincd pipes; new penstocks hned with unplaned lu

ber and running full at all times; large concrete-lined tunnels of area 100
200 sq. ft.
n = 0.0135: Ashlar masonry and well laid brickwork penstocks ovel
ft. in diameter; cast-iron concrete or steel-riveted pipes 8 in. to 20
diameter, long in use, short joints and under pressure of 75 to 150 lb. per sq.
n = 0.015: rough concrete pipes where the interior cannot be smoothed
kept clean, moderate velocities and diameters above 3 ft. penstocks of poo
;

laid rough brickwork; concrete-lined, open canals, low velocities.

71 = 0.017: canals with gravel bottom and sides well rammed, stones be

0.3 to 0.7 in. diameter; tunnels through hard rock, well trimmed and roug
• faced; very large open concrete-lined canals.
n = 0.02: rough rubble masonry; canals through rock, or with bottc
and sides paved with cobble stones; canals in earth with bottoms and si
well trimmed; small rough lumber penstocks with battens and poor alignme
n = 0.0225: canals in earth in good condition, but long in use, having m
growing freely. .

n = 0.025: canals in clay, long in use; small rivers, deep and narrow and w
no sharp bends, smooth sand bottoms and smooth uniform banks.
71 = 0.0275: canals and rivers as for 7i = 0.025, but having an occasio

bend and snag also the same, but with gravel bottoms; earth canals as
by dredging.
71 = 0.03: rivers having loose boulder beds, irregular banks, sharp ber

shallow, normal flow.

71 = 0.035: rivers with rough, irregular beds having shallows and po
snags, bends, gravel bottoms, average flood stages.
7t = 0.05: large .shallow rivers, having sharp bends, low heavily woo
banks, snags, shallows, pools, rough bottom and moderate flood conditi.
71 = 0.055: large torrential streams during high floods, with the bn
heavily- wooded and inundated; mountain streams with many falls, \»
boulders, rapids, etc.
628. Beardaley's formula for C. Assuming values for n, S and If, C i
be calculated from the formula as given by R. C. Beardsley.

c — 7
-r TrzrrTTi—zrT
0.001551 n \
(

(0.5521 +
or in its original form
1.811 . 0.00281>
.bO-t-

629. Bazin's formula for C. Bazin proposed a formula for compu

the value of C to bo used in the Chezy formula which differs from the
Ku

820
 POWER PLANTS Sec. 10-630

•mula in eliminating S and making the variation in C depend only upon

nations in the mean hydraulic radius and the coefficient of roughness,
is as good as any general formula and has the advantage of simplicity.
8 formula is

15^6fl_
C = (J20)

Values of y
! 7=0.109: very smooth surfaces; neat cement; planed wood.
» 7=0.290: smooth surfaces; planks, bricks, ashlar.
[ 7=0.833: rough surfaces; rubble masonry.
7 = 1.54 canals with mixed Unings; very regular earth or paved with
:

stones.
7=2.35 earth canals in ordinary conditions.
:

7 =3.17 earth canals in bad condition.

:

3azin's formula represents the results of a very careful study of existing

.a and is extremely valuable in designing relatively small channels and
<se with very smooth linings; it also meets the conditions of design for all
'.n channels as well as, if not better than any general formula available,

las the additional merit of simplicity.

30. Friction loss in iron pipes increases with age. Under ordinary
ditions of service at the end of 30 years we may expect to find the losses
cast-iron pipes due to friction about doubled. This is satisfactory for
gh approximations and the loss for intermediate years may be taken as
portional to the age.
31.Loss of head at entrance. The flow formulas which have been
n (Par. 606 to 629) take into account only the head necessary to over-
le friction.There is in addition to this a further loss of head in creating

Fig. 54o. Fig. 54c.

velocity of flow and

overcoming the resistance of entrance into the
in
The velocity head is equal to V^/2g. The head lost at entrance
168 with the form of entrance and is expressed as a constant times the
city head ioV^/2g. Values of f are given below.

0.5^^ (0.Hto0.02)„— 0.93^

2(7 2(7 2(7
12. Nozzles, properly designed, furnish one of the simplest and most
irate methods of measuring small quantities of water. Coefficients of
|targe for various forms of nozzles from about J in. to 5 in. have been
rflttined with great accuracy by John R. Freeman. * Nozzles are espe-
y useful in measuring the discharge through pipes, fire hose, and in testing
rrformance of pumps and impulse water wheels. With nozzles to
Freeman's coefficients are applicable, discharge measurements can
lade with an error not exceeding 2 per cent.
iS. Loss of head due to bends, elbows, valves, etc. Experimental
are either meager or lacking from which to compute the loss of head
to bends, elbows, valves, etc. Their effect only becomes important with
velocities and may be considered aa corresponding to so many additional

jl'ran«. Am. Soc. C. E., Vol. XXI, pp. 303-482.

821
 ..

Sec. 10-634 POWER PLANTS

feet of straight pipe. In long uniform pipe lines laid with easy curves t
friction loss predominates and the minor losses may be neglected. T
following table gives approximate values determined by experiments ma
by the Inspection Department of the A.s.sociatod Factory Mutual Fire Insi
ance Companies, and may be used when no exact information is availab

Number of feet of clean, straigh

pipe of same size which wouh
Name of fitting cause the same loss as the fittinj
(Loss in straight smooth pipe a
given by Weston).

2.5-in. to 8-in. long-turn ells.

2.5-in. to 8-in. short-turn ells.

3-in. to 8-in. long-turn tees . .

3-in. to 8-in. short-turn tees.

l/8th bend

634. Freeman's formula for nozzles is given as follows:

G>= 29.83 Cd^ (gal. per min.) (i

^•(i)'
where G = discharge in gallons per minute, C = coefficient of discharge,
diameter in inches of the nozzle orifice, D = diameter in inches of the piezi
eter ring at the base of the nozzle, and Pc = piezometer reading in pou

Fia. 55. —Section of nozzle and piezometer ring.

per square inch at the centre of the nozzle orifice For water-power pTi||
in engineering units the same formula becomes:

(sec-ft.)
)'
'V'-«=(b
where Q = discharge in cubic feet per second, C = coefficient of dx8
d=> diameter in feet of the nozzle onfice, C
= diameterin feet of thej
eter ring at the base of the nozzle, and A» — piezometer reading in I

water above the center of the nozzle orifice.

 POWER PLANTS Sec. 10-635

636. Coefficients for nozzles. A

value of 0.974 may be taken as a
.table coefficient (C) for the ordinary smooth fire nozzle with a nominal
diameter between 0.75 in. and 1.375 in. and under pressures
varying from 20 to 100 lb. per sq. in. For pressures less than
20 lb. per sq. in. the same coefficient may be used, but with-
out so great a confidence in the accuracy of the result. For
larger sizes of smooth nozzles ranging from 1.75 in. and 2.5 in.
Freeman's coefficients lie between 0.987 and 0.999 for pressures
ranging from 15 to 55 lb. per sq. in. For smooth nozzles from
2.5 in. up to 6 in. and under heads of more than 10 ft., Free-
man suggested a coefficient of 0.995. The following co-
efficients have been obtained by experiment for a set of
specially made smooth meter nozzles (Fig. 56):
2.5 in., 0.98; 3 in., 0.985; 4 in., 0.99; 5 in., 0.995.
The coefficients will vary somewhat in
different sets of nozzles and it is impor-
tant to know at what point the pressure
is registered (Fig. 55). If special accur-
acy is desired a set of meter nozzles
have
'ioh been carefully rated by volumetric
BSurement should be used. With
are ring nozzles the jet suffers con-
tion and the coeffi- cienta according to Free-
experiments range
'n's from 0.65 up'to 0.975
ording to the proportions of the orifice,
>36. The Venturljneter, is a prac- tical application of
rnoulli's theorem (Par. 603) to the measurement of water
Fig. 56. — Meter nozzle.

)ipes flowing under pressure. The formula for discharge is

CjDbWaW2gh
(sec-ft.) (123)
WDa*-Di,*

Fia. 57. —Section of Venturi meter.

he symbols will be understood by reference to Fig. 57. For meters with

ven ratio of throat and inlet diameters the formula may be simphfied.
(
the ratio R = D^/Dt, and let

^ irfls / 2ff \ i
 Sec. 10-637 POWER PLANTS
Then Q = CKDi^y/^H (cu. ft. per sec.) {t
iJ = 3.0
Values of 2.5 2.0
ValuesofX =6.338 6.381 6.505
The value of C varies wth the velocity at the throat, the ratio R and 1

actual dimensions of the meter. As the Venturi meters* are ordinarily o<
structed the coefficient C is between 0.97
and 1.03. These meters may be rated
backward and a coefficient of correction
found to apply to the manometer reading
(Fig. 58). The total loss of head through
the meter tube is relatively unimportant
compared with other types of commercial
meters and is so small that the insertion
of the meter in the mains of a water supply
is rarely objectionable, and the use of this
appliance is growing con-
stantly. It may be used /- r^^esctr ^auiiir
particularlywell in high- ^^-^fi^^m ,.^9# reading may be
pressure power plants by the recordi
'-a'^ed
/a^^^'OVr M«l
where a continuous ^-^^^^^^^^aztU P^ apparatus; also to mi
sure boiler feed and
measuring liqu
heavier and Ugh
than water. Exp(
ence has shown tl
with the register, C(
tinuous measureme:
have been made w
an error not exceedi
3 per cent.
Fia. 58. —Venturi meter with manometer.
637. The Pitometert (Figs. 59 and 60), by means of the differential gt
registers the difference in pressure on the two orifices, one pointed direc
against the current, the other in the exa
ly opposite direction. This difference
Eressure is not a measure of the veloc
ead directly, but is greater than
velocity head. For these instruments
coefficient (K) of correction has been foi
to be nearly a constant, and equal to 0.
The formula for velocity therefore becoi

^
^ y = K[2(7(s'-l)d]* (ft. per sec.)
where s' = specific gravity of the
(1

hea^
i liquid,d = the deflection (Fig. 61) in ii

V the velocity in feet per second, anc

the Pitometer coefficient. The liquid u
in the differential gage is usually car'
tetrachloride and, gasohne, colored
The specific gravity as put up for ii
usually either 1.25 or 1.50 (for very

) curate work the specific gravity shoul

determined for the temperature atw:
Fia. 59. — Principle of pitometer it is used).
reduces to:
The formula (Eq. 126) t

For «' = 1.25; 7 = 0.84 I^!^ =3.368d* (ft. per sec.) (Ij

V4__
For »'- 1.50; VO.%i^f~^ 5.671<i (ft. per sec.)
V2
I., in
•Made by the Builders Iron Foundry, Providence, R.larger
sizes for pipe lines from 2 to 60 in. in diameter, and
much 8ize«1
direct readmg or recording appai
use- they may be furnished with either "
Developed by John A. Cole and Edward S. Cole and owned
t'
Pitometer Co., N. Y.
824
 POWER PLANTS Sec. 10-638

To determine the discharge the cross-section of the pipe must be divided

to one or more known areas (Fig. 61), the velocity for each found and hence
e mean velocity for the entire cross-section; the discharge being simply
e product of the area and the mean velocity. For pipes the following
ble (Par. 639) is useful and the example (Par. 641) illustrates how the dia-
arge is calculated. The Pitometer is set so that the velocity is determined
th.e points as shown in Fig. 61. The pipe coefficient (see example) being
3t determined, it is subsequently necessary only to get a reading for the
atre of the pipe and apply the coefficient to the centre Telocity to obtain
mean velocity and hence the discharge by the formula:
Q = KCVcA (cu. ft. per sec.) (129)

Fig. 60. —Portable pitometer.

11. The principal use of the pitometer is for measuring the flow in
If mains where it has proved its great value in detecting leaks and waste,
liu measuring the slip of pumping engines. It can be installed and
lited for relatively small expense, without interfering with the flow,
^large penstocks and in silt-bearing water it is not recommended,
used in old pipes, allowance must be made for incrustations reducing
|jtOB8-sectional area and a traverse of several points through more than
Tiameter is preferable to the single observation and the use of the pipe
cient.

825
 Sec. 10-639 POWER PLANTS
639. Traverse table tor pitoxneter gagingrg, showing inner diame
and giving the area of ei
of each ring for ordinary sizes of mains in inches;
ring and centre circle in square feet.

Diameter Area of
of pipe pipe
(in.) (sq. ft.)

)
 POWER PLANTS Sec. 10-641

:ieyond the plane of the side, the true height of the surface or the true pressure
irill not be indicated."*
j
641. Example of use of pitometer. The following diagram (Fig. 61)
nd computations illustrate the usual method of computing discharge.

0.5 1.0 1.5

VelocHj Curre Telocltj in Feet per Second

Mean Velocity

Cross-section of Pipe Longritudinal Section on M-M.

—
Fia. 01. Velocity curve as determined by pitometer readings.

,
Deflection and velocity curves fro
 Sec. 10-644 POWER PLANTS
following paragraphs are quoted from Hughes and Safford'a Hydrauli<
(MacMillan Company):
"Procedure in mea8uring velocity. A
straight stretch of stream shou!
be selected as a place for gaging, and two cross-sections selected to mar
the beginning and the end of the area. The float should be placed quietl
in the stream at such a distance upstream from the upper of the two crosi
sections, that it will be running with the current before the first marker
reached. The time of passage between these two sections, of which tl
distance apart is known, should be noted with a stop watch; or the positio
of each float at successive intervals of time be located by engineers' transii
or sextants by intersection, and the points plotted on a scale drawing, froi
which the distance traveled in the observed interval of time can be ronipute(
The distance in feet divided by the time of each run in seconds will give ti
velocity of the float in ft. per sec."
644. "Application of rod float measurements (Hughes and SafTord
The sphere of usefulness of rod-float measurements is somewhat limited, an
the expense of making them is relatively great. Their regular use in tl
future will probably be limited to straight, deep canals or flumes where a hig
degree of accuracy is required, where a sufficient force of men is re^ularl
employed for this and other purposes, and where it is very necessary to gat
all the water used for power and other purposes, without interfering with tl
operation of the mills. Ordinarily, the difficulty of getting good resul
from the sum of individual measurements, or readings of water wheel8,_
due to the fact that the total discharge, which is simply the sum of the u
dividual water wheels, often does not include the leakage or the water use
for manufacturing purposes other than power; but the flume measuremen
of the total quantity passing to each mill will cover everything. There is vei
little opportunity to make such measurements in rivers or canals which do n(
have a regular cross-section; and for such conditions there is no question thi
measurements by current meter (Par. 662 to 666) will take the place of thoi
formerly made by rod floats. The most notable published gagirigs by ro
floats are those by Humphreys and Abbott of the Mississippi River, thos
described by James B. Francis in the Lowell Hydraulic Experiments, Dare
and Bazin's gagings, and the gagings of certain rivers in India."
645. "Limits of accuracy in use of rod floats (Hughes and Safford
With a straight, smooth flume of great depth, and velocities ranging fro
2 to 5 per sec, quantities of water from a few hundred to 4,000 cu. ft. P'
ft.
sec. have been repeatedly measured with a probable error of 1 to 2 per cen
This form of measurement, which in its successive steps gives the product •

the cross-section and the velocity of the water as indicated by the rod float
is a perfectly natural one; and its simplicity appeals to the non-teohnic
man." Rod floats cannot"be run with the lower end closer than 2 or more i

from the bottom. Some correction must be made to account for this slow
layer of water which does not act on the float. The following formula w
derived by J. B. Francis by comparing rod float measurements with a wf.
= 1-0.116 iVD-O.l) (131

where C= a coeflScient of correction which multiplied by the observed velo

ity will give the corrected velocity, and D = difference between depth of wat
in flume and length of immersed part of tube, divided by depth of water.
Values of the Coefficient C
D 8 {

1. OOolo. 995 0.992'o. 988 0.986 0.983 0.981 0.979 O.P"

1 0. 975!o. 97310.971 0.970 0.968I0. 967 0. 9G5iO. 964 0.962 0.9
2 0.960'0.958 0.957|0.956 0.955;0.954 0.952|0. 951 0.950:0.81
0.3 |--.-
\ |0.948|

Direct interpolation
I

may
} I
!

be made for intermediate values.

I
I

STREAM FLOW
646. Flow. Water power is derived from the pressure or force exert
by water in falling through a given head. Its amount is determined !

the equation
H.P. = [QX//Xi?l-^8.8 (130

828
 POWER PLANTS Sec. 10-646

There H.P. is the horse power, Q is the flow of water in cubic feet per second,
i is the head in feet, and E
is the efficiency of the water-wheel.

647. Run-ofl is the result of rain falling on the contributing drainage area
iJid represents that proportion of the rainfall that does not pass off aa
iVaporation or through underground channels, the requirements for vege-
ation, etc., being included in the broader definition of evaporation.
} 648. Rainfall records have been obtained by the U. S. Weather Bureau at
ftations geographically widely distributed for a long period of time. The
jssults are published monthly and annually in the reports of the Bureau.
I 649. The local variation in the annual rainfall in the United States
|.all the way irttm nothing in some years in the desert regions, to an occasional
laxinium of more than 100 in. in the mountains of the extreme northwest.
general mountain ranges receive a greater amount of precipitation than
.1

^le surrounding valleys and yield a greater proportionate run-off.

f 660. Rainfall map. Fig. 62 shows a map of the United States giving
jie distribution of rainfall.
"
661. The percentage of run-off, by which is meant the ratio of the run-
'J to the rainfall on the drainage basin, varies greatly and in general in-
cases with the precipitation. For this reason it is dangerous to figure
a any fixed percentage of run-off. See Par. 686.
; 652. The monthly run-off depends on the precipitation, climate, storage,
ter of the drainage basin, etc., and varies within wide limits. In
England the month of maximum run-off usually shows a flow from three
ar times that of the mean for the year, while the minimum month
:

I'quently drops to one-tenth or less of the mean, and this is notwithstanding

oomparatively uniform distribution of rainfall throughout the year.
'
653. The daily run-off shows still wider variation than the monthly,
though the monthly figures are frequently used in preliminary estimates,
his use of the monthly flows averages days of high and low flows thus giving a
'
oderate mean. An actual power output cannot be obtained equal to
iinates based on monthly flows unless very large pondage is available.
654. By Pondage is meant the storage created at a power development
id used for taking care of the variations in the draft. *' 'It is the retention
1- onp or more days of the flow of a stream during hours of light load, for
iliiring hours of heavy load." This is of the greatest importance for
pments with a varying or non-continuous load. For example, a mill on
lur week basis operates only 28.6 per cent, of the time, and hence can
~

;Illy that proportion of the flow, assuming an unregulated flow and no

iidage; while sufficient pondage to equalize the flow during the week would
•

freuse the low water output nearly four-fold. Every reservoir and mill
'rui on any stream must be operated subject to the legal rights of others
tlip stream. The study of pondage and its proper handling is complicated
the general case, but as a rule comparatively simple of solution for any
lual power plant. The reason is that it is involved with the load curve,
I natural and legal restrictions of the flowage permissible, and flow detained,
il the variation in head economically
advisable. Granting the possibility
li rif,'ht8 of pondage, the problem
reduces to a consideration of fitting the
of water to the demands for power made on the station. If the station
rries a typical combined power and lighting load, pondage is essential
satisfactory operation since the great demand for power is during the
J time and the early evening hours. If the head may be drawn down
ins the day so that the pond will be just filled up by the night flow, the
I

-t that is possible is being obtained

from the river. In some cases of
ad and mediurn-head developments the advisable reduction in head ia
utrolling or limiting factor. As the head falls the power and efficiency
:n; water whee's fall if the speed is kept up, as it must be in hydro-
tnc stations. Foresight and study of the probable range of head
ation make it possible to have wheels designed with characteristic curves
'lally suited to the case and a greater variation of head may be permitted.

Progress report of Committee on Run-off of Boston Society of Civil

Jgmeers, November, 1918.

829
Sec. 10-655 POWER PLAJ^TS

oo_o«o o_o_
"^cd'ooo
*O0

•5 « S

S ^ " TO OOO
. o >-

03 lOOIN

S2d
OT3
CDCDOtO to to CD CD CO CO CO
1-H 1— i-H ^H
O OS
I

(n O Ol 03 03 03 03 Oi 03 03 03 03 03 03 03
T77T
TTTT t-.-iiN'-'
OOCOOIN IIS
0)00 030 OOt-iO 00030 OthO^
00 00 00 a> 03 OiOi03 03 03 00 02 03 03 03 03

0(N-*0
O! 10 OOO
0-* ---i
<Nt)<OOC<3

P£

C 03

c3 O

;^o«2 O
M
o 01 1^ . -"S « -

i3t3 oj !=£

"S a> ^ o AJ-_

Hg«ao
IS « S =s

> t, IS a> •^ t, d 5;
^ tt)
"
c3 >
t.
OJ u<
P > o I, ^^
•- '^ "S ? 41

«^^§.>
Sgf^ .t >> c^ as ^, 0)
g g o i,p;
£ S £«o
ss m: * .%

«M *
OJ t<

-6 c'g o 2 « « ^O o cl^S
"* S", 3 a 3 2 1^ O OS 4) o 3 c3 .t:; o
OH pHfe
 POWER PLANTS Sec. 10-656

i56. Storage usually means water held back or stored in reservoirs which is
!' liable to increase the extremely low flows for several days, weeks or
;
iiths. The development of storage on a drainage area is of the greatest
i jDrtiince, for otherwise the minimum flows reach a very low point and
I ver must be obtained from other sources during the period of low flow.

831
 C

Sec. 10-657 POWER PLANTS

Storage reservoirs can be operated in two different ways:
(a) To produce a maximum amount of primary power, i.e., power availal
at all times. If operated in this way, reservoirs must be kept filled a lar
part of the time in order to have the water available for use during exceptic
ally dry periods.
(6) To use the stored water each year, or oftener if possible. In tl
case the reservoirs may be empty if a dry period is prolonged exceptional
A compromise between the two methods is usually best.
In any particular case the yield of a reservoir may be predicted from a stu
of the run-off of the contributing area, the precipitation on and the evai
ration from the water surface. Trial drafts from the storage are assumed a
the effect traced through a number of years. In this way very safe estima
can be made of the storage yield.
657. Example of a large storage basin. The following figures show
way of illustration the condition of Lake Winnipiseogee (Par. 666) on May
Aug. 1, Nov. 1, and Feb. 1, using 1911 and 1912 figures of run-off and preri
tation, and average figures of evaporation. The yield of the contribut
area is expressed in inches of depth on the lake area, rainfall and evaporai
are given directly in inches and the draft, 600 cu. ft. per sec. throughout i

year, is also reduced to in. of depth on the lake area for each month.

Yield of
Draft 600 Net
the con-
tributing
Evap- cu. ft.
gain or
Rain- ora- per sec.
area ex- expressed
loss in
Eleva
fall in tion
pressed in.
tion
in. in in.
Date in in. of depth
during of depth of the
ofdepth on tne
the during on the lake':
on the month the lake area
lake area
lake area for the
for the
month for the
month
month month

April 1, 1911
During April +38.35 + 1.38 -1.6 -9.56 + 28.57
May 1, 1911 Wasti

July 1, 1911 38.

During July + 1.83 +4.36 -9.88 - 8.01
August 1, 1911 30.

October 1, 1911 15.4

During October + 9.44 + 4.51 -2.20 + 1.87
November 1, 1911 17.

January 1, 1912
During January -1-11.51 + 3.12 -0.70 -9.88 + 4.05
February 1, 1912
* 44 in. represents full lake.

668. Biver gaging stations are maintained by the U. S. Government I

the State Governments on many rivers and streams throughout the coun •

This work of gaging the rivers is carried on by the U. S. Geological Sun,

Dept. of the Interior, and the observations and results are published. Tl3
publications, which are invaluable in studying the po.ssible watcr-por
development of our streams, may be obtained at nominal expense from '
Supt. of Documents, Government Printing Office, Washington, D. C.
669. Flow in open streams is subject to the same laws as the flovj
any other channel (I'ar. 602), but because of the irregularity of section '

the changing character of the bed from point to point the difficulties of fine?
a formula to fit all eonditions are manifold. The only reliable data conceri {
discharge of a stream are based on actual measurements.
660. Measurement of stream flow. The method adopted will dep'
largely on the size of the stream, its cross-section and the variation Uct«i
minimum and iiiaxinium flow. A weir can be successfully used in a si'
stream discharging a few cu. ft. per sec. and is largely employed
a

832
 POWER PLANTS Sec. 10-661

irrigation ditches. For rivers from medium to large size tlie most adaptable
tnethod is to employ a current meter and by making measurements at several
[
tages of flow establish a rating curve by means of which it is only necessary
io read a gage, compare the reading with the rating curve and find the
Mischarge corresponding to the given stage. The same rating curve cannot
lie used for both winter and summer conditions.

661. Typical hydrographs showing the monthly average stream flow in

'ec-ft. per square mile of drainage area are shown in Figs. 63 and 66, for
jhe Kansas (Kan.) and Columbia (Ore.) rivers respectively. Figs. 64 and 67
fhow the accompanying monthly rainfall in typical years. Figs. 65 and 68
fhow the accompanying monthly evaporation. These stream-flow records
r hydrographs naturaUy exhibit different characteristics according to the
I
UDcal climatic and other conditions, as noted by comparing Fig. 63 with Fig.
1 6, and Fig. 64 with Fig. 67. Furthermore, the hydrographs of the same river
ary materially as a rule from year to year, between rather wide limits; Figs.
i:

•3 and 66, besides showing the stream flow for typical years, also show the
Liaximum (wet year) and minimum (dry year) flow observed during a series
f years. It is also instructive to compare the records of rainfall with those
f stream flow; compare Figs. 63 and 64, and Figs. 66 and 67. Similar records
•ad charts should be obtained for any particular river or stream, if possible,
connection with consideration of ita water-power possibilities.
1
Sec. 10-663 POWER PLANTS
The Fteley-Stearns meter (Fig. 71) was designed for use in the Sudburj
Aqueduct of the Boston Water Works and is especially adapted for use ii
flumes or any channels where it is desired to get the velocity close to th(
sides and bottom. It is ordinarily fitted for use on a rod and is equippec
with recording dials thrown in and out of mesh by a cord. The moter cat
also be fitted up with vane and electric sounder. It then loses its peculia:
value in recording only the forward component of the velocity of the water
which makes it a true integratinjf instrument. It has been successfullj
used in large rivers and in velocities from 0.4 to 10 ft. per sec.
H
 POWER PLANTS Sec. 10-664

.iting may be constructed, but it is more satisfactory if in addition to

curve
I
lis, measurements are made with the wheels in place.
careful
664. Methods of using current meters are as follows:
t Single point at 0.6 depth.
(o)
i lb) Two
points at 0.2 and 0.8 the depth.
[
Multiple point.
(c)

t
(d) Integrating: (1) vertically; (2) diagonally.
} The single point method at 0.6 depth (a) is supposed to give the average

^jlocity of the vertical section in which it is held. Except in special cases

'

ich as natural streams uncontrolled by local*conditions this can rarely be

I
lied upon.

3
Sec. 10-604 POWER PLANTS
 POWER PLANTS Sec. 10-665

!onsumed in making the measurement there is no material change. It is

jspecially useful in showing the distribution of the velocity over the cross-
lection.
Vertical integrating measurements (d) (1) are made by slowly lowering the
ueter from top to bottom and raising it again along the same vertical path.
.a this way the average velocity for the strips in order is obtained mechanic-

8
Sec. 10-666 POWER PLANTS
selecting the method to be used. By dividing the stream cross-section b
verticals into areas of equal width, through the centre line of which the met(
is lowered and raised with uniform speed, the mean velocity in ft. per se^

Telephone Sounder
.r^

Fia. 69. —current

Price-Gurley
meter.
electric Haskell current nieti

for each section is obtained in one operation. This method is on the wliole
be preferred for deteriViinations of discharge. The multiple-point luothod
of great value in determining the distribution of velocity in any cross-sectic
which is often necessary for at least Tens
one gaging; but for determination of Pipe
discharge this method is tedious and Connection
if the stream is subject to fluctuation
in stage it is too slow. Pnll-Cord
If the channel is not too wide or „
deep the diagonal integration which connection
covers the whole stream in one opera-
tion is a very satisfactory form of
measurement because it permits a
great many measurements under differ-
ent conditions and avoids many dis-
turbing conditions. Its use is limited
by the endurance of the operator.
The double-point and single-pjoint
methods are only rough approxima-
tions, but serve a useful purpose in
securing information of stream flow at
low cost.
666. Effect of ice. Ice cover on a
stream or canal decreases the cross-
section, and increases the wetted per-
imeter or rubbing surface. Both of
these result in additional loss of head, Fig -Improved Fteley-Stea
the first through inorea-sing the veloc- current meter.
ity, the second through increasing the
fi-ictional resistance to flow. In power canals the formation of an ico co
of sufficient thickness to last through the cold season is a protection JiKai
troubles from anchor ice and frazil ice. Neither anchor ice nor frazil
will form under an already existing ice cover; the latter is therefore desira

838
 POWER PLANTS Sec. 10-667

ind canalsshould be designed with thia in mind, and the velocities should be
;ept (2 to 3 ft. per sec.) by making the cross-section ample for ex-
down
reme conditions. Anchor ice is ice which forms on the bottom of the stream
r canal and may seriously obstruct the flow. Frazil or needle ice forms, as
he name implies, in small needles where the current is too rapid for the
ormation of surface ice. It may either attach itself to the bottom or to
nehor ice already formed or it may be carried against and effectually clog
he racks of a power house.

DAMS AND HEADWOBKS

667. Dama, may be roughly
regardless of the material composing them,
iassified divisions: (a) Impounding dams for holding water
into two main
but which are not designed to have any water pass over
ack, as in a reservoir,
aem; (b) spillway dams.
668. Impounding dams (Fig. 72) are almost invariably of the gravity
Vpe depending on their own weight to resist the forces of the water except
1 the rare cases where
arved dams have been built UJ<_._10/ .

epending wholly or in part

a arch action. The present
.ractice is tending toward
eavy earth dams.
'
669. Spillway dams (Fig.
^.A(h—R'30
}) may be further subdi-
ided into gravity types and
lose depending, through
-leir on the hydro-
design,
pressure of the im-
iiitic

-:unded water to hold them

gainst the river bed, and
•chdams. The arch dam is
>ry economical of material
^it requires that the abut-
^<nts be founded in strong
ilid material capable of
king up the thrust.
;
670. CoSer dams accord-
g to their height, the nature
the bottom and the ex-
).sure of the location to
iTent or wave action are
nstructedin agreatnumber
ways. Some of the more
mmon methods are men-
med. Interlocking sheet
_

;el piling, and single or

uble rows of wooden sheet
ing with a puddled filling
tween the two rows, are Foj effect of upward pressure see
1
-ras frequently used. For
'
1 cofferdams the A-frame Spillway Dam
vered with gravel; or bags
If filled with sand piled in
Fig. 72. — Reservoir dam.
•eful rows have been successfully employed. The design of cofferdams is
3ed on the same principles of hydrostatics governing the design of any
. ler dam.
i '71. Design of dams. The
conditions which should be safely met by all
^ 'ins are stated briefly as follows: (a) the dam must not slide; (h) the dam
|£t not overturn; (c) the dam must not crush. The external forces acting
{
'•
the water pressure, the weight of the material composing the dam, the
1 ction of the foundation, ice pressure near the top, and wind and wave
Issure. The pressure usually figured is that of the greatest known freshet,
' the toe of the deepest section, without backwater. The cross-sec-
'1 of the dam is determined
by trial. A tentative section is assumed and
all the forces are computed. If the dam as first designed cannot
all the conditions of safety oris unduly heavy it is modified accorcUngly.
,.
 Sec. 10-672 POWER PLANTS
In the case of the high dams of the gravity type (Fig. 72) it is customarj
to assume the dani divided by horizontal joints, the depth of each sectiot
chosen according to judgment in each case, and to treat the sections arbitrar-
ily so selected progressively beginning at the top, testing each for sliding
overturning, and crushing. In this way a resultant line of pressure may b(
traced. In the design of masonry dams it is customary so to proportior
the section that the resultant pressure at all horizontal joints shall fall withir
the middle third whether the reservoir be full or empty. Thi!
gives a factor of safety of two against overturning, and there
will be no danger from tensile stresses on the face of the dam
There is rarely any trouble experienced, when proper con-
struction methods are used, from sliding within the bodj
of the dam itself. The joint between the dam and its
foundation is the critical point at which to guarc
against sliding. It is in this connection that tht
amount of upward pressure becomes of vit
importance. On ledge foundations, steps <

trenches should be cut to ensure a sufficien

bond. On poorer foundations the dam rnus
,be made massive enough to safeguard siKains
iliding by keeping the angle between thi
^ \^ ^^> '^ \. resultant pressure on the base and a verti
cal line, less than the angl<
of sliding of the foundatioi
material. There is no liungf
from crushing in dams othei
wise stable, except in ver^
high dams which are no
treated here.
Dams which depend oi
the hydrostatic pressure o
the water to hold them ii
place (Fig. 74) may be mad
much Ughter than the solii
masonry dams. The princi

u^s^a^£ pal calculations for strongtl

involve the deck treated as
reinforced slab and of tli
buttresses as walla subjectei
to simple compression. Fif
;

innraiimirj: 74 illustrates the action c

I ('aililnJug WuUud prcs'suiis) the resultant pressure. 1

I I I
I I I I I I M
a floor is used weep holes ar
III I I

provided to allow any seer

n ,T-,
Fia. 73. —obpiUway dam.
-11 J
^gg to escape unobstrurted
For a more thorough and comprehensive treatment of dams rofcrenc
should be made to chapter XXIX. "Principles of Construction of Dams
in "Water Power Engineering," D. W. Mead (AlcGraw-Hill Book Co
and to "The Design and Construction of Dams," Edward Wegmann (Wile
& Son).
672. Upward pressure on the base of a gravity-type dam (Fig. 7.'
should receive most careful study. The limiting conditions are, on the or
side, a tight imprevious bottom with the dam so set and keyed into it thi
no leakage can occur under the dam. This in efTect assumes an unbrokei
water-tight wall extending from below the bed of the river up to the crest i

the dam. The other extreme would be a dam founded on loose gravel <

porous rock which freely admitted the water under the entire base of tt
dam, but at the downstream toe a cut-off wall would prevent the water fro:
> escaping.
In the first case the assumption is no upward pressure whatever, tr m
. ,

second there would be pressure due to the full hydrostatic head unifom!
distributed over the base of the dam. Rarely, if ever, can either of the;

cases be found in the extreme form suggested. The truth in every case
doubtless between the two. In other words there is probably no dam exi.i
ing without some upward pressure, its extent to be determined only by
most careful examination of the geological formation of the river bed at tl
dam site and the thoroughness with which the seepage is cut off by ctit-rtl
walls, grouting or other preventive measures. Except in those cases where

840
 POWER PLANTS Sec. 10-673

rim founded on ledge rock which gives undoubted evidence of soundness

is
-id extent, borings are the essential preliminary to the study and design of
dam. No rule can be given as to the number of borings necessary but in
'
general way there should be enough to cover the area not only of the spill-
way section in the river bed, but also of the abutments and wing walls; and
yher structures near the
ver; undermining here may
,rove quite as disastrous as
nder the spillway section.
i
In the case_ of pervious
undations it is desirable to
irry a cut-off wall or spiling
i.
the upstream toe down to an
Impervious stratum. Where
ich does not exist the wall
".ould be carried to such a
ipth that the friction oppos-
g the flow of water will
jnder the seepage under the
,im inappreciable. It is good
•actice in designing and
(lilding dams
to eliminate so
;T as is possible the leakage
jhich causes upward pressure,
,it to assume in the computa-
JDns for stability the existence
. full upward pressure at the
;)3tream side diminishing
liformly to zero at the down-
ream toe.
673. Eaxth dams are per-
iips the most common type
3ul are ordinarily the cheap-
't. They can be built on
sniost any foundation as
U-offs and sufficient thick-
;88 together with proper selec- Concrete-steel dam.
()U of materials will give the
icessary irnperviousness. No
rth dam is absolutely impervious but the design and construction should
such that the water level will remain well below the downstream face of
i

e dam. Irnperviousness is usually obtained by mixing clay with the loam,

ad or gravel used for the construction.
If the foundations are not impervious, sheet piUng, a core wall or a trench
;ed with impervious material should be provided to prevent undue seepage,
core wall of concrete is sometimes used extending frOm bed rock to above
5 water level. They are frequently from 2 to' 4 feet thick at the top, with a
iter of 1 to 10 or even less. Such a core wall should be placed as far up-
leam in the embankment as possible, since in case it should prove to be
pervious the water pressure against its face would greatly exceed that on
downstream side. On this account a core of puddled clay is preferred
!

some engineers. This is usually from 4 to 8 feet thick at the top and at
St one-third the depth of water at the bottom.
j574. Dimensions of earth dams. The dimensions and slopes of
t.th dams depend on the material and method of construction. For rolled
i.bankment a top width of {h/5) + 5, where h is the height of the dam in
It, has been suggested. An upstream slope of 3:1 and a downstream slope
2.5 1 usually represents good practice.
< : The upper slope should be
l^ed on account of wave action. Beams placed 30 to 40 feet apart verti-
<ly are desirable in high earth dams, as they provide for lateral drainage
vl also give an extra factor of safety again.st sliding of the embankment,
jspillway must be provided with earth dams of sufficient length to handle
% maximum flood without the water rising high enough to overtop the
ttli embankment. Sometimes it can be cut in rock at one end of the earth
'n, but if this is not possible a masonry or timber spillway is necessary
f-l precautions should
be taken to secure a good union between the earth
cbankment and the spillway abutments.

S41
Sec. 10-675 power plants
675. The design of canals for power purposes should be made from a
economic viewpoint. Canals are employed to utilize a greater head than i
obtainable directly at the dam and must be built to give the greatest benefi
at the least cost. Head, the very object of the canal, is often unnecessaril
lost through poor design of the cross-section and alignment, or througli pei
mitting unnecessary roughness of the bottom and sides. Some slope will b
required to carry the water through the canal. This should be provided b
the canal bottom itself unless the drainage must be in a contrary directior
otherwise an extra loss of head will result, for the slope of the water wi
reduce the stream cross-section and necessitate a higher velocity to Ipass
given quantity of water. The form of the cross-section must be detcrmin'
by its requirements and the character of the material. The form should 1

such that it will remain as first built and not wash or slide. In general t!
relatively wide and shallow canals should be avoided because with any dra
ing down of the head, or with an ice cover the net area suffers a greater pr
portionate reduction than in the case of deeper, narrower canals. The a
vantage of the deep canal can also be shown from a consideration of the for;
ulasfor flow, which show that for a given area the section with the sinallt
wetted perimeter will give the best results. The velocity should be kej
low and as uniform as possible. If there are changes they should be mai
gradually and in general a velocity once gotten up should be held. The saii
statements apply to ditches whether for irrigation or power.
676. Flumes. The word flume implies a narrow waterway with vertio
or nearly vertical sides. It was formerly used to designate the canal or pei
stock conveying water to the wheels at its end. In modern practice a flun
is understood to mean an aqueduct of relatively small dimensions construct'
usually of timber or concrete employed to carry water long distances. Tl
interior surface is in general smooth and water is carried at a high veloci'
on an even grade. In computing the carrying capacity of such structur
loss by friction predominates.
677. Head-gates are usually installed at the entrance to a canal to co
trol the amount of water let in, or to shut it off entirely in case repairs a
necessary in the canal. They should be strong enough to permit the wat "
to be entirely drawn out of the canal and to protect the plant during
water. The number and size is fixed by the quantity of water and
structural limitations as weight and strength may impose. Head-.
are either hand or power operated according to local circumstances; b!
modern requirements are demanding motor hoists. In designing the pir
it is usually well to provide for stop logs for occasional repairs to the gat<
Whenever possible the gates should be so set that the water from the riv
enters at low velocity without sharp contraction or change in direction.
678. Booms either floating or fixed are usual to prevent floating dfbi
from reaching the head^gates, and in northern rivers ice is also diverted ov
the dam or through special leeways by this means.
679. Penstocks are frequently used instead of canals or in conjunctic
with them, the choice depending on cost in the case of low-head to modiui
head plants. In high-head plants penstocks and pressure tunnels bocoi
the only way for conveying water from high elevations down to the pow
house. Penstocks are usually built of riveted steel plates, wooden stavi
or reinforced concrete, depending on local conditions. They must be c:

signed for strength and carrying capacity. Structurally they must be al

to withstand the pressure due the head plus the effect of water hammer ai
also, when empty or partly filled, be strong against collap.'iing. In lo
penstocks great care must be taken to provide against water hammer,
the first place, the thickness of the shell should be selected with this in mi
and, secondly, provision should be made to take care of the surges when th
occur. Where the head permits, the most satisfactory protection is (jiven '

stand-pipes or surge tanks. Further protection is given by relief valv

and blow-out plates, usually placed just outside the power house.
The thickness of riveted steel penstocks necessary to withstand wal
hammer may be computed as follows:
, (P + p')r
' =
isiooo r ^'"-^ '''

where t = thickness of the shell in inches (should never be less thnn

inch), p= intensity of internal pressure in pounds per square inch, p'
additional pressure in pounds per square inch allowed for water hamni
r«" radius of the penstock in inches, and e = eflBciency of the riveted joii
which varies from 0.5 tb 1.

842
 POWER PLANTS Sec. 10-680

Values
Sec. 10-682 POWER PLANTS
WATEB- WHEELS
682. Hydraulics of water-wheels. Force is required to change th(
velocity and direction of any moving body. In the case of hydraulii
turbine motors water is the moving body and the water-wheel (whether im-
pulse or reaction, or combined) is the agent by which the velocity anc
direction are changed and useful work derived from the process. Th(
portion of the reduction in velocity not chargeable to friction or other lossei
occurring during the passage of the water through the buckets is a measun
of the efficiency of the wheel as a prime-mover. If a jet of water impinges
on a moving vane or bucket, assuming a condition of no friction, the bucke'
will acquire a velocity equal to that of the jet, i.e., the theoretical velocitj
due the head acting. The velocity of the wheel must be considered that o
the centre of application of all the filaments of water. Under this condi
tion, where the velocity of the bucket and of the jet are the same, the jc
can exert no pressure on the bucke
and no work is done. Actually thi
bucket velocity must in any case be de
creased by friction from that supposec
above, and the water must exert a
least a corresponding amount of pres
sure. If now the velocity of thi
bucket be further decreased until it i

of Backet
blocked, the water is exerting its max
>. imum pressure but again no work i

being done. There is some speed o

rotation between these two extreme
at which the maximum amount q
work willbe done; that is, the mail
mum portion of the velocity oi th
moving water will be converted inti
useful work. At this point the nioto
is running at maximum efficiency
Although the buckets and vanes ma:
Fig. 75. — Velocity diagram of a
water-wheel bucket.
be simple or complicated, the abov
fundamental conception holds tru
and the performance of the wheel ma;
be analyzed by a study of the velocity diagrams at the entrance and
exit of the buckets or vanes. This analysis is indicated in Fig. 75.
In this diagram S is the peripheral velocity of the bucket, Va\ is
absolute velocity of the water at entrance, Vri is the resultant of these 1

and is the relative velocity of the water at entrance. Vm and Vrt are
'

absolute and relative velocities at exit. It is the object of good desit

make Vn such that Vaj shall be as small as practicable. But this can|
so fixed for only one condition of speed and gate opening. It is this wh
makes it important to know in advance the conditions under which
wheel is to operate.
683. Types of water-wheels. Modern water-wheels may be clas
either as reaction or impulse wheels. While the same fundamental thecMl
hold for each, as pointed out in Par. 682, the outward form and the meW
of utilizing the water are radically different in the two types. The reactM
wheel (turbine) utilizes in the main the pressure of the water and tl
reactive force on the curved buckets which tend to change its directJel
An impulse wheel utilizes the velocity and impact of a jet of water direetl
against buckets on the rim of a wheel. The two types are primarily adapH
to widely different conditions: the reaction wheels are best adapted tor
latively low heads and large quantities of water; the impulse wheel to hil
heads and small quantities of water. In recent years reaction wheels h»^
been used for all ranges of head up to 600 or 700 ft., where the units m
large. But for heads upwards of 200 ft., with small flow, the impiu
wheel of the Pelton type is the natural selection. \i
683a. Type characteristic. The gpnoral design and shape of the gam
and buckets of a waterwheel determine the relation between the spe~J
revolution, the horsepower and the head acting on the wheel. This relw^
is called the type characteristic and is expressed by the following equ»««

r.p.m.VhTp. (laij
^^_
fjH j

844
 .. .

POWER PLANTS Sec. 10-683a

.here K
is the type characteristic, RJ'.M. the revolutions per minute, H.P.
le horse power and H
the head in feet. The various sizes of a given type
uaterwheel have the same K
within small Uniits, the speed at which the
must be operated for a given head decreasing as the diameter or horse-
is increased. The following table shows average values of for K
us types of American waterwheels. For relatively high speed or large
Matter a wheel with a high characteristic must be chosen.

ialuea of Type Characteristic, K, for certain American Turbines.*

Xame of manufacturer Type of wheel

'
Aiiis-Chalmers Mfg. Co Type 15 75
, AUis-Chalmers Mfg. Co Type 12 86
Wellman-Seaver Morgan Co.. Type A 93
Wellman-Seaver Morgan Co.. Type B 66
Wellman-Seaver Morgan Co. Type D 27

James Leffel & Cc. . Type Z 104

James Leffel & Co. . . Samson 62
IHolyoke Machine Co. Type B Hercules 66
Holyoke Machine Co. Type D Hercules 78
il. P. Morris Co Type O 91
I. P. Morris Co Type M 09
S.Morgan Smith Co Type K 66
S.Morgan Smith Co Type S 106
Dayton Globe Iron Works Improved New 80
American
Dayton Globe Iron Works. New American 52
i'latt Iron Works Victor 60
' Values given are for particular installations. The value of K may
ually vary over moderate limits with equally satisfactory operation.
early all manufacturers make several types of runners to cover a wider
nge of values of K, a very few types only being given above.
G83b. The performances of reaction wheels of various types made by
'
manufacturer under one foot head are given in the following table.
); any other head {H) the corresponding quantities can be found by
L;ltiplying the discharge as given in the table by H^, the speed by H^
il the horsepower by flz. Stock sizes of waterwheels ordinarily extend
>n\ 12 in. or 15 in. diameter to 72 in. and 100 in., but special wheels have
rn built with a diameter of 11 feet and over. There is some variation in
( practice of the different manufacturers in the method measuring the
iracters of wheels.
Characteristics of Standard Reaction Turbine Runners*
Type A Type B
Diam. inches
Specific speed K= 13.55 Specific speed K = 20.3
r.p.m.i h.p.i Qi r.p.m.i h.p.i Qi

15 71.7 0.0358 0.38 76.7 0.0705 0.791

18 59.8 0.0514 0.55 64.0 0.105 1.10
21 51.2 0.0705 0.75 54.7 0.1385 1.45
24 44.75 0.0915 0.975 47.8 0.182 1.91
27 39.8 0.116 1.235 42.5 0.229 2.41
30 35.8 0.1425 1.52 38.25 0.284 2.982
34
38
31.65
28.25
0.184
0.23
96
442
33.8
30.2
0.363 3.82 (
0.453 4.78
42 25.65 0.28 98 27.4 0.551 6.80
46 23.40 0.336 58 25.0 0.665 7.00
50 21.50 0.398 24 22.9 0.790 8.40
55 19.56 0.48 12 20.9 0.950 10.00
60 17.90 0.573 10 19.1 1.130 11.90
65 16.55 0.672 7.15 17.65 1.330 14.00
70 15.40 0.785 8.35 16.40 1.535 16.15
 Sec. 10-683?) POWER PLANTS

}
 POWER PLANTS Sec. 10-684

684. The speed of turbines for a given output and head is confined
(bin quite narrow limits. As noted in Par. 682 there is for any given set
conditions a best speed. This for modern reaction wheels is such that
e peripheral velocity is from 0.60 to 0.85 of the theoretical spouting
locity of the water due the head. The best speed may be, and is, varied
•
design, the recent tendency being toward the development of wheels
th high relative velocity; this is easily overdone and is oftentimes secured
the expense of part-gate efficiencies. The best relative bucket velocity
the case of'impulse wheels can be shown analytically to be 0.5 and this has
en verified by actual tests. Characteristic curves for a modern reaction
leel are given in Fig. 76.

.6 .7 .8 .9
Speed Factor .

Fig. 76. — Characteristic curves— 48-in. turbine.

;6. The
efficiency of modem w^ater-wheels has been steadily improved
bjiperiment and design until the makers can now guarantee test results of
hi 80 per cent, to 90 per cent, at the Holyoke Testing Flume (Par. 707).
Ti;et the same result in place requires the best design of the setting and
Wi rways. Many wheels which came up to specification in the Holyoke
teihave failed signally in place to show the power and efficiency of which
tn were capable. In most of these eases the fault was not in the wheel
^t n the setting. A wheel improperly installed is not given a fair chance.
ffuUy tracing the velocity through the penstocks, wheel case, discharge
id draft tube, using net areas throughout, it is possible to design
> which avoid high velocities and undue changes of velocities and
'>n, and results in place equal to the Holyoke test results may be ex-
!'C '
EflSciency curves for a modern reaction wheel are given in Fig. 76.
.

847
Sec. 10-686 POWER PLANTS
Water velocity through guide chutes. Mention has already be
686.
made importance of keeping the velocity of the water through hea
of the
gates, canal and racks low. It also should be kept low, not over 3
per sec, as it approaches the guide chutes of the runner itself. There
an exception to this in the case of sinj
runners set in the so-called scroll cai
In these, wheel makers are now requ
ing a velocity of about 15 per cent,
that due to the head acting .on the wh&
687. Mechanical details. A tyj
cal runner is shown in Fig. 77, and
special runner in Fig. 78. The genei
appearance of a vertical turbine wi
cylinder gate is shown in Fig. 79, wi
the usual form of setting in a concre
wheel pit. The same type of wheel wi
a horizontal setting in a steel flume
indicated in Fig. 80.
688. Settings. There must be eqr
chance for the water to feed to all pai
of the guide circumference. When o
or more pairs of wheels on the Bar
FiQ. 77. —Cylinder gate runner. shaft are set horizontally, extra cr
must be taken to insure that the i

wheel in the line can draw share of the water under as favorable col
its
tions as the first wheel. A pair of centre-discharge wheels should be
in the case so that the clear distance between the discharge lips of the t
runners shall be at least from 3 to 4 times the diameter of the runne
The greater distance should be used with higher heads; rough limits of hert
and corresponding distances are given: 12 ft., 2.5 diam.; 18 ft., 3.0 diam.;
ft., 3.5 diam.; 50 ft., 4.0 diam.
Single, large, vertical units have recently received special attention fn
designers and builders, and it has been demonstrated possible to obti
efficiencies with them
about 4 per cent,
higher than have been
obtained with horizon-
tal settings of equal
output. In comparing
different settings it is
important to know ex-
actly where the head
is measured; it is here
afjsumed that the net
effective head is taken.
See also Par. 711.
689. Ratings.
Water-wheels are rated
in horse-power, the
rating given being
maximum
usually the
output under the head
Fia. 78. —Special runner.
stipulated. It is im-
portant to keep in mind three things: (a) that a horse-power is a sma
unit than the kilowatt (1 horse-power = 0.746 kw.); (b) that water-wh.
driving generators must carry the normal load at from 0.75 to 0.80 fi
in order to take care of overload on the generators; (c) when once uiul«
given head the wheel is discharging its maximum quantity of wattf
further output can be wrung from it. The attempt to impose a ht:r
load can only result in reduced speed and output. Simplification w
result if water-wheel ratings for hydro-electnc plants were .it.itt-.l
kilowatts and generator ratings were stated in terms of the maximum ';
put instead of normal rated output. This would remove the source
confusion brought about by rating each half of an integral unit by ii .-"

rate standard.

848
 POWER PLANTS Sec. 10-690

.690. Draft tubes make it possible to set reaction wheels well above tail-
'ter. This is a distinct and important advantage. It makes the wheels
ressible for inspection and repair in spite of backwater conditions, and
j,mits the use of horizontal wheels direct-connected to generator or shafting
'
hout sacrificing head. In a plant subject to severe backwater, if the
ichinery floor can be set 20 ft. above low tail-water elevation, draft
fies frequently save great expense in heavy construction and waterproofing
t;he power house.
\ reaction wheel discharging freely into
t air would be acted on by a head equal
t he distance from headwater elevation
tthe elevation of the centre of the dis-
c'rge orifices, minus such losses as occur.
7; pressure against the discharge is full
Biospheric. If now we attach an air-
t'.tpipe of suitable diameter to the run-
p case and conduct the water down from
t wheel and discharge it under the sur-
I) of the water in the tailrace we have
ireased the head acting on the wheel,
Kause now the pressure against the dis-
c rge from the wheel buckets is less than
aospheric by an amount corresponding
ho vertical distance from buckets to
where the full atmospheric pres-
,

ting on the water in the tailrace

1. .mg up the column of water in the
.

A
\i

l\
or draft tube so-called (Fig. 82).
•

cr gain is effected by gradually en-

I
79.
of vertical turbine with
—General arrange-
ag the cross-section of the draft tube.
reduces the velocity of discharge and cylinder gate.
i
of the energy present as velocity
"ansformed into pressure within the draft tube. This increases the
e<!ran held up by atmospheric pressure acting on the tailwater and cor-
re cmdingly clecreases the pressure against the discharge from the wheel.
Vh good design this may amount to a foot of head. The flare should not
Ixreater than approximately 1 in 10.
he normal atmospheric pressure will support a column of water 34 ft.
iDioight. Draft tubes are seldom used longer than 25 ft. There are

Discharge
Fig. 80.- -Cylinder gate turbine, horizontal type in steel flume.
Str inevitable losses and some leakage of air which
tural limitations,
tnts it difficult to maintain to any greater height an unbroken column
of id water, essential to the success of the tube. It has been noted that
ssure within the draft tube is less than atmospheric. This necessi-
a air-tight design suited to withstand collapsing pressure.
.
velocity through the upper portion of the draft tube is necessarily
-

^'t For this reason, the interior surface should be smooth to minimize

849
Sec. 10-691 POWER PLANTS
frictionand eddy losses and in the case of horizontal wheels the obstruoti
;

caused by the shaft should be made as slight as possible. If draft tubes !

set on an angle it should never be more than 45 deg. from the vertical. 1
elevation of the outlet should be fixed so that the draft tube shall be sea!
during lowest tailwater conditions. The velocity of discharge from the tv
should in general be a little greater than that of the water into which it d
charges, but ordinarily not more than 3.5 or 4 ft. per sec. at full discharge.
691. The tailrace should be designed to carry the water away wit!
minimum sacrifice of head. It should therefore receive the same care in desi
and construction as the feeding canal.
692. In selecting the type of wheel to be installed in any power {iU
the natural conditions of head and flow, with their variations, and the po»
demand on the plant must be clearly and definitely understood. Stc
wheels can be purchased which fit a wide range of conditions; special whe
may be designed to fit a far wider range. The following points should
covered in any wheel selection: (a) head, and its variation; (6) flow, andi
variation; (c) speed, and the importance of close regulation; (rf) pov
demand, and its variation. These may best be studied in connection v
the characteristic curves of different types of turbines; it is in fact the i

way of making an intelligent selection from stock designs. The fluctuat

in power demand is probably the most troublesome point and the wh
which shows the best efficiency over the desired range may be readily picl•
out from a comparison of the curves. In the same way the effect of
variations of head on each type of wheel may be seen and allowance made
the choice. A set of common characteristic curves are shown in Fig.
these are drawn from Holyoke test results, reduced to the head under wh
the wheel is to operate.
Three examples are given below to illustrate three typical but var:
requirements which water-wheels have met successfully. The numbe:
units should be based upon the fluctuations in stream flow and power
mand; but each unit should be ready to takecare of momentary fluotuatii
(1) Ground-wood pulp mill. Here the wheels are run at full gate as 1.

as there is water to run them. High speed is important, but moderate va

tions in head are of small concern.
(2) Textile mill. There is only moderate variation in load during work
hours. Uniform speed is vital; therefore wheels which hold their efiicie
for constant speed under variations of head are desired.
(3) Hydroelectric plant carrying a railway and lighting load. I!

fluctuations in power demand are extreme and close regulation is essent

Such a plant frequently requires a specially designed runner; the requ
ments are obvious.
693. Speed regulation. The control of reaction wheels is effefl
by governors which act directly on the wheel gates. There are two eSB
types of governors, mechanical and hydraulic. Either to be most effeo
should be of the relay type in which* "the energy is transmitted froi
— —
source independent as to quantity of the centrifugal governor bsUt
In all cases in which the fluctuM
controlled by them in its application."
in load may be large and sudden some form of relief must be prot
For open canals the spillway already described for getting rid of dfebnj
answer. For long penstock lines standpipes or relief valves or both al|
be provided and careful study is needed to ensure the best results.
Linpulse wheels may be governed by deflecting the stream away fr<^
buckets or by throttling the stream. The throttling may be accompa
in the case of a multiple orifice nozzle by closing some of the orifices,
usual nozzle is known as the Doble needle nozzle. It is usually the OK
impulse wheel installations that the head is great and the velocity of the*
high. For this reason the inertia of the column of water contained^
penstock is such as to prohibit, on the grounds of safety, governaj
throttling alone. In such cases the first action of the governor is t.o «*•
the stream, the second and slower action is to throttle the flow. 1 ni^
<•

bined control is the most economical of water.

• Mead, D. W., "Water Power Engineering;" New York, McC'.raw-l

Book Co., Inc., 1908.
 POWER PLANTS Sec. 10-694

694. Governors have been developed and improved rapidly in recent

^ars. The increaaing demand for close regulation of power plants has
imulated this improvement until now there is a new type fitted to every
1
w requirement. In general it can be said that for small units and for cases
- which the textile plant is representative the mechanical governor is ad-
rably suited. For large units such as are becoming common in hydro-
practice the hydraulic governor is better fitted to develop the great
rctric
-ce necessary to operate the turbine gates. According to Mead* governor
'"cifications shoulcf call for a guarantee of the following: (a) sensitiveness
cent, load change which will actuate the governor; (6) power which
vernor can develop and force which it can exert to move the gates;
idity with which it will move the gates; (d) anti-racing qualities, such
iber of gate movements required to adjust for a given load change;
•
ral requirements of material, strength, durability, etc. The hydraulic
IT can simplify governing to a marked degree by good design of the
.astocks, draft tubes, etc
596. Operation. The cost of operating a hydroelectric plant is from
'to 15 per cent, of the first cost.
;96. Cost data. A sub-division of costs (Spring of 1921) for a typical
~ .IS follows:
Item Per kw. year
6 per cent, on $249.0 (Items 1-5, Par. 680)
-t $14 94 .

nation 10 per cent, on 42.80 (Item 5, Par. 680) 4. 28

-' per cent, on 53.0 (Items 2 and 4, Par. 680) . 1.06
1 per cent, on 105.20 (Item 3, Par. 680) 1 .06
' :;:mrv repairs and maintenance $5j per kw. year 5. 34
listration $2.00 per kw. year 2.00
- per cent, on $150.0 (60 per cent, of total cost) 3.00
iioe i of 1 per cent, on $66.8 (Items 4 and 5, Par. 680. 0.34

$32 02 .

that interest at 6 per cent, and depreciation are two-thirds of the

Steam relay to supplement dry-weather flow will add 25 per cent, to
ing cost without coal, if charged against the water power.

PLANT DESIGN
37. General ensemble. The location and relative position of the dam,
''
'works, power house, tailrace, and all other necessary structures must be
):ed to a large extent by the topography and the geological conditions
site. The choice between various possible schemes will be based in
in upon the relative cost considered in connection with the eflBciency
proposed plant as an energy producer, or as an income producer.
i?ht to which the dam may be built is usually limited by the extent
Aage damage. In a hydroelectric plant pondage may have great
making fully warranted the purchase of extensive flowage rights. The
ly section of the dam should be designed to pass safely the maximum
:!t of water that can be expected. Likewise the abutments and other
structures must be built to withstand successfully the greatest freshet
vable on the river. In this connection it is important to realize that
fxtraordinary flood conditions the channel above and below the dam,
"t the dam itself, may frequently control the height to which the water
This is especially likely to be the case when the dam is built at the
if rocky tortuous rapids or in
a bend of the river.
intake should draw water from the stream with as little change in
ion as feasible and must be protected by some form of boom which
lirect ice and floating debris away from the head-gates txfid over the dam,
ugh a waste channel designed for that purpose. Additional head ma.v
tained over that at the dam itself by carrying the w'ater downstream in
- or penstocks. The advisability of such procedure is determined by
!> of the fixed charges on the structure and the value of the increased
,. so obtained.
« whole system of waterways from head-gates through the canal or
PMock, racks, wheelpit and tailrace to the river should be designed to

ii*»d, D. W., "Water Power Engineering;" New York, McGraw-Hill

, Chap. XVIII, p. 467.
Inc., 1908;

t 851
 .

Sec. 10-698 POWER PLANTS

keep the velocities low enough to avoid excessive loss of head. Fluctuatioi
in velocity are bad, and if unavoidable the changes should be made gradual]
It is better to gradually speed the water up from say 1 ft. per sec.
the head-gates to not more than 3 ft. per sec. at the wheel gates,
the case of the ordinary vertical or horizontal setting; the exception in tl

Fig. 81. — Miscellaneous settings of water-wheels.

case of scroll case settings has been noted in Par. 686. Where more than o
wheel is mounted on a shaft it is important to provide for equal distributi
of the water among the units, and to provide against interference
the draft chest as mentioned in Par. 688. The velocity at the top of i
draft tube is nece.s.sarily high and sho
be gradually reduced by enlarging
cross-section of the tube until it iS'll
charged at about 3 ft. per sec.
j^
698. Typical settings of water wij
are shown in Fig. 81. A modern font
setting known as the spiral or scroll .(
ing is illustrated in Fig. 82, which alk
"
a longitudinal vertical cross-section.
latter type of setting is emjiloyed at.
Keokuk plant of the Mississippi Bt
Power Co.
699. The economical developmt
of a water-power proposition must dep(
upon the available power in the ri\
the market, and the degree to whi<-h au
iary power is to be employed. Two tlii
must be determined as exactly as ixj.ssil
(o) the hydrograph of the river (1

Fig. 82.
bine in a
—Single vertical tur-
spiral flume direct
668); (6) the load curve.
A thorough and exhaustive study of
run-off data should be made where th'
connected to a vertical electric are available; otherwise study must
generator. made by comparison with similar drain
areas by means of rainfall data. l.\
ing and possible storage should receive careful attention. It 8hoiil<l !»
inemberod that on streams with incomplete storage arrrafff.t arc rfuM;"'
leading to overdevelopment. Two or 3 days of flood discbarge in a mo

852
 POWER PLANTS SeC. 10-700

ibove the capacity of any possible equipment can raise the monthly
'

to give a totally erroneous impression of the kilowatt hours avail-

For this reason, daily records of flow should be used in preference
niijiiihly records, since the daily records bring out the maximum and
aiiuum flows and the final estimate can be much nearer the truth.
I''!•
probable load curve is of prime importance, and taken together with
liable pondage it will determine the number and size of units to be
to give flexibility and economy in operating.
i

00. Auxiliary power. If a relay station, steam, gas or oil, be used, it

i uld be placed as near the market or sources of fuel as economic conditions
1 rant. Its capacity must be determined by the daily and yearly hydro-
( ph and the load curve. So many combinations of conditions of pondage,
E rage and load occur that every case must have special and detailed study.
'.
3re are very few developments where a relay station owned either by the
ser or the buyer of hydroelectric energy is not almost essential.
01. Choice of units. With varying load, efficiency requires two or
1
-( minimum demand the machine or
units so that during the hours of
on the line can carry the load at good efficiency. Then as the
.'s

;nes on additional machines are cut in as needed..

02. Provisions for handling floods include: (a) flashboards; (6)
Inter gates; (c) sluice gates. It has been noted that the height to
T eh power dam can be built is usually limited by the extent of the flowage
<a

I !--ible (Par. 697). This necessarily applies to the high-water stages

lay be expected every year, and settlements for the necessary rights
ially made once for all.
, During most of the months in each year
II :i>ed pondage or head, or both, can advantageously be procured by
r:inp the dam without creating greater flowage than occurs during high
H' r from the dam at its permanent elevation. This is accomplished in a
n her of ways, but most commonly on power dams by the use of flashboards
y, h are designed to bend over or go off during floods. In this way pro-
V n is made for handling floods at the moderate cost of replacing the
fl 1 boards.
;. order to provide for the occasional summer freshet and to give greater

d liarging capacity in cases of great freshets flood gates are incorporated

'
Tiy modern dams. When warned of a freshet, probably of short
n, it is frequently possible by opening the gates in the dam to pass
ra water without straining or losing the flashboards. Flashboards
;:iiarily held in place by either wrqught-iron pins which will bend over,
:t wooden figure-fours which will break when the water rises too
rhe development of water power on navigable streams also leads
i-;e of Tainter gates, Chanoine wickets, Bear traps and other forms of

ii- dams ordinarily suited to their purpose, but which in northern rivers

:« much ice must be designed with great care.

i3. Log sluices andfish ladders are necessary appendages to most
p<er darns. A log sluice is an inclined chute on the downstream side of
ti i with a gate at the crest which is opened whenever a log drive must be
Til

-t the dam. These are usually required by law where log driving has
i^ted on the river. Fishways are required by federal law on most
and must be kept open during certain portions of the year. There
ar arious forms, two of which are mentioned. One is constructed to form a
fli t of pools, the water spilling into each successively. The other is a
c! *pt at a rnoderately flat slope with baffles built alternately from the
'

iid left sides, about three-quarters of the way across.

Buildings and foundations. The conditions controlling plant

:!re discussed in detail in Par. 697, 700 and 701. Foundations are
subject to water pressures due to head or backwater or variations
."ought to flood conditions. These conditions usually require founda-
uch in excess of ordinary building requirements.
size, height and arrangement of buildings usually follow these hy-
conditions and the type of unit selected.
Summary of unit costs. Unit costs common to most water-
flcvelopments with some idea of the range of prices (Spring of 1921)
flepends upon the amount of each contract, distance from markets,
• ties of handling, etc., are:

853
 !

Sec. 10-706 POWER PLANTS

Rock excavation under water $8.00 to $15.00 per cu. yc
Earth excavation under water 2 00 to
. 3 00 per
. cu. yc
Rock excavation in the open or behind tight
coffer dams 2.25 to 5.00 per cu. yc
Earth excavation behind tight coffer dams.. . . 0.75 to 2.00 per cu. yc
Coffer dams 10.00 to 20.00 per. lin. fl

Reinforced concrete 20.00 to 30.00 per cu. yc

Ordinary concrete 12.00 to 16.00 per cu. yc
Reinforcing material 0.06 to 0. 10 per lb.
Penstock and draft tubes of steel plate, erected. . 15 to . 20 per lb.
TESTING
706. Water-wheel testing has played a vital part in the improvement
which have been accomplished in the design and construction of turbines
Every water-wheel should be tested if possible before it is installed. Ths
a similar wheel of the same make, diameter and pattern has been tested an
shown satisfactory results is no guarantee that a wheel which has not bee
tested will give similar results. The expense of the test should never b
allowed to militate against it, for a gain of only 1 per cent, in efhcienc
will pay for the test in a relatively short time. Specifications and giiarante
requirements should be drawn with care and include where feasible pre
vision for final acceptance tests in place, in addition to the preliminary test
at the Holyoke Testing Flume. In addition to finding out whether the whei
has met the specification requirements, the tests furnish data by means c
which the use of the wheel as a water meter is possible (Par. 663).
707. The Holyoke Testing Flume furnishes the only place in this countr
where systematic testingis carried on. The maximum head is 17 ft. and tl
maximum discharge possible is between 250 and 300 cu. ft. per sec, at whir
discharge the head is reduced nearly one-third. In spite of these limitatioi
the tests are invaluable to the water-power engineer and form a comnir
basis of comparison for designers.
708. The quantities to be measured in a water-wheel test are spec
head, discharge and power output. At the Holyoke flume these are obser^ •

by a revolution counter, head and tail water gages, weir and Prony brak
respectively. Various gate openings are selected and for each opening t!
wheel is run at many speeds in order to determine the most efficient spn
for each gate.
709. For making the final acceptance test of water wheels a test
place is becoming more frequent. Such a test furnishes direct evidence
the performance of the wheels under service conditions.
710. The general problem is that of any test of power machiner
namely, to measure the input and the output. To measure the input roquir
the measurement of the nead and the quantity of water used by the ur
under test.
711. The points of measurement of the head should be seleel
to show the net head actually acting on the wheel. Friction losses in oal
or penstock and tailrace are not properly charged against the performaJ
of the turbines, however much they may affect the overall efficiency of i
plant. The point therefore at which to measure the headwater is justbef
the water is drawn to the guide chutes, and the tail-water should beobseT
at the nearest feasible point to the discharge of the draft tube. In fl
flume settings the head water is ob.served in the flume. In the or<n«
pressure-case setting a gage should be tapped into the side of the po"a»'>-i
(Par. 640, piezometers) just clear of the case in order to avoicl disi'
due to ecldies and uneven flow in the case. In a scroll-case setting, t

like the draft tube, must be considered an integral part of the whcjel .,..«.
head should be measured between the entrance to one and the discharge
the other.
712. Measurement of the quantity of water used presents aor
difficulties unlcis special provision was injide in the design of the plant,
has been usual practice to install a weir in the tailrace. Unless the conditio
are exceptional the results are subject to .serious but undeterminable en
due to the relatively high velocity of approach to the weir (Par. 609 d $eq
The attempt is made by building the crest high enough from the bottom
cut down the velocity, the head acting on the wheel is thereby reduced a

S54
 POWER PLANTS Sec. 10-713

once the actual service conditions are only approximate and

the peculiar
It is difficult to make the
;

•ilue of the test in place is partially vitiated.

inditions of the channel of approach to the weir suitable for good meas-
•ements and the expense of installation is relatively great. Whatever
ethod of measurement is used, there should be an agreement in advance
.; the buyer and seller of the wheels to accept the results. Where con-
tions for their use are right, rod floats (Par. 643) afford
an excellent means
r measuring the flow either in the headrace or tailrace.
'
The easiest measurements to make properly are probably those with a
1 rrent meter (Par. 662). The expense is slight and in the hands of careful
id experienced operators simultaneous measurements in
head race and tail-
ce will give excellent results without interfering in any way
with the normal
rvice conditions of operation. Suitable measuring stations may be
sily included in the original design of the plant at little or no extra expense.
For relatively small units fed by penstocks, the most accurate measure-
^nt without question can be made by a venturi meter(Par. 636) incorporated
the penstock when the plant is installed. When properiy rated it has the
eat advantage of giving a continuous record of flow.

713. For measuring the output two general methods are available
a hvdroelectric station.
• They are (1) to mea.sure the energy generated
metrically, or (2) with some form of absorption dynamometer. The
ctrical measurement requires that the driven dynamo shall have been
refuUy tested and the efficiency determined for all loads. Electrical
Sasurements can be made with great accuracy but the determination of
'? turbine output by this means is somewhat indirect. With the develop-
!nt of the Alden dynamometer direct and accurate measurement is
ssible. This apparatus is described as follows by Prof. C. M. Allen:
" It is a form of Prony brake, and usually consists of several smooth circular
•olvable cast-iron discs keyed to the shaft which transmits the power; a
u-revolvable housing having its bearings upon the hubs of the revolving
's; and a pair of thin copper plates in contact with each cast-iron disc, the
tes being integral with the housing. Through a system of piping, water
tier pressure is circulated through chambers between the units, each
slating of a disc and its copper plates, and between the outer plate at
her end and the wall of the housing. The water pressure is regulated by
cid or by an automatic valve.
.
Another system of piping circulates oil^f or
bricating the surface of the copper plates next to the revolving discs.
714. Advantages of the test in place. The test in place, if made com-
-e enough to cover gate openings under normal conditions of head at
all
'
plant, will serve two purposes: it will tell whether the wheels tested are
to specification; and it will provide a means of measuring the daily or
iy amount of water drawn by the plant so long as the wheels are kept
and in good repair, and the operating conditions are essentially those
ning during the test. These, records if carefully kept become of great
ue to the owner and operator of the plant.

ELECTRICAL EQUIPMENT OF POWER PLANTS

BY GEORGE I. RHODES
I
'sultiny Engineer, with Ford, Bacon & Davis, Fellow, American Institute of
J ctrical Engineers, Member of the American Society of Mechanical Engineers
ELECTRIC GENERATORS
'15. Types of generators are covered in Sec. 7 and Sec. 8.
'16. Generator characteristics required for a given power plant are
l,;ely determined by the size, overload capacity, speed, speed varia-
ti3, and possibilities of over speed of the prime mover; the size of the
[ nt, the number of units, the load factor, fluctuations and power-factor of
t ;oad; the voltage and type of the distribution system.
17. Sizes of generators. The ratio between the adjacent sizes of gen-
f t')rs varies from 1.25 to 1.50. The size limitations seem to have been
r bed only for direct-current generation, where 2,700 kw. is the largest ob-
t led commercially. Engine-driven alternators are in operation which will
Sec. 10-718 POWER plants
carry from 8,000 to 10,000 kv-a. continuously without overheating. Wat
wheel alternators are built up to 32,500 kv-a. and there is little doubt tl
larger sizes can be built if required. Steam-turbo-driven alternators i

being built up to 45,000 kv-a.

718. Overload capacity in generators is necessary only when the prii
mover has ability to deliver loads greater than rating, or in special cases
wh(
it is desirable to installa generator smaller than the maximum output of t
prime mover. Gas engines which will stop when their rated capacity
much exceeded, require generators which will reach their maximum si
temperature when continuously operated at rated load. This same conditi
is required of steam turbines when rated at the niaximura.capacity, and
water-wheels except in very unusual circumstances. Steam engines whi
are rated at their most economical load, or steam turbines having overlo
valves, require generators with considerable overload capacity. Generati
of the first class are usually designed to carry their rated load continuoui
with a temperature rise of about 50 deg. Cent. Generators of the seco
class are designed to carry rated loads continuously with 40 deg. Cei
temperature rise, and 25 per cent, overload with a 55 deg. rise.
719. Speeds of standard designs range from 75 r.p.m. upward, t
ratios between adjacent speeds being from 1.1 to 1.2. Low speeds are cr
fined to large machines. Several speeds for the same size are usually av
able, particularly in small and moderate sizes. The speed of direct-run
machinery is limited by commutation. High-speed direct-current gen.
tors, even of relatively small size, are not recommended. The speed
alternating-current generators is controlled by frequency and by number
poles. At the high speeds, ventilation becomes one of the princi]
problems, but the manufacturers have solved it to such an extent tl
machines are offered in sizes up to 5,000 kv-a. at 3,600 r.p.m. and up
30,090 kv-a. at 1.500 r.p.m.
High-speed generators deliver short-circuit currents of enormous
stantaneous value, even though the sustained short-circuit currents
limited. This characteristic is of greatest importance in large syate
particularly in reference to switching methods (Par. 799) .

720. Speed variations or fluctuations in the driving torque hay

tendency to accentuate the difficulties of commutation. In alternatii
current machines the speed variations are of great importance to para
operation, particularly when the speed is low and the number
poles is large. The driving impulse in gas engines and low-speed stf
engines being non-uniform, flywheels of large moment of inertia
required to keep down the speed fluctuations so that satisfactory par:',
operation may be obtained. It is usually necessary to have alternator?
this service designed with large armature reaction and reactance, so that
angular variations will produce a minimum of surging in the electn
circuits. With gas engines it is necessary to use short-circuited pole-f;
windings.
721. Bunaway speeds. In engines and turbines it is easily possible
provide emergency governors so that generators need be specified to st:i
only about 30 per cent, overspeed. In water-wheel units, however, the &
culty in caring for the inertia of the water in long pipe lines makes it necee.':
to have generators sale at 90 per cent, to 100 per cent, over-speed.
722. Inherent regulation. In very small plants good regulation is
be sought for, particularly on account of the lack of skilled attendance, f
also on account of the large number of other uncontrollable influen
affecting the uniformity of voltage. In the larger plants the aupstion
regulation is of less importance because of better attendance and the fe:
bility of automatic regulating devices.
In very large plants the importance of keeping down short-circuit currer
both instantaneous and sustained, looms up in such large proportions t

regulation is completely neglected except as may be necessary tn sc

proper conditions of parallel operation. In these large plants it is ii>u:i:
go to considerable expense to secvire automatic regulation of yohaur all'
ing generators of exceedingly low inherent regulation. Induction giunrai
and current-limiting reactances (See. 6), are also used in many plants
limit short-circuit currents.

850

I
 POWER PLANTS Sec. 10-723

nS. The number of units has relatively small influence except as

fectiDg parallel operation, the conditions of which are more exacting in a
!ant of many units. (Also see Par. 724.)
,724. The load factor, or the form of the load curve has particular
fluence in determining the number of units to be installed and the overload
parities of the same. With a steady load for 10 hr. per day, generators
,ould be installed to carry the load with one unit shut-down, without
"ceeding the overload capacity. With large short peaks for a few months
'

the year, and much smaller loads during the other months, the peaks can
(iely be carried at overloads even in excess of 25 per cent, for which
(Qerators are frequently specified.

726. Load fluctuations.

If the load is widely fluctuating, such as on
ictric railways of few cars, the commutation limit of direct-current
ichines determines the size to be installed. Interpole generators with
ility to commutate loads far above the usual rating are frequently used
that the average load may approach the heating limit. In alternating-
Tpnt machines this question is of less importance, as they are stable at
y considerable momentary overloads. In single-phase railway systems
r.' violent short-circuits are frequent the windings need to be specially

;. Fluctuating loads will cause considerable voltage variation and

letermine the requirements of regulation, particularly in small
dium size plants. Compounding is almost invariably resorted to
•

t-current plants and sometimes in small alternating-current plants;

'

hen there is considerable variation in voltage, especially on rapidly

:.g loads.

'2S. The power-factor determines not only the kilovolt-ampere rating

generators to be installed, but also the size and resistance of the field
: 2;s. ^lachines required to carry lagging loads need larger fields than
!ies to carry leading loads of the same magnitude. Generators are
y supplied with field windings suitable to care for full inductive loads
jior cent, power-factor. This is usually sufficient to take care of any
ion which may be expected.
n. The voltagfe. Standard direct-current machines are available at
250 volts, two-wire and three-wire, also at 600 volts, and 1,200
'Its,
alternating-current machines at the above voltages and in addition
olts, 2,300/4,000 volts, four- wire, three-phase, 6,600 volts, 11,000 volts
;.200 volts. Higher than 2,300 volts, without the use of compensators
nsformers, is not recommended in small high-speed machines. 11,000
iid above in turbo-generators, except of largest size, should be avoided,
- entirely safe in slow-speed machines. Other voltages are used at
but the machines are special. Occasionally it is desirable to use
tors connected in delta at 2,300 or 6,600 volts but insulated for 4,000
"00 volts, making it possible later to increase the voltage of the system,
voltage machines are usually star connected, because of the possibility
rger conductors and more rigid windings.
28. Foundations for electric generators are usually parts of those
<: he prime movers. The type and form is largely dictated by the require-
- of the becoming the practice to support turbo-
prime mover. It is
it ors on skeleton foundations and even directly on the floor with a
•iiont underneath. For the cost and detailed design see Sec. 10.
29. The erection of generators covers a considerable range of work
d ending upon the method of shipment. Small machines are shipped
Cipletely assembled and the erection consists merely of placing in position
a leveling. With larger units the facilities for transportation and hauling
lijt the sizes for separate parts and in extreme cases the machines are
Wiped almost completely dismantled, requiring the most careful work in
euing them and preparing them for preliminary operation by drying and
V age tests.

}0. Preliminary operation requires a determination of the polarity or

P -(OS,before actual connection to the lines, as well as careful watching and
tf ng during operation necessary to determine whether or not the machine
fpct and ready for regular and continuous service. Phases as marked
factory should not be depended upon. Phases and synchronizing
 I I

Sec. 10-731 POWER PLANTS

equipment may be checked by connecting to a spare machine and bi
bringing up to speed with the spare machine and synchronizing by the usc
the apparatus on the sp:
2W0| ——
I
1
————
I I I
1^-1 1

——
machine.
I

If no spaics
1900 available, lamps, ;ilonr
1800
with shunt transform;
connected across the op
1700 switch may be used. Sinn
1600 taneous dark lamps indica
correct phases; when lam
1500
do not darken and bright
1 1400 together crossed pha.^is a
indicated.
il300
a 731. The volume of s
1200 required for cooling
1100 1100 generally about 5 eu. ft. i

min. per kv-a. of genera'

^1000 1000
capacity.
"
ui)0 900
732. Cleaning the air
800 a matter of great iniportan
700
but frequently ncRlecti
Dirt which clogs up the :

600 passages and coats the co

500 ing surfaces prevents proi
cooling and shortens the 1

400
of the machine. Reasona!
300 cleanness may be secured
having the intake above t
200
roof, thus keeping out all b
100 the finest dust. If the s

must be taken from nea^J

ground, it should be fil^
by passing at low velfl
through one or more t|^
nesses of cheese olo
Canton flannel. _
Comd
cleaning requires large (

amounting to about
ft. per kw. of generator capacity. Means must be provided for the ;

cleaning and replacement of screens. Water screens (air washers) or hv

 POyVER PLANTS §ec. 10-733

-s are largely used in which the air is passed through falling water which
ces out the dust, and then freed from mist by baffles (Fig. 84). This
thod has the added advantage of cooling the air several degrees. The
!ue of this may be seen in Fig. 85.

'33. The cost of erection and preliminary operation of generators

_ between wide limits depending upon local conditions. Smaller
chines which are shipped assembled may cost for erection and prepara-
Q for regular service, in reasonably equipped stations, from 4 per cent.
t5 per cent, of the cost of the machine at the factory. If the machine
iihipped dismantled, the cost of erection will be about 1 per cent, to 2
"Tit. higher. The cost of erecting large machines is from 4 per cent.
- cent., and in a few cases where conditions allow shipment assembled,

per cent, can be saved.

! (An average pre-war cost, for machinea
lO kw. to 6,000 kw., was $400 per unit plus $0.32 per kw.). For
-ts add 100 per cent. Freight and haulage is dependent absolutely
ion and local conditions, and may vary from 1 per cent, to 15 per
c t. oi the cost of the machine.

34. Ventilation. The continued success of ventilation methods has

£ ost important influence in determining the life of the insulation. The
. ! •
inents call for a plentiful supply of cool air free from dust, oil and ex-
moisture. Except in turbo-generators, no special means are taken
; .11 these conditions other than those provided in the machine. In
I ;-.= turbo-generators, how-
peed
e r, large volumes of air at enor-
r speeds are passed through the
j3
T dings, and the utmost pains should

i; iken to maintain the best possi-

h 'onditions. In some stations it is
c jinary to take the cooling air di-
r ly from, and discharge it into the
t line room, but in cases where the
T' n cannot be well ventilated, this
a ligament may overheat the room
a the machines. In other stations
it::s been found possible greatly to
ii a^ie the capacity of the generators
b stalling specially designed vanes
.

rotors, thus passing much larger

"i of air. With a machine thus
ted, the coils quickly become " -20-10 10 20 30 40 50 c
<[ and much care has to be exer-
•
14 32 50 68 86 104 122 F
ci to keep out the oil that per-
ir tos
1

the atmosphere. In most Fi<5. 85. —

Safe load and tempera-
St cms it has been found important ture of cooling air (G. E. Rev.,
tc stall ventilating ducts taking cool Sept., 1913, p. 633).
ai irectly from outside the building.
' irts should be of liberal size to keep down air velocities to about 1,000
iiin. Dampers should be provided to enable shutting off the air
in case "of burn-outs. Ventilation by separately driven blowers is
bf % used and is strongly recommended by some engineers.

6. The cost of ventilating ducts arranged for cleaning the air would
H oxiniatc 2'^ cents per kw. of generator capacity under pre-war conditions
or. cents for 1921.
6. The operating temperature, combined with the kind
of insulation,
<le mines absolutely whether or not the machine is overloaded. Tem-
pe aires are difficult of measurement, particularly in respect to finding the
00 '-t parts. It is the maximum temperatures which are of importance,
""
probable that these are never found in tests. Resistance temperature
" ;s

difficult to make, and in large machines take considerable time

e
ut-down; such tests give only average copper temperatures, which
^trtainly less than the maximum. Ordinary thermometer tests give
Ksmperature of the outside of the insulation, and by means of refinements
Rjossible that maximum temperatures can be measured to within 10 deg.
V deg. Cent., but this method is not recommended. Resistance ther-
""feters and thermo-couples, inserted between the coils and the iron.

859
Sec. 10-737 power plants
are used with considerable success. The actual indicator may be locai
anywhere convenient, even on the switchboard, where continuous recc
of the temperature may be kept. This method gives more consist)
and precise results than the others and probably shows more nearly I

maximum temperatures. * Indicating electric thermometers can be instal

for $100 to $200 per machine.
737. Safe temperatures of insulation are given by CP. Steinm
and B. G. Lamme in the February, 1913, Proceedings of the A. I. E. E. as
deg. Cent, for fibrous insulation such as is commonly used, and 125 deg. Ce
for mica and other fire-resisting materials. These temperatures are '

measurable temperatures rather than the absolute maximum that may

expected in local spots. H. G. Stott recommended 20 deg. lower tempe
tures, especially on high voltage work.

EXCITATION
738. Excitation equipment should be designed with a view to the me
mum possiblecontinuity of service. Simplicity, ruggedncss, "fc
proofness" and reserve apparatus are important requirements. The meth<
in use for securing these results are greatly varied and much difTerence
opinion exists as to the best method. Each plant must be considered a
separate problem.
739. Exciters directly connected to the main generators were
earliest form in use. Each exciter is frequentlv made large enough
handle two generators, in emergencies. The cnief arguments in fa
of this method are simplicity, high efficiency and the absence of large fj

rheostats. The most important objections are the possible crippling i

large unit due to trouble with its exciter, and the fact that voltage fluctuati
in per cent, are twice as great as the speed fluctuations.
740. Exciters driven by separate prime movers may be obta
for service with any kind of prime mover. On account of their small
the efficiency of the unit is very poor, this constituting the c:
objection to their use. Where steam at atmospheric pressure is neces^
for feed-water heating, the inefficiency is of no importance. Their u^^'
determined principally by questions of convenience and economy, it bi
absolutely necessary to install them for starting purposes.
741. Motor-driven exciters are in use in almost all stations. They
cheap, economical, efficient and reliable, but cannot be used for the comp
equipment. They should not be driven by synchronous motors, bei
short-circuits on the outside system not in themselves sufficient to can
shut-down of the station, are likely to throw the motors out of step, i

shutting down the plant. Induction motors are almost invariably ii

A well-balanced exciter plant consists of units driven both byconsidereUj
motors
by prime movers. In some cases, motor-driven units are
auxiliary to the prime-mover units, and in other cases the motor-«w« "
plant is considered of first importance; the first plan is probably
favor.
742. The importance of continuous excitation points stron
storagre batteries which are frequently installed of sufficient capw
excite the entire plant for an hour. Danger of a shut-down of theJ
plant by failure of the exciters is not considered great enough in al'
to warrant the great expense of a battery. When used, it may eit
floated on the excitation busses, or allowed to stand by fully charg-
743. Another method of securing continuous service is be
with considerable success. The exciter generator is arranged to be (t
and prime mover. The motor is provided with C'
both by motor
which shuts it down if the voltage becomes low. The governor is ar«^
practically to shut off the steam at normal speed, but after r"*""*! W
r^
motor, the prime mover continues to drive the unit at but slightly
speed.
• Reist, H. G. and Eden, T. S. " Method of Determining Temperd
Alternating-current Generators and Motors, and Room Temper*
Trans. A. I. E. E., 1913.

860
I
POWER PLANTS Sec. 10-744

i 744. The size of the exciter plant depends upon the size of the power
•ant and the types of generators used. Small, low-apeed generators
-quire up to 3 per cent, of their capacity for excitation. Large, high-
deed turbo-alternators may require as little as 0.50 per cent. The exact
quirements may be obtained from the manufacturer. The total capacity
ould be ample to carry the whole excitation load with the spare apparatus
'

it of commission. The amount of spare apparatus required is not very

I'finite; practice ranges all the way from depending on the overload capacity
having two to three times the total capacity required.
I

i-74S. The number and relative size of the exciter units should be
:osen for the greatest simplicity and the required flexibility. The minimum
;e of any unit is in general dictated by the requirements of the largest
'nerator. It is doubtful if the largest exciter should be large enough to ex-
e the entire plant. Except in very large plants a size suflBcient for half
e equipment, with a total of three units, will give very satisfactory
suits.

746. exciter voltages in common use are 125 volts for all except the
The
j
rry largest plants where 250 volts are used. The generators are usually
'
t compounded. With standard exciters it is possible to run at not more
I !in 15 per cent, over standard voltage, which is quite sufficient to take
e of the excitation of ordinary alternators at full-load. Where overload
Dacities are to be used, it is frequently desirable to raise the excitation
(tage as much as 25 per cent, during the peaks. Exciters can usually
arranged for this voltage with very little deviation from standard design.
M7. The cost of exciter sets installed, ready to run, exclusive of wiring,
ins, etc., could be taken as follows: — —
Pre War: 1921:

imple-engine drive,
—
ompound-engine drive, $1,000 plus $35 per kw. plus $68 per kw.
—
$750 plus $26 per kw. plus $52 per kw.
tf am-turbine drive,
—
$425 plus $31 per kw. plus $60 per kw.
uluction-motor drive, —
$625 plus $15 per kw. plus $30 per kw.
he cost of exciters attached to the shafts of the main generators can
1
1 be expressed as a percentage of the cost of these generators; this will
;• Irom 3 per cent, to 5 per cent., depending
^
somewhat on the speed.
48. Exciter wiring systems are in use covering practically all the
-'"urrent types of switchboards. On account of the low voltage no
ations need be entered into except as may be necessary to make
lie the various sources of excitation. Occasionally a double exciter
I 3 desirable, but in most cases it adds complications without any adequate
g 1 to the service. Alternating-current wiring for motor-driven exciters
ei.ld be worked out on the basis of the exciters being most |important
f!»rg, unless, however, the presence of a storage battery makes this
t inient unnecessary. In stations above 2,300 volts, it is recommended
t transformers be used in connection with the exciter motors, as small
niiines wound for high voltage are not sufficiently reliable.
19. Excitation switching appliances. The current must not be
I' °n without at the same time short-circuiting the field windings, other-
;^'iDctured insulation will result. This requirement calls for special
i.scharge switches. It also limits the use of circuit-breakers to those
ing on reverse current, thus serving to cut out damaged exciters.
of very large overload capacity, which will blow only during most
trouble, are used for the protection of the exciters.
-'.Field rheostats for small generators are usually mounted on the
'f the switchboard, but for large machines some more convenient
n involving remote control is necessary. Electrically controlled rheo-
tre frequently necessary in large stations and are operated either
by
id and ratchets or by motor; the latter is necessary where the field
t exceeds 300 amp.

VOLTAGE CONTBOL
1. Hand regulation. Voltage is controlled in all systems by hand
re .ation, whether or not there are automatic means. Hand regulation
al is suitable only where the load is steady and the generators
'
inherently
re late well.

861
Sec. 10-752 POWER PLANTS
762. Automatic regulation may be secured by two methods; first, i

automatic adjustment of the field resistance by motors or solenoids control!

by a relay; second, the alternate short-circuiting and insertion of resistai
in the field circuits. The first method is used in the Thury regulat
the second method in the Tiixill regulator. The first method makes 1

adjustment more or less gradually; the second changes the resistance mu

more than necessary, alternately one way and then the other, while (

time lag of the field windings produces a practically steady voltage of a val
depending upon the proportionate time the resistance is in and out of circi
The latter method is inherently more sensitive than the first and is pri
tically the only one in use in America.
763. The Tirrill regulator for small direct-current machin
operates as follows (see Fig. 86). The regulation depends on the rapid ma
and break of contacts .1 which short-circuit the resistance in the shv
field circuit of the generator. The closure of these contacts depends up
the machine voltage across the relay B. The contacts closed by this rel
serve only to close or open one of the two differential windings on the niagi
C, which in turn operates contacts A cutting in or out the field rct^istan
When the voltage is high, relay B opens one winding in C which in turn can
the latter to open contact A, inserting the resistance, and vice versa. 1
final result of operation is that the contacts vibrate continuously and rem
open or closed a longer or shorter portion of the time as may be requii
to keep the voltage steady. A regulator of this type with multiple conta
at A can control machines up to 125 kw.

Spring I <=^

y^ Spring G

Generator^ £xciur

Fig. 86. —
Tirrill regulator for Fig. 87. —
Tirrill regulator
large machines.
^
small direct-current machines.

764. Tirrill regulators for large direct-current machines i

alternators operate as follows (Fig. 87) : The solenoid A is connected ar »
the bus bars, usually through a potential transformer. The coro.
lifted by the solenoid, is attached to the lever C on the other end n
a contact D and a balancing weight E. Across the exciter tcr
connected a solenoid F whose core is attached to the lever G witu >

D on the other end. This lever is pulled in a direction to close the ; orr
by a spring so designed that the plunger /' is pulled downward in n
proportion to the voltage. This arrangement gives greater sen.-'itiv.
than the simple arrangement at B, Fig. 86.
When the alternating voltage is low the weight of the plunger A ovirr^
that of the balancing weight £ and clo.sea contact D, causing relay /'
'

contact /, thus short-circuiting the field resistance and raising ilr

voltage and the alternating voltage. As the exciter voltage rise.-,
F pulls down its plunger and lifts contact D, but as long as the al'
voltage is low, the lower contact follows. When the alternating
862
 POWER PI. ANTS Sec. 10-755

m above the correct value the contact D is opened, which causes the re-
;,ance to be inserted again in the field circuit. The winding on the K
I'noid A allows compounding with the load, which may compensate for
: average line drop. In stations where there are several exciters, the relay
aperaies a number of contacts /, one or more for each exciter. In very
56 stations a separate regulator is used for each exciter.
tSS. Regrulators with exciter batteries are possible by the use of
ksters in the exciter bus under control of the regulator, bucking or boost-
the voltage supplied to the field windings.
U. Manual regulation with regulators is secured by varying the
Istaoce in the circuit of solenoid A, Fig. 87.
187.Protection against regulator failures or abnormal conditions
Uld be provided whereby excessively high or low voltage results in the
Iration of a relay, thereby making the regulator non-operative.
VS. Exciters for Tirrill regulators require careful adjustment for
^allel operation. Field circuits should permit voltages from 40 per
t. to 140 per cent, normal. They must respond rapidly and equally to
Inge of resistance. Unequal response causes the quicker machine to take
ihe load and it may flash over.

pi9. The cost of Tirrill regulators installed is from $500 to $1,500

^, exclusive of instrument transformers.
BO, feeder regulators for alternating-current circuits consist essentially
ompensators.the secondary winding of which is in series with the outgoing
uit. They are fully described in Sec. 6. There are two types, the
tact type and the induction type, the latter being preferable. These
ilators may be either single phase or polyphase as necessary. They are
illy wound for + 10 per cent, regulation. They may either be hand op-
ed, or automatically operated through a relay and motor to compensate
line drop thus maintaining constant voltage at a distant point. The
i of 2,200 volt automatic feeder regulators for ± 10 per cent, regulation
about as follows: before the war single phase, $300 -(- $350 per 100 amp.
ee phase, $600 + $600 per 100 amp. If motor-operated but non-auto-
fic, about $80 is saved. Hand-operated regulators save about $150.
1921 costs add 60 per cent.
LOW-TENSION DIRECT-CURRENT SWITCHING
Direct-current switching may conveniently be grouped in the
il.
'wing general classes: (a) Single polarity; (6) Double polarity with
lUzer on pedestal; (c) Double polarity with equalizer on panel; (d) Three
(e) Multiple voltage,
;

bviously a great number of subdivisions could be made, the number

©iusses being the most important. Fig. 88 shows the elementary wiring
of lese various classes, leaving out all auxiliary wiring and all instruments.
Parallel operation of compound generators is secured by the
1.
r connections which are usually of one-half to one-third the rated

They parallel both terminals of all series fields, making the direc-
. .

i.11')i current in all of them necessarily the same. Parallel operation is

fu discussed in Sec. 8.
3. Single-polarity switchboards find their greatest use in railway
Wi where the negative bus is at approximately ground potential, and is
.

us lly located in the basement beneath the machines; it should be insulated,

he >ver. The circuit breakers and instruments are in the positive side of
thooard and the equalizer and negative switches are on small panels or
pestals near the machines. The feeders are frequently without negative
3^ "hes.
4. Three-wire switchboards are used for combined lighting and power
iy The generators require an equalizer on each side. If both these
ins.
eq lizera are thrown in, the machines are paralleled as shunt machines,
"^ at some means must be taken to make it possible to close the equalizer
-hes only at the same time as the main switches. This usually calls for
(
pole switches on small boards and two' double-pole switches on the
, each double-pole switch consisting of one line and one equalizer switch,
obvious that a circuit breaker and instruments are needed in each side,
le case of two-wire full voltage feeders, a double-pole circuit breaker
cessary when the neutral is grounded.

863
 1

Sec. 10-765 POWER PLANTS

765. The instruments required to measure completely the output
the machines or of a feeder, comprise an ammeter or a wattmeter, or hot
for each circuit-breaker shown in the diagram (Fig. 88), together with
voltmeter on the main bus. For purposes of connecting incoming generate

One Wli« Vwo Ytlr« Iwo Wire Three Wire Ihroe Two Iwo Due i

with 'Ith Wire Wire Wire Wire Wire

Pedertal Pede«al OrouDded Ground
>'eutr&l Ne{^.

Fig. 88. —Elements of direct-current wiring.

provision must be made for a voltmeter on each machine, or a socket and pi

which will enable its voltage to be measured by a common machine vc
meter. (Fig. 91.)
766. Double-polarity switchboards find their greatest use in pov
work, particularly at 250 volts. Tbi
„ , „. are desirable where both bus bars
be insulated. Except for large staf
_

there is no disadvantage in having!

polarities on the same board. Ex
on small boards, it is desirable tol
the equalizer switches on pedestals
itTTo Alarm Bell the machines (Fig. 89).
Instruiueat Buses
:PoteDtl*l Bums 767. Multiple-voltagre s 1 w
For OOOToH
Clrculta oiult this
boards are in use where thre
Bus aud Coanect distribution is extensive. The
Lower studs of busses are operated at a voltage 1

Ammeter togethi than the main busses to take _ca

the drop in long feeders. Their
Field Switch age is usually maintained by boo
Discharge Reslstanoft although in some cases provision is r
for connecting the generators to «i
set of busses.
768. Double' bus bars are
warranted except for operating atl
Fia. 89. — Detail wiring diagram voltages. However, when there,
of generator panel. two distinct classes of service
should be kept independent, doti
bus bars are desirable (Fig. 90). [

769. Spare circuit breakers are almost necessary in heavy raill

work and provision should be made for inserting them in a simple man
(Fig. 91).
770. Auxiliary circuits are frequently installed to accomplish nd
different purposes. Some of the more commonly used are as follol
864
 POWER PLANTS Sec. 10-771

Voltmeter bus and receptacles to enable the use of one instrument for
machines; (6) Current supply for instrument excitation and the opera-
an of circuit breakers; (c) Signals indicating open breakers; {d) Remote

Auz
. Bub

Begular Spare
r-°)cir. Cir.Breaker
CI "^Breaker
Cir.Breaker

D.P.D.T. OS.P.S.T.
6 6 S.P.D.T.6
Switch O
Switch 9 Switch

To
Generator
Feeder
1 1 Feeder

Fig. 90. Fig. 91.

!S. 90 AND 91. —Wiring for spare busses and for spare circuit breakers.

rm

Maia3us B&ra
Ammeter
Potential Bus Wipe—
Support
Bheostat Uandwheel
Field Switch
Potential Beoeptacia

Kbeostat Chain )
Operating Mechaniam]

Quick Break Switch

Watt-Hour Meter

Beaistanoe

Y 24^-->*

Fig. 92. —Two-pole generator panel 2500^1, 250 v.

Jr<rf of circuit breakers and switches;

Interlocking circuits between
(e)
it breakers; (/) Reverse-current relay wiring (Fig. 89).
*• Types of switchboard panels. The accompanying illustrations,
r|2 and 93, serve to indicate general types of panels. In very small in-

865
Sec. 10-772 POWER PLANTS
stallations, the generator and feeder switches may be located on the aair,

panel. In moderate sized plants there may be several feeders per pane
although generally each generator has its own. In large systems there
sometimes a separate panel for each feeder, but this is necessary onljj i
very special cases, usually two being grouped on each panel. The requw

Fig. 93. —Two-wire feeder panels; three small feeders.

ments of ammeters and circuit breakers are the same both for generat
and feeder panels except that occasionally two feeders running to the sa:
point are protected with a single set of circuit breakers.
772. Station panels are usually provided containing a totalizing n
meter and watt-hour meter, bus voltmeter (or voltmeters if a three-w

r"

ri) it

= ) kf ^p

Fig. 94. —Switchboard supports; angle iron and pipe (Elec. Jour.,
1913. p. 168).

system), machine voltmeter and switches for auxiliary circuits and poi
station lighting.
773. Switchboard supports are either in the form of angle-iron
work or l>i-inch iron pipe (Fig. 94). An inverted channel iron, or
hard wood is sunk into the floor to which the upright supports are I

There is an upright for each joint between panels consisting of two

86a
 POWER PLANTS Sec. 10-774

')ack to back, or of The entire board is braced in an

a single iron pipe.
ipright position by The iron used varies in size
numerous wall braces.
rom 2 in. 1.5 in. 0.25 in. to 3 in. X 2 in. X 0.25 in. One and one-
X X
ourth inch pipe is generally used. At least 4 ft. of clearance should be left
)etween the board and the wall to allow for clearing and repairs. In
lirect-cirrrent practice it is customary to insulate the iron framework from
Tound.
774. Complete lines of
letailed fittings are on the
narket, facilitating almost
ny conceivable arrangement
f framework for supporting ^
he panels and bus bars. *^
Fig. 95.) Brackets with
Dccial insulators are used ^
:ir the bus bars and longi- ^
idinal -wires. Vertical ^
nail wiring is fastened to ^
le back of the board with
nail straps. Vertical con-
uctors made of copper bars
r heavy wires are usually
ipported by the studs of the
vitches and the main bus
xrs to which they are con-
"cted.
776. In laying out the
iring for the switchboard
inels care should be exer-
sed to have sufficient clear- ^^.
:ice around all live parts ^2
or more) and to avoid
in.
^
I unnecessary complica- %^
:ins. It is important that %^t
I panels be as nearly alike %
possible.
^^
776. The materials for ^ 1

mels. Marble is used in

13 more important switch- ^y-sjiK,
on account of its bet- ^^*"
irds
insulating qualities and ^^^^
tter appearance
ranee if un- ttt ^
inted; it is advisable
iltage exceeds 600.
if ine
idvisable ii the S^
Slate
likely to contain conduct-
S. j
^^^^^^^^^^^^^^^
ssi_a5_JLJ , ^_

Fiq. 95.— Standard switchboard details

?
veins but when clear is (Elec. Jour., May, 1913, p. 82).
I>eTfectly satisfactory ma-
il, considerably^ cheaper than marble and somewhat stronger. Panels
1.5 ip. to 2.5 in. thick are used, depending on the size of the switches
I

circuit breakers. In some cases even thicker reinforced panels are

i-ssary. Marble panels complete with framework cost from $2.50 to
per sq. ft., slate panels from $1.75 to $2.50, on a pre-war basis with 100
r cent, increase to 1921.
'
m. Bus-bar connections. Bolted joints are preferable in light work,
igely on account of the awkwardness of the clamps, but on heavy work,
mps have many advantages. Lap joints or butt joints with covers
be used with a uniform pressure of from 100 to 200 lb. per sq. in.
ild
copper surfaces should be well cleaned. The current density in
connections should be from 100 to 200 amp. per sq. in.
c Under these
' 1litions, the drop in the joint will but slightly exceed that in an equal
' gth of bar.
'78.Bus bars are usually made of 0.25-in. or 0.125-in. copper of various
" lihs,seldom more than 10 in. The bars are grouped together with 0.25-in.
f
t,'?^.
between them when using 0.25-in. copper and 0.375-in. when using
w5-in. copper. Aluminium bars 0.25 in. and 0.375 in. thick are some-
.
t ns used.
Fig. 96 shows approximately the relation between the number

867
Sec. 10-779 POWER PLANTS
of bars, the width of the bars, and the current-carrying capacity base
on a temperature rise of 25 dog. to 30 deg. Cent. Free circulation of air i

important and the bars should be supported on edge. Smaller spare

between the bars would greatly reduce their carrying capacity. In genera
current densities of from 800 to 1,000 amp. per sq. in. are not excessive
Where aluminium is used, densities 25 per cent, less should be figurct
The cost of copper bus bars installed may be estimated on the pre-war basi
by adding 10 cents per lb. to the cost of the copper, or 20 cents for 1020.
10000

Number and Width

Fig. 96. —Current-carrying capacityof bus bars taken from manufaot\H«
bulletins. i-i

779. Connections to switch studs between nuts should be figured

the basis of a current density of from 100 to 200 amp. per sq. in. Counecttfl
should be carefully fitted and the burr carefully reaioved from the edgeij
holes. The cost of making heavy connections between switch studs,,*
bus bars can be covered approximately by adding the cost of 1 ft. of bar i

each connection and 6 in. for each joint. For usual panels this worl^*
cost about $10 per panel plus $1.50 per 100 amp. before the war and pi
100 per cent, for 1921. ,i :

780. Switches should carry the maximum overload at a tempwit^

rise of not greater than 25 deg. Cent. Current density in the blades*
studs ranges from 700 to 1,000 amp. per sq. in. and in the jaws and hiDI
from 40 amp. to 50 amp. per sq. in. The switches must be carefully mf-
and lined up so that the full contact area is available. If the switrh ov
heats, the contact resistance will be greatly increased by oxidation.
6,000-amp. single-pole switch is about the limit of hand operatlt
Very large switches with laminated brush contacts closed by togglo jii
are sometimes used.
781. Cost per pole of single-throw switches complete with
etc., ready for mounting on switchboards was (on pre-war basis) $1.80 i

100 amp. of capacity; with 40 per cent, added for double throw and 10 |

cent, for 600-volt switches, to cover added length of blade and quiok-f"
feature, which should always be used, plus 80 per cent, for 1921 costs.
782. Fuses are the simplest means of automatically opening a cir
under short-circuit or overload conditions. Enclosed fuses are on the i

and are approved by the fire underwriters, having capacity up to 600 amfi
250 volts, or 400 amp. at 600 volts. Up to 30 amp., the contaotsj
simply ferrules on the end of the tube. On the larger fuses, cont

868
 POWER PLANTS Sec. 10-783

'nade by blades fitting into jaws similar to those on knife switches. The
,ube is filled with heat-resisting powder which confines the arc and puts
.t out quickly. All fuses are supplied with indicators to show when they
'ire blown. They will usually carry full rated load continuously, but will
)low in from one to five minutes if the current exceeds 15 per cent, overload.
783. The cost of fuses complete with the clips is about $1 per 100 amp.
capacity. The cost of the fuses alone is about 50 cents per 100 amp.
apacity, and the cost of refilling the fuses is about 20 cents per 100 amp.
apacity.
784. Automatic circuit breakers are required on all circuits larger than
GO to 600 amp. and even on the lighter circuits where overloads and short-
ircuits are likely to be frequent. In order to reduce to a minimum the
urning of the circuit breaker contacts, three contacts are successively
roken on the opening of a circuit. First the main current-carrying contacts
pen; then an auxiliary copper contact opens, and lastly a contact opens
(tween the carbon plates and breaks the entire current, thus protecting the
irrcnt-carrying contacts.
The main contacts in circuit breakers consist almost invariably of lami-
:ited copper brush bearing on flat copper blocks, and pressed down by a
iggle joint exerting considerable pressure. Several types of breakers are
lown in Figs. 97 and 98. The current densities used in the laminated con-
ets are from 400 to 500 amp. per sq. in. The entire breaker is designed for
temperature rise not to exceed 25 deg. to 30 deg. Cent, in any part.

5^.

>. 97. — Carbon-break circuit Fig. 98.— Carbon-break circuit

breaker 150-2500 amp. breaker 3000-4000 amp.

Circuit breakers are ordinarily hand operated by a lever,

|oh is of sufficient power even for the largest sizes (Fig. 98) Frequently,
.

^eyer, remote control is desirable and electric or compressed-air opera-

Itis used. The breakers are usually arranged to reopen immediately
|hout damage when closed on a short circuit. All breakers are supplied
i_an overload tripping mechanism which is adjustable to open the
ut at currents from 60 per cent, to 150 per cent, of rating. Other trip-
arrangements may be operated by low voltage, excess voltage, reverse
:

Ifent of a tripping switch located at any convenient point.

H6. Multiple-pole circuit breakers are commonly used in the smaller
Tkdties. For many purposes they are specially arranged so that if closed
Overload or short-circuit, the tripping coil will release the closing mechan-
1 and the breaker will open before the main contacts are closed. Such
era may be used on feeder panels, avoiding entirely the use of knife
"

ftes.

The cost of carbon-break circuit breakers is about $32.00 plus

'per 100 amp. of rated capacity per pole; or about 60 per cent, less on
-war basis.

869
Sec. 10-788 POWER PLANTS
788. Switchboard instruments in direct-current work should be care'
fully protected from stray fields. Wherever the bus-bar currents exceec
2,000 anip., all except the very best protected instruments will be affected
and to secure accurate readings they should be calibrated in place. It ii
customary to provide instruments with scales such that at the rated load o:
the machines, the needles will be at approximately mid-point.
789 The cost of switchboard instruments varies between wide limits
.

Ammeters cost all the way from $15 plus $1.50 per 100 amp. of capacity
to $75 plus $2.00 per 100 amp. of capacity. Voltmeters may cost from $2(
to $120 depending largely on the type. Watt-hour meters will vary u
cost from $35 plus $2.50 per 100 amp. to $200 plus $13.50 per 100 amp
Pre-war costs ran 30 per cent, to 50 per cent. less.
790. Standard switchboard panels embodying the various dovicei
described above and suitable for all classes of work have been developed anc
catalogued by the various manufacturers, so that it is now possible to buj
complete, almost out of stock, panels suitable for almost any kind of work

1 +

Series Reslstaooo Control

to be used on 250 T. Relay
or 680 T.CircuiU Not
r«iulred on 125 Volt
N. Re4 Lam;
Uircuit

"I
Opening Cuntaot

Qreen Lannp
Qr««ti Lain]

Fia. 100. —Wiring of General Electric solenoid-

operated switches and circuit breakers.

These panels can h,- i '

Fie 92, is taken from one of these catalogues.

chased for a lower price than it is possible to
make up special pan' 1;:
whenever possible. The particular type shown in <lil^ h^
should be used
colt approximately $100 plus $12 per 100
amp. without watt-hour met
per 100 amp. with watt-hour meter, equipped for .
and $220 plus $16
volts, on pre-war basis or 75 i)er cent, more
for IJ.1J1.

870
 POWER PLANTS Sec. 10-791

CONSTANT-CUBBENT SEBIES SWITCHING

791. Series systems are now used in America solely for street lighting.
It is probable that theywill continue in use for this purpose indefinitely.
The installations used series-wound jrenerators operating on
earlier
the drooping part of the characteristic (Sec. 8). When the total pres-
sure exceeded 2,500 volts, multiple independent armature windings and
3ommutators were used, connected in series externally to the machine.
The regulation of these machines is accomplished in two ways, by shunting
;he series fields or by moving the brushes, or both. Since these machines
operate on the drooping part of the characteristic curve, they have con-
;iderable inherent regulation in themselves. The adjustments are made
lutomatically by a series-connected relay or operating magnet which actuates

D.C.n. D.C. n«aettnM Indtcating Lamp

LA. Ugbtmng Arreste Indicating Lamp Shunt
S. Kxciter Secondarj L.A. Lightning Arrester
.V. EiciUr Seutt»l S. Exciter Secondary
L Icdioiting lamp ,J»^-«!^Lo«d Ciroult N. Exciter Neutral
L.S, Indiumtlng ^ * S.D. Staiii: Discharger
Short Circuiting
* L.A. — ^ Seccndaiy Ex.T. £xuiter Transformer Plug Switch
i Plug Switch Open Circuiting
'Open Circditing) Plug Switch

Ammeter Ammeter Cover

Ammeter Cover Ammeter Cover
should be
Ammeter Cover
should be Grounded
Grounded

& ^Primary
^ ^ Plug
Switches
eojioadlap Tu Source of
of Energy
80^ Load Tap:

ta. 101.— Series lighting circuits with constant-current transformers and

mercury rectifiers.

10 field rheostat or rocks the brushes. Constant-current transformers

employed very extensively for this class of service (Sec. 6) and regulate
ii^mselves almost perfectly. Each transformer is supplied with a terminal
mel, etc., which forms part of the unit. Series-wound generators are
stalled, however, to a limited extent.
792. Mercury-arc rectifiers are also employed in this class of service, in
nnection with constant-current transformers, for series direct-curent
;hting. The equipment itself is described in Sec. 6. The connections are
ustrated in Fig. 101.
793. Switching practice is' practically the same whether generators or
insformers are used. Since the opening of a series circuit causes full
'Itage across the break, and short-circuiting causes only a relatively small
orease in current, all transfers of circuits are accomplished after short-
cuiting the same. Apparatus will run on short-circuit for a short time
thout damage. The switching is accomplished very simply by means of
transfer or carrier-bus panel as shown in Fig. 102. This arrangement is
latively inexpensive and will allow almost any conceivable switching.

871
Sec. 10-794 POWER PLANTS
794. Ammeters may be connected into any circuit by inserting the prope
plug in the sockets in rows 1 or 11. When the plug is inserted the circuit i

opened and simultaneously completed through the ammeter. In direct

n

Uotor-Qenerstor
Fia. 103. —Elements of Thury system of transmission.

current work necessary to have the instruments in the line circi

it is
They must be insulated for high voltage and the cases protected with t

grounded covers to protect the operator. In alternating-current wori.

872
 POWER PLANTS Sec. 10-796

current (series) transformer may be used in connection with a standard

instrument.
796. The Thury system of direct-current series transmission (Fig. 103)
3 not unlike the series lighting systems in use in this country. Series-
wound generators are employed, developing up to 4,000 and 5,000 volts each,
I sufficient number being connected in series to secure the desired trans-
nission voltage. Currents of various magnitudes are used, approaching
too amp. maximum. The Thury system, hke our lighting systems, ia
issentially constant-current and is regulated to produce this condition, the
'oltage varying directly with the load. The system is not planned for the
;eneral distribution of energy in small quantities, but rather for transmission
substations where it is transformed to constant-potential energy. These
ubstations are in series and each has one or more motor-generators with
eries-wound motors. This system has not been received with favor in this
ountry.
796. The insulation of the machine windings. (Thury system)
;ped not be for the full voltage. If a small number of machines is contem-
.latcd, thisinsulation could probably be advantageously used, but in large
ystems of high voltage and numerous machines, the most economical
esults may be expected by insulating each machine from the ground and
om other machines. The difficulty lies largely in securing an insulating
oupling combining mechanical with dielectric strength. The machines
lust each be surrounded by a highly insulated platform so constructed as
J allow easy access without danger to the operators.

797. The switching (Thury system) may be exceedingly simple, as no

'itomatic circuit-interrupting devices are required or even desired. Since
e characteristics of series generators permit short-circuit currents but
ightly in excess of the operating currents, no devices for protecting against
icessive currents are necessary. It is probable that satisfactory switching
in be secured by hand-operated non-automatic single-pole switches, one to
iort-circuit the terminals of the machines and two others to disconnect it
om the line (Fig. 103). None of the complications usual in constant-
tential systems need be considered. The short-circuiting switch should
ve a rupturing capacity equal to the rating of a single generator. The
^connecting switches may be of the ordinary air-break type, but insulated
,- the total voltage of the system. This insulation is necessary so that
le machines may be disconnected from the lines and grounded for repairs.

798. The regulation (Thury system) consists in maintaining constant

irrent and can be secured in three ways, any combination of which may
'
used: (a) shunting the series fields by an adjustable rheostat; (6) rock-
K the brushes from the neutral point; (c) controlling the speed. The
ificulties of commutation prevent any very considerable adjustment by
first two methods, but the generators themselves are self-regulating
I'

a large degree. The automatic regulation is secured by a series relay

ich operates the field rheostat or other controlling means through direct
imection or by electric control. Large adjustments are taken care of
the starting up or shutting down of machines. Motors are regulated to
ve constant spee'd by centrifugal governors which actuate the field rheostat
il rock the brushes. Protective devices are required for short-circuiting
t terminals when the voltage exceeds rating.

ALTERNATING-CUERENT SWITCHING
799. The principles of alternating-current switching are not
, cessarily different from those of direct-current (Par. 761 to 790). The
aie equipment and apparatus may be used for low-voltage work, except
sUght modifications to avoid eddy currents. The elements of alternating-
rrent switching arrangements are shown somewhat progressively in Fig.
1. The symbols indicate oil switches, (O) capable of being opened
der load and disconnecting switches (X) incapable of interrupting
y except the smallest currents.
The simplest arrangement is that shown in sketch A (Fig. 104), where
» generators and feeders are grouped at either end of a single bus.
ftches B to E indicate arrangements for sectionalizing the bus by dis-
mecting switches, which permit the division of the plant at any desired
bt; some sectionalization by oil switches is frequently desirable. The
873
Sec. 10-800 POWER PLANTS
ring bus shown at E probably has the greatest advantage. Doubli
busses are shown at F, G and H, which have the added advantage that an;
group of feeders may be supphed from any group of machines; double
throw disconnecting switches, and double-throw oil switches are shown
but the latter are not recommended. The relay bus system shown at J
and M gives some control of the sectionalizing under load.
The need for increased reliability of switching, as well as increased fl(

bility has led to the arrangements shown at J to /t inclusive; sketch I 8h(

spare oil switches arranged to replace any of the others, through disc
necting switches. In the other layouts, there is usually a spare switch
each generator or feeder group, so that no equipment need be kept out '4
service on account of switch trouble alone. Obviously, switching arrange
ments without limit can be devised to allow almost any conceivable swiUl
ing operation. y

Iff" r" ff t V

P I
R
Via. 104. —Elements of alternating-current switching.

800. Group switching is usually resorted to (Figs. \OiN and 1041

in very large stations of moderate voltage, where the number of feeders J
relatively large. It facilitates starting after a shut-down, and simplifies tl
sectionalization of the loads for any purpose. It also provides the maxinni
of flexibility with a minimum of expensive oil switches.
801. High-tension power stations using transformers require bot 1

tension and low-tension bus systems. The great expense of high-i

switches and the large space necessary for their enclosure has- led to v.
simple high-tension layouts. For example, the Ontario Power Coinp:ii
employs the complicated low-tension layout M
and the simple high-tinii'
layout D (T Fig. 104).
802. The grounded neutral has proved advantageous principal
in systems having extensive underground distribution, the object In ii

to open the circuit breaker of a grounded feeder before a short-iini

between phases can occur. A resistance is usually inserted betwoni t

874
 POWER PLANTS Sec. 10-803

ni-tral bus and the ground, of such magnitude that the current flowing
grounded feeder will comfortably operate its overload relays. When
-phase star-connected generators have a third harmonic in the e.m.f.
,. c, it will appear as a voltage between neutral and ground.
.
Where dissimi-
r machines are operated in parallel, a considerable voltage may develop be-
voen their neutrals which will make their interconnection dangerous.
-uch cases it is necessary to introduce resistance in these connections.
- common practice, however, to operate with but a single machine
; Tided, which prevents interchange of neutral current and still protects
.> system.
803. Current-limiting reactances are in use on large systems to
i:it short-circuit currents, thus protecting generators and limiting the
\ of the oil switches. These reactances are of the air-core type (Sec.
I hey are used in two ways: those permanently inserted in the cir-
-, and those inserted only during switching operations. The ordi- _

iiv turbo-generator will deliver instantaneously on short-circuit, from

) to 50 times rated full-load current; a reactance sufficient to reduce this
is apparently all that is necessary in present installa-
15 times full-load
ins. This reactance may be introduced in the machine leads, in the bus bars,
m
the feeders. The first method is commonly used for permanent inser-
)n in very large stations; these reactances are quite large and expensive.
second, method is recommended for use between sections of the bus in
iiis where the switches would otherwise be inadequate. The third
iiod is used for insertion of reactance only during the opening of a short-
uit; there are two switches in series, the first inserting the reactance
ormally short-circuited), thus limiting the current to be broken by the
'^rind which is mechanically interlocked to open immediately afterward.
~e reactances are small and may even be included in the oil pots of large
'hes.

—^Var---*!

Fia. 105. — Disconnecting switches.

J04. Disconnecting switches
(Fig. 105) are ordinarily used for section-
iring bus bars or circuits, or for isolating apparatus for grounding or
lair, but not for switching under load. They are used sometimes,
U-ever, in place of oil switches on one side of parallel transformer banks.
iconnecting switches should not be located to open downward unless
Iks are provided to keep them from jarring out. In very heavy work
<e should be used to avoid loops in the wiring which on short-circuits
'i produce magnetic forces sufficient to open the switch. The coat
;
300-amp. disconnecting switches is about $6.00 + $0.80 per 1,000 volts.
j> cost of 600-amp. disconnecting switches is about $12,00 -|- $1.00 per
'00 volts, mounted on metal bases, or 20 per cent, greater than pre-war
I ts.

05. Expulsion fuses (Fig. 106) are used for connecting potential or small
£ iliary transformers to the bus. They are usually arranged also as discon-

875
Sec. 10-805 POWER PLANTS

Fia. 106. — Expulsion fuse. FiQ. 107. — Westinghouse typo B

300 amp. 15,000 volt oil circtfl
breaker.

Fig. 108. —General Electric type H-3 oil switch.

 POWER PLANTS Sec. 10-806

!Cting switches. They consist essentially of fine fuse wire confined in

roiiginsulating tubes closed at the lower ends. The blowing of the fuse
id the resulting confined arc suffice to blow the conducting vapors out of
c open end, thus putting out the arc. The tubes are arranged for con-
nient removal and refilhug. They are recommended only in small capaci-
>s and moderate voltages, although they are offered up to 60,000 volts,
amp. They cost about $20 plus $0.50 per 1,000 volts.
806. Oil circuit breakers are used for interrupting current at all voltages
ove 600. Three of the numerous types of oil switches are shown in Figs. 107
109. The contacts open under oil and the arc is put out by the cooling
tion, and the pressure of the oil. When a circuit is opened the resulting

14'3'
15'10"

__*_

7'9i"

FiQ. 109. —Westinghouse type GA oil circuit breaker, 400-600 amp.,

135,000-155,000 volts.

w ,ends to impart a more or less violent motion to the oil, away from the
'.

CO acts, but its inertia and pressure due to depth resist the action and
^<lilily quench the arc. This pressure becomes very great in violent
aht-circuit interruptions, and has been observed as high as 150 lb. per sq.
in few in. away from the arc. Contacts of various types are used and
•Have certain advantages; many are arranged with auxiliary contact for
^thinal breaking of the circuit. Most of the breakers are arranged to
op by gravity.
special circuit-breaker oil is used which is fluid at low temperatures
*^is free from moisture. The oil level must be carefully maintained in
OF ition, and the oil must be changed when burned by short circuits.

877
Sec. 10-807 POWER PLANTS
807. The temperature rise should never exceed 25 deg. to 30 deg
Cent, in the hottest part at continuous full-load. The voltage rating i;

determined by the insulation distance to the grounded parts and by tht

breaking distance of the contacts. The Westinghouse Company dcsigru
its high-capacity high-voltage breakers, with a ground distance of about :

in. plus 0.25 in. per 1,000 volts, and with a total breaking distance per poli
of about 10 in. plus 0.33 in. per 1,000 volts. Breakers are standard up ti
155,000 volts.
The current rating is determined largely by the size of the current^carry
ing parts and may even be in excess of the safe rupturing capacity. Breakers
for very high voltage are usually from 300 to 400 amp. capacity, while IqB
2,500-volt or even 13,000-volt work they are available up to 4,000 amp.

Switch on Pipe Framewoik Switcli in Cell Beraote From Pimel '

Fig. 110. — Mountings for small, oil switches.

808. Oil switches for panel mounting (Fig. 110) usually have U
poles enclosed in a common grounded rectangular steel oil-filled tank wB
is removable by dropping it away from the contacts.
This type, wl
mounted on panels, is not desirable above 2,500 volts and 3,000 kw. stait
capacity. J^
809. Wall and framework mounting (Fig. 110) with remote oonP
using this same type of switch (Par. 810), extends its capacity to SMI
12,000 kw. at 2.500 volts, or to 6,000 kw. at 15,000 volts.

878
POWER PLANTS Sec. 10-810
 Sec. 10-811 POWER PLANTS
811. Remote control. In most cases electrical control is used where
hand control is undesirable. The operation in most types is secured by
solenoids, a powerful one closing the switch, and a Ughter one releasing
a latch whicn permits the switch to open by gravity. In the General
Electric type // switch (Fig. 108) a motor is employed for the purpose of
winding a spring which on the release of a stop by a solenoid closes or opens
the switch, depending on its position. Following the operation of the switch
the motor again winds up the spring. Pneumatic control is used in some
cases in very high-voltage work. For wiring see Figs. 100 and 111.
Lever Control-Switch Pull Button Control-Switch

> 812. The ultimate breaking capacity of oil circuit-breakers is di

termined by a great number of variables and the term itself is not verj
definite. The manufacturers use for this term the maximum size of static
in which they recommend the breaker. Obviously this is not the uUiinai
breaking capacity. A breaker would be safe in a station of low speed vmi
giving low instantaneous short-circuit current, while it might be dostroyc
In a turbo-generator station of the same size._ Important faptor!? dftc
mining this rating are voltage, length of break, size and strength of oil tac

880
 .

POWER PLANTS Sec. 10-813

control of the oil, etc. Generally breakers with a separate tank per pole,
or with a separate tank for each contact have larger breaking capacity
than those where all the poles and contacts are grouped in one tank. A
breaker operated at less than standard voltage will have its ultimate breaking
capacity somewhat increased.
813. Hand
control of oil switches is used for panel-mounted switches
and for remotely mounted switches, in the smaller stations. The remote
control is secured through bell cranks and rods (Fig. 110). Where the
switches become numerous and are too far away, or the station is of too
large capacity, hand operation is undesirable.
switches for floor niounting (Fig. Ill) have each pole enclosed
814. Oil
in a heavy grounded tank and may be supplied with weather-proof entrance
bushings and cast-iron covers for the operating mechanism, allowing use out
of doors. They are available for voltages from 25,000 to 150,000 and are
suitable for stations of almost any size.

815. Methods of Operating Oil Switches*

1
f On panel

Sfknual On wall
On flat surface
( Remote In cell
On pipe framework
Without electric
»
B.
„ 4 _
motor / Std. sw. op. mechanisms trip or with elec-
jj 3 j^^^/
',

tric trip
jilactrical
D. c. standard mechanisms
Solenoid
A. c. special switches
f Pneumatic
J Float
lechanical
/ Air
Pressure reg
\ Liquid
'^iutomatic Control
f Series f Direct relay 1
With or f Constant
j''ithout trip \ D. c. trip } without i ] Overload
'ries ) time [ Inverse
ans- With or without
Auxiliary / Push button shunt transformers
trip \ Low voltage or series resistance
Depend- Short-cir
"I
A. c. trip
ing on With- Direct cult
load in out
f

trip
On panel Overload, D. c. trip
secon-
}
relay
I

[ a.c.
On shaft J

daries J
Reverse power,
With- D. trip .

out Instan- Reverse A. c. trip

time taneous phase D. c. trip
element Differen
tial low
voltage } D. c. trip
under
load
Depend- Over- / A. c. trip
ing on With With Con- load D. c. trip
\

time time stant or

relay
element inverse
Reverse power,
,
element J D. c. trip
,_,(aohments:
WM Auxiliary switches (Circuit opening)
ndicating switches (Circuit closing),
{Electrical
nterlocks
Mechanical

Rushmore, D. B., " Electrical Connections for Power Stations," Trans.,

i.E. E., May 28, 1906.
'M.
881
Sec. 10-816 POWER PLANTS
816. Switches tor cell mounting cover: (a) the above type where sui
mounting increases the safe rupturing capacity about 15 per cent. (6) a mod
fication of this type with individual and stronger tanks for each pol
sometimes with separate cells for each pole, which is suitable to 40,()(
kw. and 2,500 volts, or even higher with special design; (c) switches havii
two separate round pots per pole each containing a separate contai
and each pole in a separate cell, which are suitable for all capacities, partic
larly up to 25,500 volts.
817. The source of energy for operating switches should be of utmo
reliability. Storage batteries are almost invariably used exceptin sini
stations where the exciter system is used. All switching mechanisms shou
be designed to operate satisfactorily on a range of voltage from 40 per cei
below to 20 per cent, above normal.

Uotora Ugbtlns

Luwvv^ Constant Currant

Transformer

Oil Break Switch. Automatio

circuit Breaker

Secondary Relajs
Used with Current Transfonnefi
-L Orerload-lnstantaneous

Overload- InTerse Time

£ Orerlowl- Definite 'Hmfl

*^ Reverse Current t

^ DlffereotUl Beverse f.

^£ Belectire Reverse t

^ Underload t

?T? Voltage Balance

Series Relajl

~0- Overload lustantaoeouB

-o- Overload laTerfl* Tim©

,
-^ Beverso Current t

] ojC*
Re^e"* PhaB« t

-8- Selective Overload Inxcrv Tim

Relajfl Marked- 1 **« ticnerall

Inatantaneous and are bo showii

Where Two or more Relajs

Ihowo In one location. It

Indicates that either F' r:n i

he used, which erer is I'l n

Qeneralon (1 ( ) (j to the Oiwrating Couditij!.!

Fio. 112.— Use of relays (Hewlett, Trans. A. I. E. E., Mar., 19 1-'

818. Relays are used operating under all of ;' the conditions out'
Par. 816. The most common arrangements are shown in Fig. 11-
Hewlett, Traits. A. I. E. E., March, 1912). The most common typi
solenoid with plunger and the meter type very similar to the induct
i

Adjustment for current is made by position of plunger in first tyi

strength of spring in second. Adjustment for time js made by l'<
oil pot resisting motion of plunger or disc and
magnets resisting turou

882
 ;

POWER PLANTS Sec. 10-819

irmature of motor type. Definite time limit is secured by clockwork.

Jsual adjustments by bellows or magnet give a time in inversely as the
>ctuating force.
It is important that under short circuit conditions relative settings remain
inchanged. The cost of three pole relays varied from $25 for plain
'iverload instantaneous to S60 for reverse current inverse time limit before the
rar, with an increase of 75 per cent, for 1921. Sojne types cost this amount
• ler pole and special types are considerably more expensive.
819. The cost of oil switches varies between exceedingly wide hmita,
;epending largely on rupturing capacity and voltage. Pre-war costs cover-
ig three-phase switches were; For small systems up to about 5,000 kw. and
-f>ii volts, kw. and 2,500 volts, or 6,000 kw. and 15,000 volts, about $70

-^10 per 100 amp. for very large systems of 25,000 volts or lower, roughly
;

!)lus $20 per 100 amp. hand operation being unavailable. For very
,,., oltage systems there is usually only one current rating for each voltage;
.

uh switches for 44,000 volts will cost from $400 for a 15,000-kw. rating to
1,21)0 for a 50,000-kw. rating; for 110,000 volts, from $1,500 for a 15,000-kw.
iting. The cost of electric opera- „„„ „.,.,^ M.inTn.n,. m^» Switch
on IS about SoO additional, exclus- ^ ^.
e of control wiring. For 1921 , 11A ~,
)sts add 20 per cent for the smaller Q^ f/*f^

stems and up to 80 per cent, for pj

Series Tr^DB.

(• larger. Trip Coll ff~ I Trip Coil

820. Mertz-Price System of
lay protection depends on un- M>ln bwltch
iial currents at two ends of con-
ict or in trouble. The series trans- Series
Trmnj.
rmers at the two ends are inter-
nneoted so that, normally, no Trip Coll a
'["iUl»j kclaTfl IrlpCoU
flows through the relay. rte

U
- nt

limce due to trouble cuts out

pparatus (Fig. 113).
821.
r
Instrument
generator panels includes:
equipment Battery :fr
rv
I
zlz Battery

(i) One alt«rnating-current am- U&in Trans*

ter (where phases are likely to be
balanced an ammeter is often sup-
d for each independent phase, or Berlee Trans.

'
rent transformers and transfer
itches for connecting the single
1 meter to any phase; (b) one alter-
1 ing-current voltmenter (or volt-
1 ter receptacle and plug to connect Trip Coii
§ [J
Trlp(
eommon voltmeter); (c) one
t

cet-current field ammeter (op- Fig. 113. Mertz-Price systems of pro-—

tial); (d) one indicating wattmeter tecting transformers and cables.
'lied for parallel operation); (e)
;)ower-factor meter (or wattless kv-a. indicator, optional); (/) one fre-
y meter (optional); (y) one ground detector (not common); (h) one
hour meter (optional but desirable); (i) one synchronizing outfit;
urrent (series) and potential (shunt) transformers; (,k) one automatic
(

r y (optional).
22. Instrument equipment for feeder panels includes:
) One alternating-current ammeter (ammeter transfer switches may be
u 1 if phases are unbalanced) (b) one indicating watt meter (optional)
;

(' >ne automatic relay; (d) current (series) transformers.

23. Instrument equipment for station panel includes:
) Synchronizer (extra one optional) ;
voltmeters for each phase of
(b)
p bus (optional); (c) frequency meter; voltage regulator (optional);
((i)
taUzing wattmeter (optional); (/) totalizing watt-hour meter (optional).
i. The cost of high-grade switchboard instruments mounted
wiring, exclusive of instrument transformers, was before the war as
iiaiiel
s: ammeters $40, voltmeter $45, single-phase wattmeters $50, poly-
wattmeters $70, single-phase watt-hour meters $70, polyphase watt-
^, meters $125. Large variations in price however exist between various
s aad grades, but may be taken at 50 per cent, increase for 1921.

883
Sec. 10-825 POWER PLANTS

825. The synchronizing: equipment in a station must be ample enoi

to prevent any possibility of failure, and should be in duplicate in all exci
small stations; there should also be s;
B«8tttuce-!!«actuuM
chronizing lamps in case of failure of i

Box
instruments. There should be more tl:
one set of instrument transformers av;
SjDchronisin Indicftior
\
able for the bus voltage. Synchroni
wiring should preferably be as simple
possible (Fig. 114).
826. Instrument transformers (S
6, and Sec. 3) are generally used whene-
the currents exceed 100 amp. or the volts
Reoeptade
600. They are designed for 5 amp. a
Jteoeptaole _ _
1 10-volt secondary. Separate transform
I Running of ample capacity should be provided
relays and for instruments. Potent
WO Volte il IhlO

Fig. 114.- -Synchronizer wiring

Volte

t
f

above 15,000.
(shunt) transformers are usually oil ini
lated for all voltages above 4,000 and c
rent (series) transformers for voltai
Instrument transforn
using shunt transformers. wiring must be grounded thoroughly, b(
at the transformer and at the board,
prevent high potential on the panels in case of burnouts.
827. The cost of high-grade instrument transformers was about
follows: on a pre-war basis with up to 80 per cent, increase for 1921.
Series type, 2,500 volts, $10-|- $0.60 per 100 amp.; 11,000 volts, $30 +
per 100 amp.; 33,000 volts, $604- $18.00 per 100 amp.; 66,000 volts, $17.'
135 per 100 amp.; shunt type, 200-watt size, $20-|- $8 per 1,000 volts.

T.P.S.T. Oil S»ltch

SUrting

Field,
Switch
Oonneotlons for EaflM'^
Qeoenitor
I
Control
j Rh«atiit
Motor and bwltoh
"Xmrneter
Altomkting I

M
Fig. 115. — Three-phase generator panel.
888. Types of switchboards using the apparatus above described i

divided into three classes: .«;

1. Self-contained panel type. ^.

2. Remote nicchunically operated: (a) panel boards; (h) bench boSH
3. Electrically operated: (a) panel boards; (6) bench boards. iJ

The capacity and voltage of the station largely deteriiune th*>i

as discussed under oil switches, type 1 being suitable for the 8IU
and type 3 for the largest systems. Space requirements for the dim
types are not materially different. Typical panels are shown in Figs.
to lis.

884
 POWER PLANTS Sec. 10-829

829. Eelative costs of switchboards are approximately 100 per

;nt. fortype 1, 120 per cent, for type 2 and 140 per cent, for type 3 (Par.
'18). These figures are approximate only for the same electrical layout,
hereas different layouts would undoubtedly be used for the stations for
hich each type would be suitable. The following table gives the costs of
pical panels shown in Figs. 119 to 121.

Conneotions for Enflne

OoTernoT Control
Motor and Swltoh

Fig. 116. —Quarter-phase generator panel.

830. Approximate Cost of Switchboard Panels*

C. H. Sanderson, Elec. Jour., 1913.

Kind of panel Volts Amps. Fig. Cost U.B.C

2,200 440 9,200
enerator
6,600 385 7,800
2,200 345 9,200
jeder
6,600 350 7,800
jnerator
2,200 360 9,200
6,600 310 7,800
leder
2,200 260 9,200
6,600 265 7,800
inerator 11,000 1,240 12,500
6,600 1,130 15,500
eder !
11,000 1,045 12,500
6,000 940 15,500

i^'.l. Cost of switchboards. Switchboards on pre-war basis cost from

lio $8 per ,w. of capacity including all wiring and apparatus installed:
8c 80 per cent, for 1921 costs.
2. Mimic or miniature bus bars are invariably installed on the faces
pf 16 control boards in large stations. They represent by single bars
eitly the electrical relation of the main switch controlled by each control
•w;h and thus greatly simplify the operation.
3. Grouping of panels. It is customary to arrange the panels as
J
loWs, beginning at one end; voltage regulator, exciters, station auxiliaries,
8* ators, feeders, with blank panels sufficient to care for any reasonable
*^ ision of the plant. With remote control, particularly electrical, this
B C. = Ultimate breaking capacity of circuit breakers set for in-
3t£ aueous trip. Costs include all apparatus necessary and all structures
sn n but no wiring. Add 10 to 20 per cent, to cover installation.
Add 80 per cent, for Estimated 1920 Costs.
 ,

Sec. 10-834 POWER PLANTS

arrangement of the switches themselves may be impossible on accou;
desired electrical layout, but the panels may be so arranged to advan
Remote-control bus structures and switches should be located where
is room for considerable extension.

^sTDt. Sw. '

Fw. 118. —Single-phase double circuit feeder panel.

83i. The operation and care of switchboards. Small stations

say 5,000 kw. do not need any special operators foi; the switchboard,
engineer on watch has ample time to take care of any switching opew
With larger stations special operators become necessary; up to 10,000 Icj

886
 POWER PLANTS Sec. 10-835

fjerator on a watch is enough and, during the light load periods, if the
^-rangement of the board with respect to the turbine room is suitably, this
)eralor may be unnecessary. Above 10,000 kw. an operator continuously
I watch is necessary and frequently an additional man to take care of
sconnecting switches and the cleaning and repair of oil switches. Above
1,000 kw. it is customary to have additional men until in the very large
lations, there are never less than two men on the board at all times.

Fig. 119. Fig. 120. Fig'. 121.

! 18. Bench boards

are used only in large stations where the number of
c uits is very large. A great saving in space is possible because the instru-
n its do not crowd the control switches, thus allowing two or more generators
t handled on a single panel. Some of the types are shown in Fig. 122.
L!

Fig. 122. —Types of bench boards.

6. Load dispatching in some form is necessary on complicated systems.
T load dispatcher has full control over and knowledge at all times of the
CO ition of the system. He usually has a map
of the system indicating
tti condition of all electrical apparatus
and issues all orders by telephone
fo he putting on or taking off of any machine or cable. Emergency
con-
Qi ns require a certain suspension of the direct control of the dispatcher,
01 m such cases a carefully worked out routine must be followed. Some
v< large systems have no man formally called a dispatcher but in such
ca the senior operator in the largest station ia given final authority and
lu rders must be obeyed.
887
Sec. 10-837 POWER PLANTS
STATION tRANSFORMER INSTALLATIONS
637. Transformers of practically all types are used for high-tens
power-station work. On account of the size and voltage of most stati(
of this kind, the main power transformers are usually oil insulated, with
without water cooling, and of the shell type of construction. See See
838. Air-blast transformers are rarely used above 15,000 volts i
in sizes above 1000 kv-a. They are available, however, up to 33,000 v(
and 2,500 kv-a. These extremes should be avoided on account of insulat
and cooling difficulty.
839. Self -cooled transformers are built in sizes up to about 8,000 k\
but the space required is large on account of the necessity of outside cool
tubes or radiators. Up to 1,000 kv-a. corrugated tanks give satisfacti
results.
840. The question of single-phase vs three-phase transform
is not definitely settled.First cost, efficiency, simplicity of wiring and 6
space, point to the latter, but in installations of few units the desirabil
all
of flexibility frequently dictates single phase. When operated in de
two units connected in open delta will safely carry about 60 per cent, of
load that a full bank will carry. This same ability also exists in shell ty
three-phase transformers operated in delta, both primary and seconds"
provided the damaged coils are disconnected and short-circuited.
relative floor space occupied is shown in Fig. 123.

Single Phase Water-Cooled Translormer^ Total Capacity 6000 Ky-A

Three Phasfi Woter-Cooled IvmaSaansia Total Capaotty eOOOSv.A

Three Fhase. Air -Blast Trannformerg Total Capacity 6000 Ki-A.

Fia. 123. — Relative floor space of single-phase and of three-phase

formers (G.E. Bulletins).
tl|

841. Water cooling^ is most generally used in large installations,

water supply must be continuous and pure. Whore cooling water mui
purchased cooling towers can be used to advantage. It is dcwirable tpl
negative pressure in the cooling pipes to prevent leakage into the oil.
842. The amount of water required is approximately 4 gaL
min. per 1,000 kv-a. capacity. This amount is not rigid. In winter
siderably less is necessary, and in summer fully twice as much can be uw
advantage.
843. The cost of water-cooling systems is from 15 cents to 50 «
per kv-a., depending on the source of supply, or approximately 100 per ^

above pre-war costs.

888
 POWER PLA.VTS Sec. 10-844

844. Air-cooling requires blowers taking about 0.25 per cent, of the
itput. They are usually electrically driven and require from 3 eu. ft. per
in. to 5 cu. ft. per min. per kv-a. at pressures from 1 oz. per sq. in. to 0.5 oz.
sr sq. in., depending on size. The first figures are for 100 kv-a. size and
18 latter for 1,000 kv-a. size.
845. Oil-insulated transformers are in reliable service up to 150,000
sits and 14,000 kv-a. and down to very small sizes at 25,000 volts. They
e the most satisfactory in the average central station.
846. Forced oil cooling can be used for all sizes and gives satisfactory
suits. The transformers usually have plain boiler iron shells. The oil is
'imped in at the bottom and overflows at the top, passing through glass
i^ht tubes to cooling coils located where good air circulation or cooling water
available. This method avoids the possibility of water leaking into the
through defective tubes, as the oil may be kept under slight pressure,
also allows the convenient drawing of the shells w^ithout special piping.
Ae chief objection is that a fire may put the entire equipment out of service,
le cost is from 45 cents to 90 cents per kv-a. of capacity, which ia con-
;lerably higher than water cooling, but there is a considerable saving
the cost of the transformers due to absence of cooling coils.
847. Fire danger from transformers, while not negligible, has been
?atly exaggerated in the past. In some installations each bank has been
iced in a well-drained fire-proof chamber, in addition to being equipped
th a piping system to enable the rapid emptying of the shells into a buried
ik. Some of the latest and very important installations have been con-
ructed with simple barriers between banks opening into a common passage.
e drainage system is still important but is used principally to facilitate
lairs, inspection and the treating of the oil.

J48. Convenient handling of the transformers should be provided for

'ifr by an overhead travelling crane, or by mounting on trucks on which

y may be moved to an inspection pit.

149. Transformer oil must be kept particularly free from mois-
':e; one part in 10,000 will reduce the dielectric strength 50 per cent.
ying outfits, which dry the oil by forcing it through successive sheets
• blotting paper, Were available before the war at from $500 to $1,000
h- capacities of from 5 to 20 gal. per min. For 1921 costs add 80 per
LIGHTNING ARRESTERS
Lightning protective apparatus is used in power stations to
50.
I the apparatus therein from abnormal potentials on the system,
tpct
^;ther caused by lightning disturbances or by switching operations.
J' ideal apparatus will immediately relieve the
s em of excess voltages, allowing no flow of the To Line
(1 amic current of the system, and be ready for
li lediate service again.
Spark Gap
il. The magnetic blow-out principle is fre-
iy employed, particularly in low-voltage ar-
The spark gap is placed between the poles
lectromagnet (Fig. 124) excited by the flow of
f nt which immediately bows out the arc. Series
r; tances are usually employed with this arrange- Magnetic
Blow out Coil
Choke coils are simple open air core reac-
perted between the arresters and the appa-
o be protected to choke back the lightning
Ijirbances, which are of very high frequency, thus
V'iBg the arrester to discharge with a minimum
»n on the station apparatus. To secure the full '^° urouna
Ifit of the choke coils, the connections to
|ter8 should be as straight as possible.
the Fig. 124. —
Magnetic
blowout lightning ar-
. Spark gaps
are used in practically all types rester for low voltage.
;eBters, set at sufficient distance to prevent
Jong oyer at ordinary voltages. Obviously something additional is
"<i to limit the flow of dynamic current after relieving
the excess poten-
Their most conimon use without considerable modification is to protect
former secondaries, a single gap per bank of transformers being used.
Sec. 10-854 POWER PLANTS
854. Series resistances are usually inserted between simple spa
gaps and ground for the purpose of arresting the current. This is accoi
plished, however, at a sacrifice in efficiency of the arrester in removing t
disturbances which frequently have considerable current volume. Tl
method is used, however, in many types from the lowest to the highi
voltage.
866. Fuses inserted in series with a gap (Fig. 125) are not uncommc
They serve to relieve t

j_L' J system and interrupt t

--a-vn I
« current, but they have f

serious disadvantage
being able to handle
oi
a single discharge. A si
pie circuit breaker is son
times similarly used on lo
voltage systems.
All of the above arrani
ments have their simplic
to recommend them 1
they are inadequate on
but very small or low-vc
age systems.
866. Horn gaps ;

modified spark gaps wh

Fig. 125. — Air gap lightning arrester with fuse,
ranged in a "V" with
consist of conductors

suitable gap at the bottom. The flaring sides are shaped so that the
in rising by the heated air is lengthened and finally blown out. Care
proportioning is necessary, but even then the horns will fail to put out
arc from a heavy current.
857. Multigaps, which consist of a large number of gaps in series, betwi
relatively large cylinders of non-arcing (composition) metal, have ma
advantages. When placed between line and ground the potential drop

QiiQji2ii3i2il2li3i2iiQii9i2ii9i2ii2'i2ii2iQii2ii2ii2ii2ii2ii2ii5!i2iOil2!l2»Qii2ii2«2-
TTTTTTTTTTTTTT TTTTTTTTTTTTTTTTTT

Gaps "
f

Fig.- 126. —Voltage gradientdynamic

across multigap arrester
current.
with and withoj
|

greater near the line than near the ground, due

torf
tween gaps is much
electrostatic capacity of the cylinders (Fig. 126). This makes r'^"'
whicn
a much greater aggregate gap distance than with a single gap,
,

aids the quenching of the dynamic arc. Lightniiig disturbances, <

high frequency, cause a still greater potential gradient, which will

aii^-

disturbances to pass at a relatively low excess voltage

As soon w,;
au g
gaps break down the flow of current causes an equal drop
in

890
 POWER PLANTS Sec. 10-858
rhe non-arcing metal has a low boiling point and
aiowmg the dynamic arc to be resumed on acts as a rectifier not
reversal of current ff' ?he
ntriefimKhlraciror'-
^^'^ ^^^^^^^ ^'^^ -'"^^ «^ .^J^'^.lL lit
'
868. Multipath arresters allow high voltages
urface ot a very high resistance rod
to discharge alonir the
in numerous very fine snarks the
*° ^^"^ -^
"""''^'^ This Vpe isTx^ted* to
'=°"*''^"«
SlisThar^es'"""
869. Graded shunt resistance combined
reatly
with multigans allows a
increased effective number. Referring to Fig 127 which slTows
'^ *^^ ^^'^^^^^ Eleotrilco.. tfe /.^I'liL'tltaSl
'oL^aTirfc^r"sTt*hr'
D w e r g r o u p of 700
aps, the resistance
eing low enough
) accomplish this
esult. When ~
reaking down,
le flow of current o
irough the high t
sistance causes a

I
PTO^27.— Ele-
mts
^ nt
a^ster.
of graded
multigap
^
Fia. 128.— Characteristics
.05

of
arrester.
.06
Amperes
aluminum lightning

891
 . ——

Sec. 10-861 POWER PLANTS

861. Care of multlgap arresters requires the frequent removal of du
best accomplished by blowing with compressed air. The arresters shoi
be disconnected during this process.
862. Alumlnura-rcell lishtning arresters depend for their action on \
properties of aluminum when inserted in a suitable electrolyte, shown
Fig. 128. When an e.m.f. is applied between two electrodes, insulati
films are formed which break down if the forming voltage is exceed
and reform immediately when the voltage becomes normal. This c
more nearly conforms to the ideal than any other arrester; it may be i

for a very small increase in e.m.f.; its discharge rate is enormous and
immediately resumes normal condition after the discharge. Since the ce
can be formed to withstand permanently only about 300 volts, a grt
number in series is required for high potential systems. Conical shap
aluminum electrodes are mounted on re
with allowing a uniform space 1
spacers
tween (Fig. Electrolyte is inserted
129).
these spaces, great care being required to ^
uniform depth. The whole stack is then i

serted in a tank of oil.

863. Charging aluminum arrestei
Continuous connection to the line is n
possible on account of the loss of energy, a:
therefore horn gaps are usually connected
series. This requires frequent charging of t
cells, at least daily, because the film grac
ally dissolves, more rapidly in warm weath
Care of aluminum arresters requires r
only this frequent charging, but also watchi
the charging current which is a guide tot
condition of the electrolyte. Care should '.

exercised to prevent freezing of the electrol;

£l«otToIjte. — ^1 at very low temperatures, as it might deatr
Cones in the arrester.
CroSB Section IZ^
AlumlDum 864. Arrangement of arresters on pol
Cones phase circuits may consist either of an i

Complete roster between each line and ground, or arii!

Oentttring ters for each line connected together on <
Contact
Spring. ground side and then to ground through an i!

ditional arrester. The first method is Ujjj

where the neutral of the system is groumi
and the second where ungrounded.
c ^ inn
FiQ. 129.
aluminum
—Construction ^t
/~i 1

arrester.
i- 01
865.
,
Grounds lighting
,
for
,. .^.
arrest
^
']

should be most carefully made. Numcr

iron pipes driven several feet in the ground and interconnected by a cop
strip are good. Copper plates buried deep in coke with earth fillii
also used. In addition the arrester ground should be connected to tin
frame, piping, and other grounded materials in the building.
866. Summary of uses of various types of arresters.
(1) Spark gap
(a) Series resistance 1 f D.C. systems, all voltages.
(b) Fuse \ i A.C. trolleys, along the line.
(c) Magnetic blowout
(d) Plain — Single point on transformer secondaries.
] [

(2) Horn gap j_

(a) Series resistance "I f A.C. systems, all voltages, l^
(b) Fuse on poles.
[
i,

J [ D.C. and A.C. series systems.

(3)
(4)
Multipath
———
Multigap A.C. systems.
(a) Plain
Frequent location along D.C. lines.

Frequent location along small distribution systemSt

(b) Series resistance —
Frequent location along systems up IS.OOOjf
of mods
(c) Shunt resistance 1 [ Station use on systems

(d) Shunt and series re- } { size and length of line,

sistance,

892
 —
POWER PLANTS Sec. 10-867

(5) Aluminum cell

(a) In small jars or tanks, / D.C. systems along the line and
\ D.C. stations.
(b) All stacks in A.C. systems up to 7,500 volts.
one tank,
(c) Separate tanks, A.C. system up to 150,000 volts.
867. The cost of lightning: axrester equipment was on pre-war basis,
or 100 per cent, higher for 1921). Three-phase grounded-neutral systems:
Juminum cell, S70 + $10 per 1,000 volts; multigap type, $13 per 1,000
olts. Three-phase ungrounded: Aluminum cell, $100 + $15 per 1,000
olts; multigap type, $15 per 1,000 volts.
'
868. The cost of 200-amp. choke coils of the "hour glass" type, was
efore the war about: $20 + $0.50 per 1,000 volts, up to 70,000 volts;
30 + $0.80 per 1,000 volts, above 70,000 volts; the increased cost per 100
lip. is about $7. Pancake-type coke coils cost about $12 + $20 per 100
Tip. for 2,500-volt service and $40 + $40 per 100 amp. for 25,000-volt
'rvice. Add 65 per cent, to estimates for 1921 costs. The cost of instal-
tion of the above can usually be covered by a 15 per cent, increase, in
'Idition to freight.
POWER STATION WIBINO
869. Bus bars are made either of copper as discussed in Par. 778 of
is section, or, in the case of high-potential stations or moderate potential
;
small sizes, of copper tubing, copper rods, and sometimes brass or iron
! be. Special bends and fittings are available for this pipe work. Where
^
.3 current capacity is small, the physical stiffness required dictates the
"e of conductor. Bus bars are seldom continuously insulated. They are
lally supported in the open in small low-voltage stations, and in all stations
I
very high voltage. CeU structures are used in stations of moderate
tage in all except relatively small stations.
Switch wiring on the board, or on the switch structure, should be
570.
I and well insulated for the full voltage, because the wires are particularly
I
itr together at this point. Stranded wires are seldom used except for
i pie layouts where accurate alignment is not necessary.

>71. Main generator and exciter wiring should be run by the shortest
Jsible route and provided with ample insulation, even above ordinary
ruirements. This wiring is not protected by automatic switches. Multi-
c ductor cables are not recommended and alternating-current and direct-
c ent wiring must not occupy the same duct.
72. Instrument and control wiring form practically the nervous
8; cm of the power plant. Great care must be used to avoid trouble and
o the highest grade of insulation should be used. Iron conduit should
h -fd for all of the wires, terminating as closely as possible to the instru-
panels and to the transformers. Terminals at oil switches and instru-
transformers should be most carefully protected to prevent high-
«.- ..jn current from reaching them during switch troubles.
AH instrument
w ig except that in main circuit must be thoroughly grounded both at the
in ument transformer and at the panel. Terminal boards on the panels are
of eat assistance in calibrating instruments. Alternating-current and
di t-current wires should not be run together any more than can be avoided.

3. Lightning-arrester connections should be as simple and direct aa

pp ble in order to secure maximum protection. Disconnecting switches
shld always be used.
I. The prevention of corona on wiring of very high tension requires
sp<al care. All sharp corners on the wiring and the switching apparatus
Mv be avoided. Also see Sec. 11.
'5 Bus and switch compartments (Fig. 130) are made of brick,
one and concrete, either plain or reinforced. Openings for switch
tion, etc., are usually covered with asbestos doors conveniently hung.
t)rick is used for the main walls, soapstone is used for horizontal walls
sser barriers. Concrete is frequently used throughout. Whatever
aterials of construction, their insulating quahties are not depended
and the conductors should be supported on insulators designed for
joltage with a wide margin of safety. Wide differences in design are
I'le, as is indicated in the cuts, and it is seldom that the same arrange-
\
18 used in two stations.

893
Sec. 10-876 POWER PLANTS
876. The cost of bus and switch structures varied widely, fron
$50 per switch in small sizes to $300 per switch in large capacity switches foi
15,000 volts on pre-war basis or $90 to $600 for 1921.

877. Ducts and iron conduits are largely used in power station i

but the latter should be avoided for alternating-current work of more ^

 POWER PLANTS Sec. 10-878

ry moderate current capacity. Clay or fibre ducts laid in concrete in the

lor, or built into the ceiling cost, from 20 to 50 cents per duct ft. before the
ir and 110 percent, higher in 1921. Iron conduit supported by clampe
3ts, in place, from 12 cents per ft. for the ^-in., to $1 per ft. for the 4-in.
e on pre-war basis or 100 per cent, higher in 1921.

878. Bus-bar Compartment Dimensions

Bus Dimensions, inches

size
inches A
1-2 X i
2-2 X i
1-3 X i

2-3 X i
wire
wire

wire
wire
wire
 ;

Sec. 10-881 POWER PLANTS

881. The cost of power-station wiring varies greatly and is exce<l
ingly difficult to estimate. The cost of wire, supports, insulators, e
can be obtained from manufacturers' lists, and usually an addition of fr
25 per cent, to 50 per cent, will cover the cost of labor, the larger percentts
being for the smaller wires on pre-war basis or 50 to 100 per cent, for 19
The cost of drawing into conduits varied before the war from 1 cent t;i
cents per duct ft. and from 3 to 10 cents in 1921. The coet of joints s
terminals varies between that of 5 ft. and 10 ft. of wire. The total cost

Fio. 134. —
Wall outlet i
slab and tube of insula
.

material.

Fio. 133. — Cross section of transformer Fio. 135.— Thomas

ing for 66,000
wall
volte,
Ij*"

and switch galleries of high tension power j

station (G.E. Rev., 1912, p. 698). ;

^
"f
capari
wiring varied before the war from $0.50 to $3 per kw. of station
gear,
100 per cent, more on 1921 basis in addition to the cost of switch i

and compartments.
MISCELLANEOUS "'
Electrical considerations seldom have
pn
882. Plant location.
power tu
derating influence on the location or general arrangement of a
 POWER PLANTS Sec. 10-883

'he location affects the cost of the distribution system, for moderate and
)W voltages, directly as the square of the average distance of the load; on
iigh-potential systems, the variation is more nearly proportional to the
[stance. Other conditions being equal, however, it is obvious that the best
Kation is as near as possible to the load centre.
883. Parallel operation. Large systems frequently require the parallel
Deration of power stations, and little difficulty is ordinarily experienced.
1 some cases where plants in close proximity are thus operated, the service
inditions require that the stations shall not be automatically disconnected
om each other except in case of trouble in
-e tie lines. In other cases provision is Copper Conneotliig.

ade for the immediate disconnection of the

itions in case of trouble in either. The B^'fti^iNut*"' 8MH -^
tter arrangement is used where there is no Eubb«r a«.k<>t
nnection between the systems supplied by Uaiiobie iron
e stations, other than directly between the C»p No.66
ition bus bars. Where stations are widely
jarated, parallel operation is not satisfac-
ry when the resistance drop in the connect-
5 lines exceeds 15 per cent, on alternating-
rrent systems and 50 per cent, on direct-
rrent systems. The operation of such in-
rconnected systems requires careful ar-
igement, frequently making it necessary
have a load dispatcher in full control of
switching operations.

POWER-PLANT ECONOMICS
BY GEORGE I. RHODES
W*. Load fluctuations largely deter-
ne the desired overload capacity of units.
Ijhting systems have steady loads except
f peaks shown by the usual load curve,
llustrial loads are very steady except for
ctain kinds of applications to intermittent
'•k using large units. Railway loads have
csiderable fluctuation even in the largest
8 iems. Swings of five times the average
a experienced when but a single car is
r ning. twice, when about ten are running,
a to 120 per cent, when a very large num-
b are running.
Sudden peaks are always a possi-
86.
b on a lighting system, and occur when-
,y
e a sudden storm appears.
•
An increase
iioad of as much as 100 per cent, within a Mallwble Iron
V'/ few minutes is not uncommon. Cap No.5e
HallMble Iron
16. The load factor machine, plant
of a Brass Nuu
otystem is the ratio of the average power Copper Conneotiiig
tc he maximum power during a certain hug
Pnd of time. The average power is taken
o^ a period such as a day, or
a year, and
tt maximum is taken over
a short interval r^
of le maximum load within that
period. In ^^^- 136.
ea case the interval of the maximum load
loo — 'ni.
Thomas roof insu-
'**°'" ^o"" 66,000 volts.
8b Id be definitely specified. The proper interval is
usually dependent upon
10 conditions and upon the purpose for which the load factor is to be
oe -mined The yearly average of
daily load factors is frequently used.
^ft'Sec. 2o.)
factor is the ratio of the sum of the maximum power
<lo''"j^*'f"v*^
oeinds of the subdivisions of any system or part of a system,
mi mum demand of the whole system or to the
of the part of the system under
«0' deration, measured
at the point of supply.
i. The load to be carried is
probably the most important factor to be

897
Sec. 10-889 POWER PLANTS
considered in power-plant design. It determines the size of plant, the kin
of plant, and the size and number of units. Typical load curves are show
in Figs. 137 and 138. These curves are such as would be obtained fror
15-min. readings of watt-hour meters but do not show the exact load o

100

80

60

40

20

100

80

60

40

20

100

80

60

40

20

100

80

60

40

20
 POWER PLANTS Sec. 10-890

890. Capacity factor is the ratio of the average load to the total rated
capacity of the equipment supplying that load. This factor is not very
definite on account of variations in methods of rating apparatus.
891. Fixed charges as ordinarily defined with reference to power plants,
are the charges necessary to carry the investment and to replace the equip-
Llghting and
Industrial
Dally Load Factor
Winter 49J{
Summer 71^
Arerage 64 Jt
Weekly Load Factor
Winter 45%
Summer 66%
Arermge 59$
Annual UF. 40%
DlTersHy, Win. .10'%
Diversitj, Sum.. 154%

LightliiK.Industrlal,
Inter. Ry
Daily Load Factor
Winter 64%
Summer 7 1 ((
Average 66%
Weekly Load Factor
Winter 60%
Summer 66 %
Average 60 ^
Annual L.F. 43%
jDiversitjr, Win.. 100%
DlTenltj, Sum.. 149%

Llgh.ting,Industrlal,
Inter, and City Ky.
DttUy Load Factor
Winter 68%
Summer 7S4(
Average 6jj{
Weekly Load Factor
Winter gt%
Summer 65%
Average 61%
AnnualUF. 45%
Dlvereltj.Win. 112%
Divemltj, Sum. .141%

Lightiug, and.
City Ry.
Daily Load Factor
Winter 47%
Summer 61%
average 50 %
Weekly Load Factor
Winter 43%
Summer 46 %
Average 45%
Annual UF. 32%
Diveraitj, Wln..l08<
~ .120^
Sec. 10-892 POWER PLANTS
893. Interest as used in engineering computations is the annual cost
of the money required for the work. It is affected by the credit of the
company and the condition of general business at the time money is bor-
rowed. If money is raist^d by bonds sold below par, as is frequently the
case, the cost of money is not only the only interest rate on the bond, but
this amount is increased in proportion to the amount the bond is sold below
par and, also, by an amount which set aside annually will make up this
deficit below par when the bond is retired or paid. Six per cent, should be
used as an average cost of money, but it varies between 4 per cent, and 8
per cent., the lower figure for municipalities and the higher for industrial
corporations.
893. Profit on the investment, namely, income above the total of all
required expenses, interest, etc., should not ordinarily be considered in
engineering work.
894. Taxes are proportionately more variable than interest, ranging from
less than 0.5 per cent, to as high as 2.0 per cent. It is generally the case,
however, that high taxes and low interest coincide, so that the probable varia-
tion of the total of interest and taxes is from 6 per cent, to 9 per cent. 7.6 ;

per cent, is the figure frequently used.

896. Insurance of power plants against fire varies from less than 0.1
per cent, for fire-proof modern plants, to as high as 1 per cent, for the old
type of plant with oil-soaked wooden floors, etc. Insurance in a modern
Elant may seem unnecessary, but the regular visits of insurance inspectors
ave a beneficial influence on the operation of the plant which is frequently
worth more than the cost of the insurance. The figure commonly used for
the cost of insurance is 0.5 per cent.
896. The cost of depreciation is one of the most commonly neglected
and one of the most important elements of the total cost of power. The
existence of depreciation in some form is generally recognized, but it is fre-
quently neglected in actual operation of companies, either because of lack
of income or desire for immediate profit.
897. Physical depreciation is the result of deterioration due to wear
and tear caused by regular use, decay and the action of the elements.
898. Legally Approved Depreciation Bates
Compiled by Henry Floy. Maintenance not included. ';

A. Arbitrators, Atlanta, Ga., Street Lighting Controversy. H

B. New York Public Service Commission, 1st District.

C. St. Louis Public Service Commission, St. Louis, Mo.
D. Chicago Traction Valuation Commission, Con. Traction Co.
E. Wisconsin Railroad Commission.

Depreciation, per Key to

Property cent, per year ,

authority
(straight line)

Aerial lines 5
Air brakes 5
Air compressors 4 to 5
Arc lamps 6.67
Arc lamps 8
Belting 5
Boilers 3 5 to 4
.

Boilers 6.67
Boilers, water-tube 5
Boilers, fire-tube 6.67
Boilers, water-tube 5
Boilers, fire-tube 10
Bonds . . 6
Bonds . . . . 50 wearing value
Bonds 5
Brrpching and connections 3.5 to 10
Buildings .ivi.U'J. .L-nii 1-5
Buildings, brick IniiiJi, 2

900
 . 5

POWER PLANTS Sec. 10-898

898. Legrally Approved Depreciation Bates. — {Continued)

Depreciation per
Property, cent, per year
Key to
authority
(straight line)

Buildings '.
. 7 . . 2 to 4
Buildings, wood 2
Buildings 2
Cables, underground, high-tension. 5
Cables, underground, low-tension. 50 maintenance cost
Cables, aerial, lead-covered 6.67
Cables, underground, lead-covered 4
Cables, underground, lead-covered 5
Coal and ash handling machinery. 7
Coal and ash handling machinery. 5
Coal and ash handling machinery. 10
Condensers 4
Condensers 5
Condensers 5
Condensers 6.67
Conduits 1
Conduits. 2
Conduits 2
Cross-arms 8.33 to 12.5
Engines, steam 3 to 5
Engines, steam 5 to 7.5
Engines, gas 6.67
Engines, steam, slow-speed 5
Engines, steam, high-speed 6.67
Engines, 5
Enginefl, 6.67
Feeders, weather-proof insulation Dependent on ob-
served wear
Feeders, weather-proof insulation. 6.25
Foundations, machinery Same as life of appa-
ratus supported
Foundations, machinery Same as appa-
life of
ratus supported
Fuel-oil handling machinery 4
Generators 3 to 8
Generators 5
Generators, modern type 5
Generators, obsolete 6.67
Generators, steam turbo 5
Generators, steam turbo 10
Generators 6.67
Heaters 4 to 6
Heaters, feed-water, alosed 3.33
Heaters, feed- water, open 3.5
Meters, electric switchboard 5
Meters, electric service 6.67
Meters, electric 8
Motors, railway 3.33
Motors, railway By inspection
Motors, railway 5
Motors, railway 5
Paving 50 wearing value
Piping and covering 4 to 4 .

Piping and covering 5 to 6

Piping and covering 5
Piping and covering 5
Piping and covering 6.67
Poles, steel 2
Poles, wood in concrete 5
Poles, wood in earth 5.5 to8.33

901
Sec. 10-898 POWER PLANTS
898. Legally Approved Depreciation Bates. — (Continued)
Depreciation, per
Property cent, per year
(straight line)

Poles, iron 2.5

Poles, wood 10
Pumps 5
Pumps . . 5
Pumps, small steam 6.67
Pumps 5
Pumps 6.67
Rolling stock, open car bodies 4
Rolling stock, open trailer bodies 4
Rolling stock, closed car bodies 5
Rolling stock, trucks 3.33
Rolling stock, closed & open cars 3.33
Rolling stock, trucks 3.33
Rolling stock, car bodies and equip.. . . 6.67
Stack 3
Stack, steel 10
Stokers, fixed parts 5
Stokers, moving parts 20
Storage batteries. 5
Storage batteries 6.67
Storage batteries 5
Switchboard and wiring 3
Switchboard and wiring 6
Switchboard and wiring 5
Switchboard and wiring 8
Telephones 10
Track, rail joints 5
Track, ties, 5
Track, rails Dependent on ob-
served wear
Track, special work 8.33
Track, straight and special work 50 % wearing value
Track, straight track 5.5
Transformers, station service 5
Transformers, station service 6.67
Turbines, steam 5
Turbines, water 3.33
Turbines, steam 6.67
Wire, trolley Allowance of 80.5 lb.
per 1,000ft. for wear-
wearing value of No.
wire
Wire, trolley Allowance of 106.8
lb. for No. 00 wire.
Wire, trolley No. 0, under 1 min 50
headway
Wire, trolley No. 00, under 1 min 40
headway
Wire, trolley, No. 000, under 1 min Jf3.3
headway
Wire, weather proof 6.25
Wire, weather proof 7.5
Wire, weather proof TO % maintenance cost

899. Functional depreciation i.s the result of lack of adaptation to

function, caused by obsolescence and inadequacy. Obsolescence is due
to changes or advances in the art which renders a piece of apparatus, or a
whole class of it. obsolete and uneconomical of use, as compared with new
types which have been developed at a later date and which are much more
efficient (H. G. Stott, Tram. A. I. E. E., p. 1619, 1913).

902
 POWER PLANTS Sec. 10-900

MO. Llf6 expectancy of equipment. The life expectancy of power-

lant equipment, taking functional depreciation into account, is as follows:*

Scrap value,
Total life
Property per cent, of
(years)
original cost

Buildings 75 5
Boilers, stokers and furnaces 20 5
Conveyers, elevators and hoists 20 1
Turbines, complete 12 10
Engines and condensers 12 10
Piping, values and traps 12 3
Pumps 12 5
Synchronous converters, transformers and
exciters, etc 20 10
Switching apparatus and instruments 12 5
Alternators 12 10
Motors ._
20 10
Tools and sundries 10 3
Storage batteries 10 10

901. Scrap value. It is obvious that in computing the net annual amount
of depreciation tne scrap value of the apparatus must be deducted from the
original or first cost.
902. Methods of caring for depreciation. Charging to repairs all
replacement of apparatus, either in part or as a whole, is expected in many
companies to care for depreciation. Ordinary repairs will not prevent a
machine from finally reaching a point, due to wear and tear, where it will
have to be replaced and in small companies this replacement would cost
such a large proportion of the total investment that it is desirableto accumu-
late a fund for the purpose. If replacements are charged to repairs this item
will become irregular in amount, which is a very undesirable condition.
In very large companies the irregvdarity becomes less and consequently the
method can be used with success.
903. The straight-line method of computing depreciation is based on
the assumption of a uniform reduction in value. It is commonly assumed
that the accumulated depreciation fund, under this method, bears no interest,
but such is not necessarily the case. The method has the great advantage of
being very simple in application.
904. The amortization or sinking fund method of computing de-
preciation assumes that the accumulated depreciation fund is invested
and bears interest. The effect is to make the annual rate less, of course, than
it would be if the fund bore no interest. This method is not easy of appli-
cation to actual conditions. Some authorities consider that it represents,
more nearly than the straight-line method, the depreciation in actual value
of the property as determined by what a purchaser could afford to pay for it.
906. Calculations of depreciation, by whatever method, should be
made separately for each type of equipment, taking into account its expected
ife and its scrap value. There is much chance for error in deciding on a
percentage to apply to an entire property, and if used it should be determined
'rom a detailed calculation. It is evidently subject to some variation from
iimfi to time as new equipment is added.

•06. Obsolescence is commonly regarded as a type of depreciation to be

'harged to the cost of power. This is not necessarily the case. Obso-
escence does not accrue from day to day, like physical depreciation, but
iccrues coincidently with advances in the art resulting in new and more
iffietent machinery or methods. The full physical life of equipment is possi-
ble in any event, whether or not obsolescence occurs, and the question
•vhether a piece of equipment should be replaced before it wears out is de-
erminable by equating the saving in operating expenses against increased

* Stott, H. G.. "Power Costs"; Trans. A. I. E. E., 1913, Vol. XXXII, p.

112.

003
Sec. 10-905 POWER PLANTS
fixed charges. In comparing different types of plants it is misleading to
consider obsolescence as different for the various types.
Physical and functional depreciation costs must not be added. If func-
tional depreciation will shorten the expected life the proper rate to care for
this shortened life should be used, which includes physical depreciation.
Eminent engineers have incorrectly allowed a percentage for physical
depreciation and an additional percentage for functional depreciation.
907. Summary of H. O. Stott's Classification of Operating and
Maintenance Costs
(Material and labor separated for each item)

Production costs
 POWER PLANTS Sec. 10-910

'
910. Classification of operating expenses. A very complete form of
cost analysis has been given by Mr. H. G. Stott, whose paper* should be
•
consulted for details. His summary is presented in Par. 907.
911. Analysis of the Average Losses in the Conversion of 1 Lb. of
Coal into Electricity f

j
B.t.u.
Sec. 10-913 POWER PLANTS
913. Power Plant Costs per Kilowatt
(H. G. Stott)

Min. Max.
Real estate I
$3 00 . «7.00
Excavation \\ 75 . 1.25
Foundations, reciprocating engines 2! 00 3.00
Foundations, turbines 0. 50 0.75
Iron and steel structure 8.00 10.00
Building (roof and main floor) 8.00 10.00
Galleries, floors, and platforms 1 .50 2.50
Tunnels, intake and discharge 1 .40 2.80
Ash storage pocket 0. 70 1.50
Coal hoisting tower 1 20. 2.00
Cranes .
0.40 0.60
Coal and ash conveyors. . '. 2 00. 2.75
Ash cars, locomotives, and tracks 0.15 0.30
Coal and ash chutes 40. 1.00
Water meters, storage tanks, and mains 0.50 1.00
Stacks 1 25. 2.00
Boilers 9 50. 11.50
j

Boiler setting j 1 . 25 1.75

Stokers !

1 . 30 2.20
Economizers 1 . 30 2.25
Flues, dampers, and regulators 0.60 0.90
Forced draft blowers, air ducts 1
1 25 . 1.65
Boiler, feed, and other pumps 0.40 0.75
Feed-water heaters 20 . 0.35
Piping, traps, and separators I
3.00 5.00
Pipe covermg j
60. 1.00
Valves 0.60 1.00
Main
;

engines, reciprocating 22 00. 30.00

j

Exciter engines, reciprocating |

0.40 .0.70
Condensers, barometric or jet 1 00. 2.50
Condensers, surface 6 00. 7.50
Electric generators 16.00 22.00
Exciters 60. 0.80
Steam-turbine units, complete* $10.00 $15.00
Converters, transformers blowers 0.60 1.00
Switchboards, complete 3.00 3.90
Wiring for lights, motors, etc 0.20 0.30
Oiling system 0.15 0.35
Compressed air system and other small aiixil. 0.20 0.30
Painting, labor, etc 1.25 1.75
Extras 2.00 2.00
Engineering expenses and inspection 4.00 6.00

914. Analysis of the Average Losses in the Conversion of 1 Lb. of Coal

Containing 12,500 B.t.u. into Electricity.
Producer Qas Engine Plantf
-'..: ,.|,,i T .:
 POWER PLANTS Sec. 10-915

91S. Cost of 1 H. P. per Year, Compound Condeiuinff Engines,

10- hr. basis, 308 Days per Year*
(Wm. O. Webber, Engineer U. S., Feb. 2, 1903, p. 144)

Size of plant
Sec. lO-Ql^ POWER PLANTS
,«<>aij|Ud TTCT

M 00 00 C4 ;o<oco

00 O0t~O0

^M

0« •rt t- to lO 00t^U5

U5 U5 U50X5
5
a
o
Old
oo
lO iO—iN
 POWER PLANTS Sec. 10-919

140

«120

M 80
-s
a
I
A 60

Io ^
Q

S 20
 Sec. 10-921 POWER PLANTS
plant. As the number of units increases, this portion becomes relativelj
Bmaller. It is probable that the ratio of full-load labor costs per hour tc
no-load costs varies from 2 to 1 in plants of a single unit, to 5 to 1 in planti
of a large number of units.
!
(c) The coal required to maintain a plant ready for instant service wit!
one unit running at no-load, consists of that required for its no-load steam
that of the auxiliaries and that for banked fires xinder sufficient boiler capa-
city to carry the peak load. This total no-load coal ranges from 25 pei
cent, of full-load coal in a plant of one unit to 8 per cent, in a plant of manj
units.
Cd) Operating repairs and other expenses are very indefinite and un-
certain except over a long period of time, but probably vary in direct pro-
portion to the load, thus being independent of the load factor.

^o^uotion Coat of Power

and Load Factor
.i- One Cult Plant
B-Manj Vnlta •
 POWER PLANTS Sec. 10-921

so
iSec. 10-922 POWER plants
922. Example of comparison of power costs.*
Let Ci, C2 = total cost per kw-hr. in plants 1 and 2,
/i, 72 = fixed charges per kw-hr. in plants 1 and 2,
F\, Fi = fuel costs per kw-hr. in plants 1 and 2,
Li, 1/2 = labor costs per kw-hr. in plants 1 and 2,
Oi, 02 = total other costs per kw-hr. in plants 1 and 2,
/i, /j = cost per 1,000,000 B.t.u. in plants 1 and 2,
li, li — average hourly wage in plants 1 and 2,

Ri, Ri = average daily load factors in plants 1 and 2

Ci' = total cost in plant 2 reduced to plant 1 conditions.
Example:
Ci = 6.5 mills per kw-hr. Ci = 7.5 mills per kw-hr.
7i =2.0 mills per kw-hr. /2 = 2.5 mills per kw-hr.
Fi = 3.0 mills per kw-hr. Fi = 3.0 mills per kw-hr.
Li = 1.0 mills per kw-hr. La= 1.5 mills per kw-hr.
Oi = 0.5 mills per kw-hr. 02 = 0.5 mills per kw-hr. • ,

/i = 10 cents per 1,000,000 B.t.u. /2 = 8 cents per 1,000,000 B.tffl.!

ii = 30 cents per hour ^2 = 40 cents per hour ,

ft = 50 per cent. ij =40 per cent.

+
0.5] [0.945] = 7.08 mills per kw-hr.
'

«= 2.0 -I- [3.75 -1-1 125

That is, the second plant were operated under the same labor snc,
if
fuel cost and the same load factor as the first plant, it would cost 7.08 mill'
per kw-hr., as against 6.5 mills; this is less efficient operation, but not as bai
as indicated by the uncorrected figures. The correction for fixed charge
should more properly have been made on the basis of annual load facton
923. Suitability of different types of power plants. Steam
electric plants are most suitable under conditions of moderate or low loa
factor and fuel costs. Gas-driven and hydraulic-electric plants are suil
able only with high load factors and fuel costs.
The steam- engine -driven plant is suitable only in small sizes or wher
it is necessary to run non-condensing, under which conditions it is mor
economical than the turbine. It is more expensive in first cost in all siie
The steam-turbine- driven plant is of general adaptability to all sin,
and loads with the above exceptions.
The iOW-pressure turbine offers a very satisfactory and most economic
method of extending existing engine-driven plants with economy equal i

best modern practice. It has little advantage for new plants, however.
Oas-engrine driven-plants are most suitable in small sizes where fir
cost is not greatly in excess of that of steam plants, and where the diffe
ence in economy is much greater. Larger sizes have excessive investme
costs and expensive maintenance which are balanced by fuel saving on
with high load factors and steady load.
Hydraulic plants are suitable when there is a use or market for a season
delivery of power at high load factor. Very few plants, except at Niagai
have a summer output in excess of 25 per cent, of rating.
924. Modem tendencies in power-plant design point to inexpenai
plants of high oper,ating economy. Expense of construction is reduced 1

simplicity in design, using few large units; reliability is secured by the use
the highest quality of materials and apparatus rather than by duplicat)
with its attendant complication. Operating economy is secured thrc
better control of combustion, the use of highly efficient apparatus wli
efficiency adds relatively little to the cost of the entire plant, and the attei
ant reduction in labor cost through the simplicity of the plant and t
small number of operating units. The development of stokers allowing vf
high rates of evaporation in the boilers with high economy, has reduced t

Investment costs in boiler equipment and building and also improved oper
ing economy by reducing the amount of coal consumed in banked fir
There is a strong tendency toward compactness of layout, allowing oi

•Adapted from Stott, H. G., Gorsuch, W. S., Tran*. A. 1. 1. E.

MB
I
 1

POWER PLANTS See. 10-925

ufficient floor space for the dismantling of apparatus during repair. The
lerfection of the mechanical design of turbo-generators permits the use of
keleton foundations in which the condenser can be placed with great apace
conomy. The electrical switching equipment still has a tendency toward
ipensive complication, which the writer believes will gradually give way to
implicity and ruggedness, except in the largest plants.
925. Improyement of economy of existing plants requires, first of all, an
ccurate knowledge of all the elements entering into the cost in that particular
lant, and then a gradual elimination of the elements producing ineflBciency.
926. Boiler-room practice affords probably the most fruitful field for
nprovement, as it has hitherto been the most neglected. Numerous instru-
lents, meters and devices are on the market which make possible a continual
leck on the efficiency of the boiler room. It is not only possible to know the
_

irerall efficiency, but to determine readily just what are the causes of in-
Bciency; there are automatic devices, also, which remove some of these
mses. A
careful study should be made as to the variation in efficiency
ith peak load and load factor, so that the inherent improvement in economy
ith good load factor shall not be mistaken for the results of better operation,
eterminationa should be made as to the projjer number of boilers to use,
e relation between active fire hours and banked fire hours, and just when it
profitable to let the fires go out. It is highly important that the boiler*
emselves be kept clean both inside and out; means are available to facili-
ite this work, both chemical and mechanical. The firemen should be care-
Uy instructed in proper methods of firing and closely watched to see that
ey follow instructions.
927. Engine or turbine room operation offers a less fruitful field for
iprovenient since the inherent economy of the units, more particularly of
e turbines, is less under the control of the operators. With engines,
wever, it is highly important that valve settings be maintained properly,
le proper loading of units has some influence on economy. The balance of
haust steam produced and that needed for feed-water heating is par-
ularly important at light loads, when ordinarily there is an excess of steam
lich is wholly wasted. Electric drive of some of the auxiiiariei frequently
•ves as a corrective. Air leakage into the condenser is an important
jrce of loss.
928. Electrical operation offers a relatively limited field for improre-
int in economy. It is frequently possible, however, by rearranging the
Qtilation of windings and keeping them properly clean, to carry a better
arage load on the prime movers, which adds to the economy and also to
! effective size of the station.

')29. Labor Labor costs can frequently be reduced by arranging

shifts.
'flapping thus providing the necessary men during peak loads,
shifts,
^;hout unnecessary men before and after. The efficiency of labor should
I measured not alone by its cost per kw-hr., but by the cost per unit of
'
rk performed.
)30. Repairs should be made as soon as their necessity is discovered. A
1 h grade of maintenance is usually cheaper than lax maintenance, and
i.reases the effective life of the apparatus.
>31. Economy In supplies does not mgan cheap materials, but the
<)ioe of those best adapted to the work and which give the lowest total
< t for the object accomplished.

BIBLIOaRAPHY
32. Steam, gas and oil plants.
';^ABPENTER, R. C. and Diederich, H. —"Experimental Engineering and
• iNELL, J F. C.
— —
I.nual for Testing." John Wiley &Sons, Inc.,New York, 1914.
"Power House Design. Longmans-Green Co.
. N'

. Y., 191
' ,

-Ieter, H. C, Jr. "Steam Power Plants." McGraw-Hill Book Com-

riy, Inc., New York,
— 1912.
lEBHARDT, G. "Steam Power Plant Engineering."
F. » s John Wiley &
New York, « j'

W. — "Notes on Power Station Working."

^is. Inc., 1912.
\CKsoN, J. Elec. Inst, of
New York, 1912.
A. — "Power Plant Testing." McGraw-Hill Book Company,
t^tn.,
.lOTER, J.
r. N(B,w York, 1913.

013
 Sec. 10-932 POWER plants
" Rules for Conducting Performance Tests of Power Plant Apparatus. "-r7
—
Trans. Amer. Soc. Mech. En^s., New York, 1912.
Shealy, A.M. "Steam Boilers." McGraw-HillBookCo.,Inc.,N.Y.,19l2
—
Peabody, C. H. and Millbb, E. F. "Steam Boilers." John Wiley i
Sons, Inc., New York, 1913.
—
Perry, J. "Steam Engines and Gasand Oil Eng." MacMillanCo., N.Y
——
Thomas, C. C. " Steam Turbines." John Wiley & Sons, Inc., N. Y., 1910
Martin, H. M. "The Theory of the Steam Turbine." Longmans
Green Co., New York, 1913.
—
MoYER J. A. "Steam Turbines." John Wiley & Sons, Inc., N. Y., 1914
—
Morris, W. C. "Steam Power Plant Piping Systems." McGraw-Hil
Book Company,
DeLaval, C. G. —"Centrifugal Pumping Machinery." McGraw-Hil
1909.Inc.,

Book Cornpany, — New York, 1912.

Inc.,
LuCKE, C. E. "Gas Engine Design." D. Van Nostrand Co., N. Y., 190S
Clerk, D. and Bubm, G. H. — "The Gas, Petrol and Engine." Ne« Oil
York, John Wiley & Sons,
Habder, H. and HnsKissoN, W. M. — "Handbook on the Gas Engine.'
1909 and Longmans-Green Co., 1913.
Inc.,

McGraw-Hill Book Company, New York, 1911.

Carpenter, R. C. and Diederich, H. — "Internal Combustion Enginee.'
Inc.,

D. Van Nostrand Co., New York, 1914.

Fbrnald & Orrok. — "Engineering Power Plants." McGraw-Hill
of
N. Y. 1920.
Allen, H. — "Modern Power Gas Producer, Practice and Applications.'
D. Van Nostrand Co., New York, 1908.
Wyer, — "Producer-gas and Gas Producers." McGraw-Hil
S. S.
Book Company, New York, 1906.
Inc.,
Hydraulics.
Hughes and Sappord. — "A Treatise on Hydraulics." The MacmillK
938.

Co., New York, 1911.

Smith, H.,
—"Hydraulics." John Wiley & Sons,
Jr.
— New York, Inc., 188f
:

Daubuisson de Voisins (Bennett's Translation). "A Treatise on Hydrat

lies."
—
Weir experiments by M. Castel.
Fteley, a. and Sterns, F. P. "Flow of
Brown &Co., Boston,
Water over Weirs."
Little,
Tran.
185i

Amer. Soc. C. Vol. XII

Bazin, M. H. — "Flow
E., (pp. 1-118), 1883.
of Water over Weirs." Annales des Fonts«

Chauseus, Mem. et Doc, 1888, 2d semestre, pp. 393-448. Translated b

Marichal and Trautwine, Proc. Engrs. Club, Phila.

Francis,
— J. B.
—
Water Supply and Irrigation Papers. U. S. Geo. Survey.
D. Van Nostran
"Lowell Hydraulic Experiments."
New
Weston, C. E. — "Weston's Friction
Co., York, 1883.
Water Pipes." 3rd of in Editio'
D. Van Nostrand Co., New York, 1903.
Mead, D. W. — "Water Power Engineering." Edition. McGra\ 1st
Hill Book Company, New York, 1908.
Camerer, Dr. R. — "Verlesungen uber Wasserkraftmaschinen."
Inc.,
Verli
von Wilhelm Engelmann, Leipzig and Berlin, 1914.
934. Electxical equipment and economics.
Baxter, Wm., Jr.— "Switchboards." N. W. Henley Pub. Co., N. Y., 191
—
CoLLis, A. G. "High and Low Tension Switch Gear Design." D. Vi
Nostrand Co., New York.
—
Floy, H. "Valuation Public Properties."
of McGraw-Bn
Utility
Book Company, — New York, 1912.
Inc., '/"J
Foster, H. A. "Engineering Valuation Public D. V of Utilities."
New York, Ji
Gebhardt, G. D. — "Steam Power Plant Engineering." John WU
Nostrand Co., 1912.

& Sons, New —

York,
Inc., 1911. ^| '

Hawkins, G. W. "Economy Factor Steam Power Plants."

Koester, Frank. — " Hydroelectric Development and
in
Engineerini
D. Van Nostrand New York,
Meyers, D. M. — "Preventing Losses
Co., 1911.
Factory Power Plants." En in
New York,
Taylor, W. T. — "Transformer Practice." McGraw-Hill Book Co
Mag. Pub. Co., 1915.

I pany.
Croft,
Inc., New York, 1913.
T.— "Wiring and Equipment." McGraw-Hill, N. Y. 1920.
Clewell, C. C—
"Machine Shop Elect." McGraw-Hill. N. Y. 192f
Millbb, K. B.— "Telephone Practice." McGraw-Hill, N. Y. 1920.

914
 SECTION 11 >*^

POWER TRANSMISSION
BY
HARRY E. CLIFFORD, S.B.
h on McKay Professor of Electrical Engineering, Harvard University,
Fellow, American Institute of Electrical Engineers

AND
CHESTER L. DAWES, S.B.
isistant Professor of Electrical Engineering, Harvard University, Member,
American Institute of Electrical Engineers

CONTENTS
(Numbers refer to Paragraphs)

fi smission Systems 1 Fundamental Considerations of

El -heal Calculations 8 Line Construction 135
Ffes of Inductive Reactance Poles 146
_a Charging Current 41 Steel Towers 168
3e ral Eeatures of Design 61 Pole Accessories 174
^c na 65 Pole Braces, Guys and
Ui Insulators 70 Anchors 187
3y m Disturbances 48 Conductor Construction 193
3ym Connections and High-tension Cables 206
S ;ching 86 Substations 217
Po r-factor Correction 99 Operation 228
3ti Spans
jCB in 102 Transmission Economics 234
3t!ngth of Supporting Cost Data 240
Sabers 123 Bibliography 247

m
 .

SECTION 11

POWER TRANSMISSION
TRANSMISSION SYSTEMS
1. Systems in common use. There are three systems in common i

to-day: the direct-current (Thury) system, abroad only; the single-ph;

system, in railway work and the three-phase system, for general transmissi
;

These systems may be compared as follows, in terms of effective cum

and voltage. ,

Direct-current :

Current per wire =I

Voltage between wires = £ (J> £-*> <£)
Voltage to neutral =E/2
Power =EI
Single-phase :

Current per wire =/ AC ..: H

Voltage between wires = £
Voltage to neutral =E/2
Power =£/ cos $

Three-phase :

Current per wire =/

Voltage between wires = fi
Voltage to neutral =£/v3
Power = y/ZEI cos

2. Copper efficiency of the various systems*

Relative Tota
Relative Relative relativ
voltage
current loss per
between wire
con<lui
per wire we IK
wires

Direct-current
Same max. voltage. 70.7 141 50 50
Same effective volt-
100 100 100 l(Vi
age

Single-phase 100 100 100

Three-phase. 57.7 100 66.7

3. Direct-current (Thury) system, t Direct-current transmi.s>

at present limited by the difficulty of obtaining a voltage sufficient! >

for economical transmission, but Thury has developed in Europe a

voltage, direct-current system, and a number of such plants are at ji

• Voltage between wires, transmission distance, power transmittr

power loss are fixed; unity power-factor assumed. With the same cfi'
voltage to neutral, all systems have the same copper efficiency.
t Still, Alfred. "The Thury System of Power Transmission by
LX
i tinuous Currents."
Bell, Louis.
sion."
Elec. World, Vol. (1912), pp. 1093, 1144.
"Recent Developments in Constant Current Trai
Elec. World, Vol. LXIII (1914), pp. 350, 361, 583.

916
I
 POWER TRANSMISSION Sec. 11-4

vmg satisfactory service (Fig. 1), The required line voltage is obtained by
.nnecting series-wound generators in series, the voltage
per commutator
nging from 1,300 to 4,000 volts. Each generator is mounted oTrninsu-
ted platform and connected to its prime mover by an insulated
coupline
hen not in use, the generator is short-circuited. In this system the current
mamtained constant by automatic devices which control the prime-mover
eed, shift the brushes, and shunt the field, and the
voltage is made to vary
tn the load. Ihe power is deUvered to motors similar in construction to
e generators. The motor speed is controlled by shifting the brushes and
nultaneously shunting the field. Line voltages approximating 70 000 volts
3 in use, and a transmission distance of 112 miles
(Moutier-Lyons) has been

f" n
2 Motors Motors 2 Motors Two Motors Ughtnlng Amatcn
V.H<j~"8000 Volu 500 Voluj 3000 Volt,
j

Fig. 1. —
Typical Thury system.

.
claimed for Thury system: (a) power-factor alwava
^?iTn*v**u*^®'
pressures for the same line insulation
'^ZlH-^'^^M^^'"''^'^''
indicate that with given line insulation, (tesrbv
«^
Aiternating current voltage)
direct current may be twice
maximum pressure occurs onlvd,,r?n^
«mum loads; (c) no dielectric The
.
.

losses; (d) two w1?eron°y to bei^ulated^

underground single-conductor cable can be obtained
; for 60^000 v^lts and
ih grounded neutral, the fine pressure would be
120 000 volte (h no
''"'^ ^^^"^«^« ^'^d abnorZ^ voltage rles
anumbPr'nfTr"" ''°''^t' °''" be operated in series and a station
ted to the inl i?'^ can be Ton-
^-"""^ switching arrangements very simple-
(ihrh^H
ydrauhc ^"'J^^- ^^^
Z , I- *
stations under variable head, greater efBciencv can be
." ""^"-^--y: (J) afapted for indSsTriaTwork
^ rTng cons^rnfttourrl'? ^'^^ "°^ repairs can be easily and
t no ic^ operation .• '^^"i'' safely made whUe
S
1
after grounding the conductor at the
t 'f."»
applicable poin^ Question
question
1
1 to systems with grounded neutral)

\J mpossibihty of securing overload torque

on the motors^ even for a Rhi^t

'"^ occasional railway installations,

a:lit^tlStd^hftranfmitt^t'.'''''^P*

U .f lati^ to^fhaTth'^- po^y^pCr sfngle-pC^n^p^ol

m^o-r^^^'e^
...rat^when operating sin^le-Sa*s\\orh°Ilfit?^^^^^^^^^

Three-phase transmission and distributioD

a'sJ!frs!dfn^1L''nfh^°"'-

917
 : '

Sec. 11-8 POWER TRANSMISSION U

ELECTRICAL CALCULATIONS
8. The required size of conductor for a direct-current line may
readily estimated. With a given power, P watts, to be delivered at volta
Er, the value of current, /, is determined from the relation
I =P/£?r (amp.)
One mil-foot of copper has a resistance of about 10 ohms at 15 deg. ce
(62 deg. fahr.). If tne conductor is operated at a normal current densitj
0.001 amp. per cir. mil, the drop per ft. will be 0.01 volt, regardless of I

size of conductor.
9. The total voltage drop may be expressed:
e = 0.01XJ (volte)
where I the total length of conductor in ft.
is If the current density
different from this normal value, e will be in direct proportion to the curr*
density. Thus, if the density is 1 amp. per 1,200 cir. mils, and I = 1(X),000 :

then e =0.01 X 100,000 (1,000/1,200) = 833 volta.

10. Efficiency of transmission may be expressed:

1? = 5r4- 100 (per cent.)

iir +e
If the receiver voltage in the above case were 10,500, then i

+
10,500/(10,500 833) or 92.6 per cent.
Power 1 ost per mil-foot of copper at the normal density is represented
the expression:
/2r=(10-«)2 10 = 10-« (watte)
Total power lost at the normal density is
I-R=10-iXc.m.Xl (watts)
where cm. is the conductor cross-section in cir. mils, and I is the total len
of conductor in ft. If the current density differs from the normal,
right-hand side of Eq. 5 must be multiplied by the square of the ratio of
densities. Constant current high-voltage systems are usually so desigi
that the line losses are kept within prescribed limits.
If P, the power delivered, Eg, the generator voltage, and R, the line re
tance be given, Er, the receiver voltage, may be found from the follow
equation.

-f['*\FS] <—
The minus sign is only used when
the efficiency of transmission i--

than 50 per cent, which practically never occurs.

11. Example of design. Required to transmit 2,000 kw. 15 milee
10 per cent, line loss.
It is customary to allow 1,000 volts per transmission mile, but this ma} •

modified somewhat by considerations of line cost. Assuming a pressuM

the receiver of 15,000 volts, /=• 2,000,000/1,5,000= 133 amp. The pen
sible voltage drop =• 1,.500. Let e' = voltage drop at normal current aens ;

then e' =0.01X30X5,280 = 1,584 volts at normal density. Actual den

•

must be '.- amperes per 1,000 cir. mils. Hence the cir. mils required )

133 X p5^ X 1.000 = 140.000.

12.The regulation and efficiency of a single-phase or a symmetr 1
polyphase system may be calculated by considering one conductor o .

assuming a neutral which has rero resistance and zero reactance, b"
return wire. A three-phase system may also be treated as a single-:
system transmitting one-half the power.
Sine waves of current and voltage, and balanced loads are assumfd •
following paragraphs. The eflFects of harmonics and unbalancing can usiV
be neglected but may be treated as special problems if conditions warr ••

IS. Alternating-current transmission-line calculations. A i^i'

-

t phase or symmetrical polyphase system having resistance per wire R

and reactance per wire X ohms and a load current to neutral of /
at power-factor, cos 9, is represented in Fig. 2 and the voltage relation

918
 :

POWER TRANSMISSION Sec. 11-14

Iurn vectorially in Fig. 3. The electrostatic capacitance assumed to be

Jigible.
[no wing the receiver voltage, Er, the generator voltage, Eg, may be readily
i'ulated.

Ea = V(.ErCose+IR)^ + {Eraine±IX)i (7)

I
minus sign is used when I leads Er.
i^ may also be written

'i
E, = Ery(^oos fl+^)*+(ain »±^)' (8)

1 ation (8) ismore convenient than (7) as the quantity under the radical
i; is of the magnitude of unity and the position of the decimal point is
Be readily determined.
T V z*
t* Per cent, regulation = —?^r-^100 (9)
Xir

Efficiency = ^^^^
Er I cos e+I'R
the sending-end voltage, Eg, the load power P, in watts, and the load
•or-factor, cos B, are fixed, Er is found by the following equation:*

(i?2 + X2)P2 P{R cos e +X sin e)

frxVliV^- A* C082 e
where
Eg^ cos e
A = S," \ \F (11)

ir practical work it is usually more convenient to assume a regulation,

hEr from (9), and solve for Eg by the use of (8). If the calculated regu-
Mu then differs materially from that assumed, another trial may be
le^sary. If the receiver
a T than the generator
fo.ge be fixed, the problem
B ich simplified.
Example
of singlc-
>t lecalculation. Trana-
ni on
distance, 20 miles;
[crating voltage, 33,000
0 frequency, 60 cycles per
;

full-load power-factor,
aeing of wires, 48 in.;
—ilile line loss, 10 per
;ei of power generated.

-Ovd

f 2.- — Equivalent trans-

ission line to neutral.
Fig. 3. —Vector diagram line.
of transmission

lined power at receiver = 5,000 kw. Assuming 15 per cent, regula-

e e.m.f. at the receiver equals 28,700 volts, and the voltage from
neutral at the receiver is 14,350 volts. Current per wire =
J.u.U(X)/(28,700X0.85) =205 amp. Loss per wire = (0.10/0.90) X (5,000/2)
= ^ kw. Resistance per wire = 278,000/(205)2 = 6.61 ohms. Resistance
ieriile = 6.61/20 = 0.331 ohm.
Fm the table of Par. 40 the nearest size of wire is No. 000 A.W.G. copper,
lavir 0.342 ohm per mile or
a total resistanc - (20 miles) of 6.84 ohms.
l^ictance per mile (Par. 40) of single conductor, 0.692 ohm. Total
|»«.nce, 13.84 ohms. IR= 1,400 volts, 7Z = 2,840 volts. Substituting in
1,400 \ 2
= 14,350
V(0-8^0 + 14,350,)> (0.527+^^^)'= 17,140 volts.
,

17,140-14,350
Regulation 100=19.44 per cent.
14,350

Electric Journal," Vol. XVII, Feb. 1920, Page 76.

919
 «

Sec.11-15 POWER TRANSMISSION

The calculation shows material error. Assume 19 per cent, regulation,
7 = 212 amps., /ft = 1,450 volts, /.Y = 2,940 volts.

1,450 2,940 \i
Eo = 13,870 V(o. 850 + 13,870) + (0.527 + 13,870/' :
16,750 volts.
16,750 13,870
The calculated regulation is 100 = 20.7 per cent.
then
13,870
this checks closely with the 19 per cent, regulation assumed, another t
is unnecessary, unless greater refinement is desired.
The efficiency then becomes n = 2, 500,000/[2, 500,000+ (212)26.84] or 8'
With aluminum as the conductor, the reactance drop would be sligl
less.
16. Example of three-phase calculation for a line having the same c
stants as are given in Par. 14. Transmission distance, 20 miles; general
station line voltage, 33,000 volts; frequency, 60 cycles; load power-fac
0.85; spacing of wires, 48 in.; permissible line loss, 10 per cent, of po
generated; power at receiver, 5,000 kw.; voltage to neutral, general
station, 33,000/ -v/S = 19,050 volts. Assuming 15 per cent, regulat
voltageat receiving station = 19,050/1.15= 16,570 volts. Current per wir
c Qcit)
1
5,000,000/(3X16,570X0.850) = 118.4 amp. Loss per wire =-^^X^
185 kw. Resistance per wire =185,000/(118.4)2 = 13.20 ohms.
Resistance per mi!e= 13.20/20=0.660 ohm.
Prom Par. 40 the nearest wire size is No. 1 A.W.G. which has a n
ance of 0.683 ohm per mile.
Total resi8tance= 20X0.683=13.66 ohm?.
Reactance per mile (Table 42) 0.734 ohm.
Total reactance , 14. (iS ohms.
.
/« = 118.4X13.66 = 1,617 volts /A' = 118.4 X 14.68= 1,738 vol
Substituting in (8) ____„^.^
£. = 16,570lJ(0.850 + 3^«il)^+(o.527 + ^„)^18,870 v,

^^'^^°
Regulation = J^^^lOO = 13.88 per cent.
This checks well enough with the 15 per cent, regulation assumed.
Efficiency

n =, ^^.r rl^^?lw^:r-.^. o i^ = 1,667,000/1 ,858,000 or 89.6 per

cent, i

1,667,000 +
(118.4)213.66
16. Use of complex quantity. Analytical solutions of pro'^ '

involving vector qu
/X Sin may be made by rt

each vector into two >

nents, one along a hor

or X called the
axis,
reals, and the other i

A' the vertical, or Y axis, c J

, ^ the axis of imaginnries. '•

-JIR latter component is prer <l

Sintf by y=(\/-l) with c- +

sign according to whetn
leads or lags with respeij*
the positive real compq *$
lag being measured i *
clockwise direction.
„ ^., ,
Fio. 4.— Vector diagram
,. ^ ,
of transmission Ime
.... Fig. 3 may be treato "X
^,^jg niethod, as shown in t-
using complex quantities. ^ .^^^^.^ ^.^^j, quantity «" i

solved into a real compto'

along Er, the axis of reals, and into a quadrature component along tniJ»

> of imaginaries, at right angles to Er.

Eg''e+je' = Er + I (cos 0-j sin 0) («+ jX)
Each quantity represented in Fig. 4 is obtained by performing the
,,
''
«"

920
 )

POWER TRANSMISSION Sec. 11-17

[ication in (12). each component of current is treated as

(The effect of
[he other did not exist.) The plus sign is used when / leads Er. The
alute value of Eg is givenby \/e^ + e'^.
.7. Example of analytical solution of three-phase line using com-
icquantity. Consider the problem of Par. 16.
Eg = 16,570 + 1 18.4(0.850 -;0.527) (13.66 + yi4.68) = 16.57 + 1,374 +
:ere

r5-i852 + 916=18,8604-j623. Hence J?j = \/l8,8602 + 6232= 18,870.

eeulation = —— !
T^"c.^?r
100= 13.88 per cent., as before.

Nentral
-Equivalent transmission line showing capacitance and leakance.

Line capacitance has negligible effect on short or low-voltage lines,

..

ir for such hnes, may be neglected. On the longer lines of higher voltage,
hine charging current has a marked influence on the line regulation, and
lie must be considered in the design of the line.
1 longer lines of higher voltage the charging current must be taken into
:oideration. It leads the voltage by 90 deg., and because of the line react-
ir it tends to produce a rise in voltage from the sending end to the receiving
,

!D With an in-phase or with a lagging current the effect of the charging

lU'Ht is to improve the line regulation and the generator power-factor,
fie receiving end is open-oircuited, the voltage at the receiving end
>emes greater in magnitude than the voltage at the sending end.
R/2 X/2 R/2 X/2 Ji X

- la. 6. —Nominal "T" line. Fig. 7. — Nominal "ir" line.

>'i. Nominal "T" line and nominal "n" line. A transmission line
Itbrmal frequencies may be represented by a single conductor having a
in rm linear resistance {R = r
f^f r . . .), reactance (X = Carre ShoTing th« EeUUon between
Lme Voltage and J)ietance
- ~x -{ X . . .), leakance (G
150,000 VoIH
" " ff + Voltage at the Beceiier -
. . ) and capactive Load
.
.60,000 K.W,
lUiptance (B = b +b+ . . . ^ower- factor at " - 0.8 6
n rallel between the line and JUuf -laO Mile:, 300,000 aU,
leial (see Fig. 5). The exact JCouductor Spacing 15 ft.
in; tical placement
such a of
ID'S rather complicated, and
or radical purposes the shunt
idittance consisting of the
ea nee G and suseeptance B
na be considered as concen-
'ai at the centre of the Une
.Fi;6), or in two admittances,
sac of one-half the total Une Voltage drop in line.
witance, placed at opposite
3nt:>f the hne (Fig. 7). The former is termed a nominal T and the latter a
sof lal ir, or a split condenser. In the former case the entire charging
'UTat flows over half the line and in the latter case one-half the charging

921
 «

Sec. 11-20 POWER TRANSMISSION

current flows over the entire line. The leakage current can \isuall]
neglected. Where the corona and insulator losses are not negligible t
effect may be included. If the transformers are to be included with
line, their equivalent single-phase resistance and leakage reactance mus
added to the line resistance and reactance respectively; the energy c
ponent of the no-load current must be added to the line leakagc-cun
and the quadrature component or magnetizing current must be subtra(
from the line charging-current.
20. Voltage distribution. The true voltage distribution and
approximate voltage distribution for a 150- mile, 150,000- volt, 60-cycle
are shown in Fig. 8. It will be noticed that for the fundamental freque
the difference is very slight, especially near the ends.
21. The charging current for a given voltage, Ec, is
Ic = 2TfEcC (amp.) (

where /is the frequency in cycles per sec, Ee the voltage across thecond
ser terminals in volts, and C the condenser capacitance in farads. The val
of le for different spacings and sizes of conductor are given in Pars. 44,

R/2 X/, Rh ^h I

Fig. 9. —Nominal "T" line. Fig. 10. — Vector diagram of now

"T" line. Power-factor • f?

22. A nominal "T" line is shown in Fig. 9, and Fig. 10 shows the ve(
relations in the circuit for unity power-factor load. Fig. 11 gives i

vector diagram when the Toad current I

IX by an angle 9 with respect to the

. ;

-2 voltage. It will be observed th

condenser charging current is in i:

ture with and leading the voh:iL

consequently the iR drop leads Et b '

deg. and iX leads £c 180 deg. It will

R —
A'^vwwv
X

m
''ellBABBS^

Fro.—Vector
nominal "T"
11.
line.
diagram
Power-factor
of Fig. 12. —Nominal
"" cos e.

be noted that Ee is at some potential between Eg and by Et but for pi

purposes, E, is assumed equal to Er, and no appreciable error result-
charging current. In fact, the calculated charging current may be i

by many times this amount, due to the fact that the e.m.f. wave
alternator may differ appreciably ffrom a sine wave. This last
should be carefully investigated if a high degree of accuracy is desif'
is evident, from inspection, that Figs. 10 and 11, are not capable of
geometrical solution.
28. nominal ir line is shown in Fig. 12, and the vector diagram is
in Fig. 13. The condenser current le/'i leads Er by an angle of ('

and is readily combined with the current / to form the total current

\ /„ = \/(/ cos #)'-f-(/ sin e-Ic/2)*

cos 6(, = I cos 0/It
where cos S and cos 6o are the load and resultant power-factors, respect.,;^

022
I
 POWER TRANSAflSSION Sec. 11-24

n $ becomes negative, when I leads Er, but the square of the second term
ider the radical still remains positive.
1 The problem is then treated by the method employed in Pars. 12 to 17.

loX

Er
(b)
-Vector diagram showing effect of line charging current.

14. Example
of calculation of a three-phase with capaci- system
"idce considered. Power to be transmitted, 50,000 kw: Substation or
;.eiver voltage, 140,000 volts. Distance, 120 miles. Fuequency, 60 cycles.
!ll-load power-factor, 0.90. Spacing of wires, 14 ft. Allowable power loss
i line, 10 per cent, of power at receiver. Power lost in each wire =
.'00,000/3 Voltage to neutral (receiver) = 140,000
= 1,667,000 watts.
• _ 5 000 000
/3 = 80,830. Load current per wire = 3 y ^830 X 90 "^^-^ amp.
ifsistance per wire = 1,667,000/(229.2)2 = 31.75 ohms. Resistance per
le = 31.75/120 = 0.2646 ohm.
'rom Table 40, 0000 copper or 336,400 cir. mil. aluminum have the
I rest resistance, 0.272 ohm per mile. Use aluminum on account of its
tater diameter. The total resistance is 0.272 X 120 = 32.64 ohms,
lim Table 43, by interpolation, the reactance per mile of wire = 0.795
Cq. Total reactance = 0.795 X 120 = 95.40 ohms. From Table 45
't charging current per mile per 100,000 volts is found to be 0.541 amp.

^lal charging current, = 80,830 X 0.541 X 120 ~ 42.57

,
, . .. ,_ „,
amp. Charging
.

TririTinfi

drent at the receiving end of the line 7^/2 = 52.47 /2 = 26.24 amp. From
ill. 15 and 16, Par. 23, Jo = V'(229. 2X0.90)'+ (229.2X0.4358^26^47'-
i2.0 amp.
s cos 9„ = (229.2 X 0.90)/219 = 0.9420
Ji= 219. OX 32. 64 = 7,148 volts. JX = 219. 0X95.40 = 20,890 volts. By
cation (8)

!7. = 80,830\/(o.942O+|;^^)'+(0.3355+gg0) = = 96,2OO volts.

tTien the receiver load is removed, the substation voltage will rise, due
1< he line charging current flowing through the inductance of the line. On
oju circuit from (b) Fig. 13, E, will be:
e s .

Er=yJE,^-(^Ry+^^X (17)

he ~R term is negligible. £r = 96,200 + (26.24X95.40) =96,200 + 2,500 =

«i 00 volts.
•egulation = —
98 700 '
p.
80 8^0
'
or 22.10 per cent. Efficiency = 50,000 X 10'/
[5)00X10» + (3X219.0»X32.64)]or91.4 per cent.
i. The analytical
or complex solution of a nominal t line having
aieciable capacitance may be obtained by adding the voltage drop due
toie load current and to one-half the total line charging current (passing
thugh the line impedance) to the receiver voltage.

E, = e+je' = Er+I (cos 0-jaine) (R +jX) +~ (ff +}X) ( 18)

•'•e£j = the generator voltage from phase wire to neutral; .Er = the receiver
cige from wire to neutral; 7 = the load current; fl = the phase angle of

923
 '

Sec. 11-26 POWER TRANSMISSION

the load; 22 = the resistance per wire; X = the reactance per wire; ai
/e = the total charging current. The geometrical position of each quanti
is. shown in Fig. 14.
This diagram determines the effect upon the generator voltage of differe
load conditions at the receiver, the receiver voltage being kept constant

afc = + jIcR/2
6c = - IcX/2
cd = + IR cos e
de = + jIX cos e
e/ = — jIR sin
fh = IX sin
-j-

Fig. 14. —Vector diagram of line using complex quantities.

S6. Constant load and variable power-factor. Since the receiv
voltage is assumed constant,
triangle abc (Fig. 15) will not change. Triangl
cde and Triangle cde will not change, since / cos is fixe
efh are similar.
eA/ce-A/d«=(/Xsine)/(/X cos e) = tan9. J = P/(jEr cos 9) or / sin 6
P tan d/Er=Peh/Erce. As ce, P and Er are fixed, / sin varies as tan
Therefore the point h must move along eh, toward h' if the lag of the curre
increases and toward e if the lead of the current increases, and eh must
proportional to tan 6.

r''^.

Fig. 15. —
Constant load,
able power-factor.
vari- Fig 16. —power-factor.
Variable load, con«t«

S7. Variable load and constant power-factor. (Fig. 16). ej,

(IR sin e)/(IR cos 6) =tan 0.
Since cde and efh are similar triangles, ef/cd = eh/ce = tan $.
Therefore, angle ech = 0, which is constant, and h must always lie on ch.
Since cd and de are both proportional to /, « will move along ce and
will always be perpendicular to ce. 6' shows the construction for a leadi
current.
38. Constant voltage maintained at receiver by use of syncbrono
apparatus. The generator voltage, assumed constant, will move ak
arc hthi (Fig. 17). The length cc
equal to / cos (R + iX) at no-lo
It is then proportional to the po>
taken by the synchronous appaxat
and ei will move along cet with more
of load. eihi is equal to / sin * (/
jX), hence is proportional to the <i»
rature component of the current
order to maintain constant rei
voltage, with increase of loail
must decrease until at ej it is e<|i
Fig. 17. —
Constant voltage at
receiver.
zero and this point must corrcspn:
unity power-factor. With fu
increase of load eihi reverses and
> current leads as at ejAj. This condition may be obtained by coinpoumii
or by changing the excitation of the synchronous apparatus, either bi
matically, or by hand.

634
 POWER TRANSMISSION SeC. 11-29

29. Example of analytical solution of nominal v line usintr com-

iw quantity. Consider problem of Par. 24, see Par. 26, Eg = 80,830 +
3.2(0.90-/). 4358) (32.64 +>95.40) +
(J52.47/2) (32.64+y95.40)=80,830
:3,735+;19,680-y3,260-;"29,540+j857 -2,500 = 94,600+^17,280 or 96,200
Its (absolute).
U no-load 96,200 = + (y52.47/2)(32.64+;"95.40).
.E:r

The quadrature resistance drop is negligible. Hence .Er«»96,200 +

(.24X95.40) =98,700 volts, which checks with the result obtained in
Ir. 34.

Exact methods of calculating regulation may be desirable if the

10.
long, the line voltage high or if harmonics be taken into consideration.
l> is
)uch methods involve the distributed nature of the line admittance.
1-mulas for such lines expressed in circular trignometric functions are very
ciplicated. If hyperbolic functions* are used the relations become quite
B pie.
1. The general equations of the transmission line in hyperbolic
fictions are:
El = Et cosh VZY ± Iiy/Z/Y sinh y/zY (19)
/i =/2 cosh VZY ± {Et IVzJy) sinh VZY (20)
K^re .Bi and E% are the respective voltages from phase wire to neutral at the
B<ling and receiving ends of the line if the positive sign is taken. If the
native sign is taken E\ and E^ are the respective voltages at the receiving
a sending ends of the line. The same relation holds true for the currents,
I nd li. Ordinarily the positive sign is used, as the receiver voltage and
Icl current are generally known.
is the impedance per wire = ii+;X, and Y is the admittance from phase
wi to neutral =G+yB, though the leakage G is usually negligible in an
A'lal line.
xpanding the cosh and sinh terms in a converging series by Maclaurin's
Torera, and neglecting the terms after the second, the following expressions
»i obtained:
£:i=E2 (14-Zl'/2) ±Z7j(l ZK/6) + (21)
/i = /2 (i+zr/2) ±y£2(i+zr/6) (22)
t. Example
of calculation using general equation Par. 31. Con-
si again the problem of Par. 24.
r

= Ej = generator voltage, £2 = £^r = receiver voltage = 80,830 volts.

Z'e + ;Z = 32.64 + y95.40, Y= (?+ jB = + i6.49 X 10" <, I\ = generator
cient, to be determined. 7j = /(cos e- j sin e) = 229.2(0.900 -yO.4358) =
2(3-;99.88. Applying equation (21)
g:80,830[l + (^^-^+^Q-^-^0^^^-«-^»X^"-) ] + (32.64+.^5.40)(206.3-,^9.88)
[•^ ^
(32.64+i95.40)06.49X10-<) l

=94,340 +yi7, 164 = 95,900 volts. (Absolute)

le no-load receiver voltage and the regulation may be found as in Par.
Mlq. 17.
kewise /« is readily determined.

/,=(206.3-y99.88) [i+(32.64+y95.40)(y6.49X10-«)-|

+ (32.64 +i9o.40) (6.49 X

10-«)1
+ 0'6.49X 10-<) (80,830) [1

= 201.8 -y42.70 = 206.2 amp. (absolute)

aphic diagrams or charts are available for giving the vector values of
"""(Vzy) and cosh (VZY) in (19) and (20) without having to compute the
exiiaions contained in (21) and 22). See Bibliography 13 and 14.
vennelly, A. E. "The Application of Hyperbolic Functions to Elec-
trical Engineering Problems." McGraw-Hill
Book Co. Inc., 1916.
"Artificial Electric Lines." McGraw-Hill Book
Co. Inc., 1917.

925
Sec. 11-33 POWER TRANSMISSION
S3. Equivalent "T" line and equivalent "ir" line. A simple or
nominal T-line, Fig. 18, iu which the entire line admittance is considered as
being concentrated at the center, may be converted into an equivalent
T-line by multiplying each linear im-
B tanh 6/2 *' -* tanh^/2
pcdance Z/2 by tanh - /-, where 9

A^vr- —isms^ e/2

^oooob^ /Vv-
yjz »B ^
Y and by multiplying the total
admittance Y by sinh 6/9. If the
equivalent constants Z' and Y' be
ipy^y used in computations, the line as far
as the terminals A and JS and be-
yond are concerned will behave in
steady state as if the line ad-
-*B the
mittance were uniformly distributed.
P'la. 18. —
Equivalent "3"" line,
Tables of the conversion factors
sinh 9/9 and tanh B/e are given in Par. 46 and 47. „ v j
Fig. 19 shows a nominal H line of linear impedance Z=i?+j A, and a
capacitive admittance, F/2, at each end of the Ime. If R-\-jX\>b multiplied

by (sinh and r/2 by (tanh 6/2) /{e/2), where

e)/d, 9 = VzF, the line as
far as theends (and beyond)
are concerned will behave in sinh
the steady state exactly as
if the line constants were
uniformly distributed. The
new line is then considered
an equivalent T-line and its
characteristics are then calcu-
lated by the method of either
Par. 24 or 26.
34. The
potential
relation
and current
of
Fig. 19. —
Equivalent "x" line.
along: a line can be ex-
pressed simply by hyperbolic functions. A line AB, Fig. 20, has a uniform
total conductor impedance Z, a uniform total admittance Y, and a load at
B of Zi ohms impedance. The vector hyperbolic angle of the line is 9 =
y/ZY. The hyperbolic angle of the line, including the effect of the load
,
impedance Zi, is 9'= 9 -t-9i,
I

r* 7}^ *i
where 9i = tanh~^ — -z=rr
Vz/v
The hyperbolic angle of ti

line to any point P, h units

distant fromB, is 5p = ha + 9i,
where a — ^/zy, the propa-
gation constant per unit
length of line: {z is the imped-
ance per unit length of line,
and y the admittance per
unit length of line). Like-
-Relations of potential and current wise, the hyperbolic angle
along a line. Sc to any point C, h units
distant from B'\s ic= Ua-\-6\.
The relations of the voltages, currents, impedances, and admittances an-
as follows:
Vp _ sinh ip /p cosh ip Z^ tanh <> Fp cot h ip
(See Par. 50 also.)
Vc sinhic' Ic cosh4«' Zt tanh «c Yc coth a«
80. Charts and diagrams, when drawn to a sufficiently large scale, are
convenient for determining the electrical characteristics of transmission
lines. It is essential, however, that the precision and limitations of the
curves be known. Even if great refinement of calculation be desired, »ucb
diagrams are useful for checking computed results. In a handbook it u-
not possible to present the diagrams on a sufficiently large scale. It haf
seemed wise to explain their construction, with data, their methods of use
and also to refer to the original articles in which they are described.
 . —
POWER TRANSMISSION Sec. 11-36

36. The Perrine-Baum * regulation diagram, originally proposed by

F. A. C. Perrine and F. G. Baum and based on the diagram shown in Fig. 13,
forms a convenient method of studying transmission line regulation. To
facilitate use of the diagram, the effect of phase displacement is taken into
account by rotating the impedance triangle BDC. _

The load current is proportional to 1/cos = sec 9, and the impedance

drop, being directly proportional to the load current, is obtained by laying off
the phase angle as shown in Fig. 21o. If BD is the impedance drop for unity

^70

->\ ^y /<

"'^'^lo. 21a. Fig. 216.

Fig. 21. —Perrine-Baum diagram.
power-factor, then BD' = BD
sec 9' is the impedance drop for the power-
tactor cos d', and BD" =BD
sec 6" is the drop for the power-factor cos 6",
etc.; that is, the impedance-drop vector always terminates on a straight line,
drawn at right angles to the drop BD
for unity power-factor.
The diagram is shown in Fig. 216, in which the line capacitance is neglected.
Its use will be clear from the following example:
37. Example of calculation using Perrine-Baum regulation
diagram. Assume 1,000 kw. to be transmitted to a substation at 0.90
power-factor, lagging, the voltage at the substation to be maintained
oonstant at 10,000 volts. The line has a resistance of 8 ohms and an in-
ductive reactance of 15 ohms. The line capacitance is neglected. With unity
power-factor, the line current is 1,000,000/10,000 = 100 amp. Referring to
Fig. 21(6), lay oS OB = 10,000 volts, fiC = 100 X 8 = 800 volts, and = 100 CD X
.15=1,500 volts. If the power-factor were unity, OD
would be the voltage
it the generating station. To determine the generator voltage for 0.90
;power-factor, lagging, draw GH
perpendicular to BD
and lay off to the
right of an angle, BD
•^ DBF, whose cosine is
equal to 0.90. The line
impedance drop will be
BE =IcR/2 represented by BF, hence
_ y OF shows the voltage at
-. .

ctB—leX/Z
,
the generating station for
this power-factor. For
any other power-factor,
„ — cos fl, lay off the angle 9
^r to the right of BD for lag-
Fig. 22.- Effect of charging current. ging currents, and to the
left of BD for leading
•urrents. The voltage at the generating station will be determined by the
ine joining O with the terminal of the line impedance drop for the given cos 8.
for other loads, hence other values of line current, BD is divided into
)roportional parts, and lines parallel toOH are drawn as shown. For example,
.he voltage at the generating station at one half-load and with a power-factor
.>f 0.9 (lagging), is represented in the diagram by the line OF'.

I
— —
' * Bibliography 1

927
Sec. 11-38 POWER TRANS.\fISSION

Line capacitance is taken into account by assuming a constant load voltage;

from this assumption the charging current is calculated, taking this current as
in quadrature, leading, with respect to the receiving voltage, if the power-
factor is unity. The drop due to the charging current in one-half the liw
impedance is laid off from the receiving voltage vector as shown in triangle
BEB', Fig. 22 (also see Fig. 14), and the usual impedance triangle B'CD
constructed from B' the end of the vector representing the impedance drop
due to the charging ciirrent. The usual diagram, sucn as is shown in Fig
21, is then constructed upon the impedance triangle. It will be noted that
this method assumes that the charging current is fixed in phase and magni-
tude, which, though not strictly accurate, is sufficiently so for most purposej
in overhead line calculation, except for lines of great length.
38. The Mershon* diagram. If the e.m.f. diagram shown in Fig. 3 if
rotated about O as a centre through an angle 8, where cos 9 is the power-
factor, and all e.m.fs. are expressed in per cent, of the voltage generated al
unity power-factor, the line
drop, neglecting the charging
current, being measured alonf
a radius with center O, then c
simple diagram for determining
regulation may be developed
Such a diagram is constructed
by drawing a series of concen-
tric circles ab, cd, etc. (Fig. 23]
upon a coordinate system o:
equal squares; a side of one o:
these squares is equal to th<
difference in radii between anj
two consecutive circles. Tht
radius OB is taken at 1(X) i>e:
cent, and the coordinate space:
may conveniently represent in
tervals of 5 per cent. Thi
power-factor is cos 9 and i.

numerically equal to the pro

jection of OB' upon the horizon
Having
Fig. 23. — Mershon diagram.
tal axis. definite lim
constants, and with a load o
f;iven power-factor, the resistance and the
reactance voltage drops are calcu
atedin per cent, of the receiver voltage. Starting at the foot of the ordinat
representing the load power-factor, follow this ordinate up to its interscctior
with the first circle, which is the locus of the point B of the impedance triangle
From this last point lay off on the coordinates the impedance triangle. Th
circle upon which the apex D lies will give the per cent. drop directly. Th
diagram constructed to scale is given in Sec. 12, Fig. 11, and the table of See
12, Par. 31 is calculated for use with it.

An example illustrating the use of the Mershon diagram is given in Sec,

12, Par. 36. , ^ ^ i
39. The Dwight Chart,t shown in Fig. 24, gives a simple method <
determining regulation. With the original chart the precision is stated ti
be better than one-half of one per cent, but on account of the reduction i'
sire from the original, the precision obtainable with Fig. 24 is slightly lei
than this. The directions for use accompany the diagram.
40. Resistance of transmission-line conductors will be found in th
tables given in Sec. 4, under the appropriate sub-heads.

TABLES OF INDUCTIVE BEACTANCE AND CHARQINQ CURREN,'

41. The inductance and capacitance of transmission lines m»
be calculated from the formulas given in Sec. 2. The values of inducti^
reactance and charging current for wires of standard size, with usual spacmi
up to 20 ft., at both 25 cycles and 60 cycles, are given in the tables in Pa,
42-46. Nineteen strands arc assumed for cables of 750,000 to 350,000 cir. nu
• Mershon, Ralph D. "Drop in Alternating Current Lines." Tr
American Electrician, Vol. IX (1899), p. 220.
t Dwight, H. B. "Transmission Line Formulas. D. Van Nostrand e
928
 - '

POWER TRANSMISSION Sec. 11-39

inclusive. Seven strands are assumed in the smaller sizes. The effect is the
different number of strands on the reactance and charging current is very small.

Tables 46 and 47 give the hyperboUc correction factors ?^^hl and *?:^*.
e e

DWIGHT CHART
roK OrrtRMNINQ TH£ VOITAOE REQUUkTION Of TBANSMISSKDN aRCUrTS OONT&lNlNa CAPACfTANCt

OOmtCT WITHIN APPROXmuTElY ONE HAl^ Of ONE PER CENT A^^

Of UNC VOLTAOE FOB 1JNE8 UP TO WO MILES U3NQ *N0 FOR .ue^°'
'
UM08 OIVINQ NOT MORE THAN 16 PER CENT —,t^t
•"TANOE OR REACTANCE V01.T8 . pC^
\t»

of
wo^^
itOP
L^-f^^
fti^^

lOlUAOINO

-J 0%'^ f-

(0
u
-I

o
o

DIRECTIONS ^oT
"
! A STRAJOMTC DOE ACROSS
ART FROM THE SPACINQ PONT
Hv^
•0 RESISTANCE POINT. AND READ V.
^A
Short i imfc
IE EPROP IN PER CENT Of E
.!20ooo^!Aj<iv„^^„
,

te 1*0^8 g»'<vA«i.y
^^^ 65
70 ,
,-v.tnurM OF LINE IN MILES
//,
i! '
~ yS,™^T*OE AT LOAD OR RECEIVER END ^
wiT??/]/*? ""^ °'^'''' ^ REPRESENTS A DROP IN
LiitS^r^"!'"'"^ """ O" ™E SAME SlOE OP THE ZERO r
1^4 ^ 'tITe S^'pgs'lTfIiD^'"-
""* * "'^ '- '°'^*°' ""^•' ^'
Sec. 11^2 POWER TRANSMISSION

a r
^ 2

§ 2!

5 o

S g
POWER TRANSMISSION Sec. 11-42
 Sec. 11-43 POWER TRANSMISSION

\
POWER TRANSMISSION Sec. 11-43
Sec. 11-44 POWER TRANSMISSION
POWER TRANSMISSION Sec. 11-44
 —
Sec. 11-45 POWER TRANSMISSION
—
1
"-^
POWER TRANSMISSION Sec. 11-45
 Sec. 11-46 POWER TRANSMISSION

in IN 05 COIN
nnnnn nnmnoi INtNr-l-Hi-l 00050>l35 OOt^t-
(NNININN ININN(NIN IN IN IN IN IN (N IN <->-" --l ^ i-H >-l

C<1 00 Ttl 00 rjt

i
POWER TRANSMISSION Sec. 11-46
Sec. 11- POWER TRANSMISSION

o
 POWER TRANSMISSION Sec. 11-46

ooco (M O 00•-<
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00 050r-r}<00 O30r-<10 00
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Sec. 11-47 POWER TRANSMISSION

t-(— t-b-t- t^t^h-WtO OCOiOiOl*

^^^Tj*T}< ^Tj<'^-^T}< ^^^^^ Tjt rJ4 ^ Tj< Tj( COCOW

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^DioooooM
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cooorooow coioioroo "nioooo

ooot^'n^ roiN—iOO t>.«o>nOTi-i O100-*.
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 POWER TRANSMISSION Sec. 11-47

MM MMM(NIN IN rq M IN N

t^N OC:lN-*«0 -UMi-ioOM

-H-.JI OCC^WO t^OJ-HiN-* lOt^OOOJO
cDwt^t~t~ r~t^oooooo xooooxg? ogsgsc; o g?
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C<<«i-ii-iOO IN-*-<JiS<l» Ttlt-O0l>>0 MOOC^l^

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<000 OOOOO

-<tO 0-*t^OIN C5-*- 000-*OiO OMCDOOO

050 C<lMif.Ot^ 00O5C
00
 ' 1

Sec. 11-47 POWER TRANSMISSION

<COr-(N00

t»aoooaooo oioooiO a)a>a)(3>o a>o>a>aia> aaxc

r-osoooco (NOc^Oit^ ot^oo-^o OS iO T}< r-* <i< cc^ot^

t^O»OCCcD CCCO005OO5 t^-X-'t^^'^O o^^-^t^"^ r-COM
00505C105 O^-iC^^O OiC^OO^O O'0»-<t^^ i-<Oit*
C«5c«3'<fiOO OOOSO^M CCncOOOOS i-i(M <»i lO 05OM
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t>-
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doOod OO^^'H rt.-^,-HrtrH ^^w^-H ^^^

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,

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^lOiCU^iO »0»0»^»010 iO»^iCiCiO »0»0OU5»0 ^ *!*< ^

00 00 to 050 03 50 0; -^t^
06 occult- to t^-HOOh-O >1<!N(N>00
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i
 POWER TRANSAflSSION Sec. 11-47

CO c^ -HOC in C^ -Ht^CMt^
00 coco O)
t^coaONcD
^ O CO "n
0> 00 CO
r)» T)!
t^ 0> 00 1^ i<:i CO .-I

oooo t- 1>. ir> cc "O lO'^coc^i-H rnooooto lO'^eoc^'-i

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05 t^ai i-ioo
COC^ >-hOOi O0t^lCTt<-M t~COt^ — (M
r» 05 -^ CO lO <D00O --N CO -^ Tt- tC lO »C
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C^O OOOCJOOO ^»(NCOO!C0 O-^t^t-u? "COlNiMt*

coo
1~
1-1
Sec. 11-48 POWER TRANSMISSION

SYSTEM DISTURBANCES
Surges* and disturbances occur in a transmission circuit, whe
48.
circuit conditions are in any way altered. An oscillation is a recurrin
disturbance due usually to the oscillation of energy between the electrostati
and electromagnetic fields. An oscillation of low frequency, or one that i

rapidly damped, ia called a surge. Disturbances may be produced b

causes within the system itself, such as switching, grounds, changes c
load, or they may be produced by external causes, such as lightning.
In an oscillation, the energy passes from one form to the other, so thai
assuming no loss,
iI,i2 = JCe2
or
e/i^y/L/C (23
e isthe voltage produced by a sudden suppression of the current i. L and (

are the line inductance and capacitance respectively. If the line resistanc
and leakance are negligible, the term y/L/C is usually called the natura
or surge impedance of the line.
From Eq. 23, the maximum voltage possible to occur on suppression o
the current / is:

e = lVL/C (24
This rise of voltage limits the current that may safely be interrupted am
renders a short-circuit dangerous.
Any change in load will alter either e or i and as the energy of th
electrostatic and electromagnetic fields cannot change in zero time, e and
must pass through some transient values before the steady state is agaii
reached.
If r, the resistance, is equal to or greater than -s/L/C, the transient is non
oscillatory, and quickly dies out. If r is less than y/h/C, the transient
|
oscillatory. The energy is dissipated as heat in the resistance, in hysteresi
losses in the fields themselves, or the insulation of the system may breal
down allowing the energy to manifest itself in an arc.
In the above relations the constants of the line loads and of the termina
apparatus have been neglected.
49. The frequencjy at which the transient oscillates is

/= l/(4v^) (25
when the open at one end and grounded at the other. If the line i
line is
open at bo*h ends, / = 1/2 VXC
/ is the natural frequency of the circuit
The transmission frequency should be so chosen that the natural frequenc;
is not exactly an odd multiple thereof.

60. A wave of potential or current attenuates in magnitude ani

phase as it travels along a transmission line. The propagation constan
per unit length of line is a and the propagation factor is «""=«"*;
X «"'**', where « is the Naperian logarithmic base, and o = ai+/<n«
\/zy = ^/(r + jlo>) {g + jcw) z, r, and I are respectively the impedancf
;

resistance and inductance per unit length of line; y, g, and c are respectivcl
the admittance, leakage conductance and capacitance per unit lengtli of lint
a)-'2ir/, where /is the frequency; r and z arc cxprcssetl iu ohms, y and gi
mhos, I in henrys, and c in farads all per unit length of line, ai is the attenu
ation constant and on is the retardation angle per unit length of lin<
If the line is long or if its terminal load impedance is equal to the line surg
impedance, e""^ gives the shrinkage in amplitude of the current or volts?
per unit length of line; t'jai has the properties of a circular angle ai radial
and is the factor which shows the lag (space phase) of the wave occurring i-
eacn unit lengtn of the hne. After a wave has traversed /'units length <
the line, its phase lags behind the wave then being delivered by the generate
I'at radians, a = ai + jVa >nay also be called the hyperbolic angle p^^
unit length of line. As an example, if o = 0.000072 +
j 0.0007854 hype:!*
bolic radians per mile, an initial voltage wave of 100 volts traveling along ti

• Bibliography 27-30.

946
 POWER TRANSMISSION See. 11-51

line becomes 93.05 volts at the end of the first 1000 miles and lags 0.7854
circular radians or 45 deg. behind the wave then being delivered by the
'Generator. Roughly, in each unit length of line, a wave shrinks in amplitude
by an amount equal to ai times its initial ampUtude.
1 Over the entire line of length i>, an initial voltage wave attenuates to a E
'voltage El where Ei = Ee-^ = £7^-^^-^^^ = EU'^^ X t~^^^); e = l'a; ei = l'ai;
St = J'az;
d is the propagation constant of the entire line. 9i is the attenuation
jonstant and 02 is the retardation angle for the entire line *~^i is the amount
current or voltage wave traveling along the entire line shrinks in amplitude,
a.

and such a wave lags 6i radians behind the wave then being delivered by
the generator, a single wave only being considered.
A wave of frequency /travels over the line with an apparent or group velocity
5= — , where w = 2ir/. If 02 is given for one kilometer of line, t = kilometers
as
oer second.
If r = 0, and ff
= 0, r= 1/ -s/lc. For a free, uniform line surrounded by air,
n which the internal inductance is neglected, v is 300,000 kilometers per
iecond very nearly, the velocity of light. The actual velocity of propagation
i)/a2 is less than this, due to the presence of resistance, leakance, etc., which
lissipate energy.
The wave length X = 2T/cn, holds for the steady state and for the transient
itate as well. X is the distance a wave must travel to lose one cycle or 2ir
adians with respect to the ge nerator phase.
'
The complex quantity \/(r + }lu)/{g + jcoj) = y/z/y = zo is usually
surge impedance, the natural impedance or the character-
^lled the
'stic impedance of the line, zo is the impedance that the line offers
\X any point to an advancing wave of the frequency under consideration.
:rhat is, the current t = e/zo, where i is an advancing current wave, and e the
orresponding voltage wave. If the resistance and leakance be neglected.

The surge or natural impedance of the ent ire li ne is Z« = -s/Z/Y. If the

esistance and leakance be neglected, Zo = "wIi/C = y/l/c.
The propagation constant wZY and the surge impedance y/Z/Y both
ppear in equations 19 and 20, Par. 31.
61. Forced oscillations are produced by a source of energy external
o the circuit, such as lightning, whose frequency has no relation to the
:rcuit constants. The frequency of such oscillations is that of the source of
:iergy. The disturbances which often follow such forced oscillations have
re<iuencies that are determined by the line constants and the terminal
Qpedances.

j
.62.E&ect of transients. When a traveling wave passes from one part
f a circuit into another of different constants, the voltage wave, ei, will
hange its magnitude to ej, as follows.

nd the current
(^)
. . Zi
rZi + Zt\ (27)
(^^)
here Zi and Z2 are the_surge or natural impedances which are equal,
eglecting losses, to \/Li/Ci and yJht/Ci of the two parts of the circuit,
•ispectively. (See Pars. 48 and SO.) Thus a wave passing from one part
: a circuit to another having a greater ratio of inductance to capacitance
ill develop an increased voltage and a decreased current. This explains
le breaking down of transformer windings, due to surges entering them.
n the other hand, if a wave passes from an overhead system into a cable,
le voltage will be reduced, and the current increased. This explains the
If-protecting quality of cables to surges.

947
Sec. 11-53 POWER TRANSMISSION
55. A line whose length is a quarter wave is determined as a fin
approximation by

where L is the length in miles, / the frequency in cycles per sec, and 186,00
the velocity of light in miles per second and also the velocity of an electri
wave in miles per sec. if all losses be neglected. Actually the wave velocit
is much less than this value owing to the presence of resistance, leakanci
etc. It can be shown that such a line, with constant generator voltagi
tends to regulate for constant current at the receiving end, and the mail
tenance of constant voltage at the load therefore becomes difficult. Th
voltage may rise to dangerous values when the circuit is open, though a loa
at the receiving end tends to neutralize this abnormal potential. The fn
quency corresponding to a quarter wave length of line is the lowest frequenc
at which the line can freely oscillate. It cannot oscillate at a frequenc
corresponding to either a half or a whole wave length when the circuit i

open at one end.

64. Oscillations originating in the transformer. High voltag
transformers have an appreciable electrostatic capacitance between turni
and also to ground, together with a large equivalent reactance. This not on!
tends to create very high frequency oscillations in the transformer itself, bu
also to produce voltage rises that may puncture the insulation. Protectiv
apparatus must therefore be so designed that these oscillations ma
be suppressed within the transformer or readily pass from the transformc
to the line, while, at the same time, outside disturbances will be prevente
from passing in the reverse direction.
56. Lightning disturbances* may be due to a charge induced on tb
line by a nearby cloud which discharges, thus allowing the line charge to flc
suddenly to ground; toinductiveactionof a nearby discharge; todirectstroki
Such disturbances may be of high frequency and may either start a destru(
tive arc to ground or shatter the insulators near the spot of original disturl
ance. Waves may be propagated in both directions, causing damage s
some remote point.
66. Lightning disturbances may
be minimized by the use of on
or more overhead ground wires, grounded at frequent intervals. Darnag
to apparatus may be practically prevented by installing arresters, prei
erably of the aluminum cell type, near the apparatus, for example, acres
the high-tension bus bars at the generating station; at substation entries
and near outdoor transformers and substations. Lines have been protecte
by operating them just below the critical corona voltage (see Par. 65 to 69
Any disturbance that tends to raise the voltage, immediately increases th
corona loss to such an extent that the energy of the disturbance is thereb
dissipated.
67. The selection of protective equipment is governed somewhat b
local conditions. The degree of protection necessary depends largely upo
the value of the power that is being transmitted, and the financial loss ii
volved by a shut-down or by an interruption of the service.
58. Local short-circuits may be isolated from the rest of the system b
properly selected automatic oil switches equipped with relays which are <

either the instantaneous, reverse-energy, or inverse-time-limit type

Lightning arresters should be able to care for any abnormal voltage rise di
to switching. (See Pars. 48 and 97.) To prevent the current flowing into
short circuit in one portion of the system rising to dangerous values, powe„
limiting reactances are interposed between the different sections of tig
system. |i

69. Detection and clearing of grrounds. Grounds may be detected V

some form of electrostatic detector, placed on the switchboard. An arcin
ground on an ungrounded system may be cleared by the arcing grour
suppressor, shown in Fig. 25. The selective relay may operate electn
statically, or electromagnetically by the use of potential transformen

•Creighton, E. E. F. "Protection of Electrical Transmission Liness

Trana. A. I. E. E., Vol. XXX (1911), p. 257.
*

948
 POWER TRANSMISSION Sec. 11-60

W^hen a ground occurs on any phase, that phase is temporarily grounded

oy the proper oil switch, selectively operated by the relay. This lowers
ihe voltage across the arc, which therefore ceases, and the switch then opens
[through a resistance to prevent ^
Oscillations) and the groundis thus
i;leared. In a cable system the
'srounded phase is permanently
,;onnected to ground, as otherwise
;he arc would immediately re-form
vhen the switch opened, due to
he short distance between core
ind sheath. Interlocking devices
)revent the siniultaneous opera-
.ion of more than one switch at a
ime, thus avoiding a short-circuit
in the system.
A short-circuit suppressor o s ^
hrows a fuse directly between Fig. 25. — Arcing-ground suppressor.
)hases, shunting out a short-cir-
uit arc. Subsequently the fuse automatically interrupts its own current.
Vhon these are used, power-limiting reactances are desirable in order to
irotect apparatus from mechanical injury.
60. Overhead ground wires unquestionably reduce the interruptions'
o service due to lightning, although there are no available data stating just
ow great the advantage is. It is estimated that one wire will reduce these
itcrruptions about oO per cent., and that two wires will make a still greater
eduction. Galvanized iron and steel, because of their low cost and high
ensile strength, have been commonly used for this purpose. Copper-clad
onduotors may have a lower impedance to the high-frequency discharges
"
lightning than either galvanized iron or steel. <

QENEBAL FEATURES OF DESIGN

61. The
conductor for a given transmission system is influenced by such
iCtors as climate, topography, length of span, reliability, amount of power,
ausniission distance and the economics of the problem. Copper,
iuniinum and aluminum steel re-inforced (aluminum cable with a steel
irei (see Sec. 4), except in special cases, are used extensively for the con-
ictors. Copper has high conductivity, is very ductile, is not easily abraded,
as high tensile strength, a high melting point, and can be readily soldered,
luniinum has a conductivity about 60 per cent, that of copper. For the
line conductance, it has only one-half the weight of copper. It is ductile;
iid easily abraded; has 1.4 times the linear coefficient of expansion of
•pper, giving greater sag, and would therefore require higher towers
)r the same length of span. The tensile strength of all aluminum cable
much less than that of copper, though the ratio of tensile strength to
I'ight is greater for aluminum. The tensile strength of aluminum steel-
nnforced cable compares favorably with that of copper. (See Par. 109.)-
ne melting point of aluminum is lower than that of copper, so that aluminum
ill be more easily burned by arcs and short-circuits. For the same con-
uctance, aluminum offers a greater surface to wind-pressure, so towers
lUst be designed with greater transverse strength. All-aluminum cable is
ot recommended for sizes smaller than 4/0. Neither copper nor aluminum
attacked by the atmosphere to any extent. In the United States, the
"ice of aluminum is always held slightly below that of copper of the same
tnductance. In view of increased cost of pole line necessary to its employ-
cnt, there is comparatively little incentive to use aluminum in small sizes
wire. In Canada and on the Continent of Europe, aluminum has found
vor.
62. For extra long spans, it may be found economical to \ise either iron
steel as conductors, because of their much greater tensile strength. As
ese metals are subject to corrosion, they must either be galvanized or
"opper-clad." Phosphor-bronze has been proposed, but its much higher
^t the same conductance practically prohibits its use. The table in
for
ir. 63 shows a comparison of various conductor materials, and more
laplete tables may be found in Sec. 4. ''• ii --lU•ijiw, :,

949
Sec. 11-63 POWER TRANSMISSION
63. Comparison of conductor materials on basis of equal
conductance

Metal
 POWER TRANSMISSION SeC. 11-65

COBONA
66. Electric Corona occurs when the potential of a conductor in air is
.raised to such a value that the dielectric strength of the surrounding air is
exceeded. Corona manifests itself by bluish tufts or streamers appearing
around the conductor, being more or less concentrated at irregularities on
the conductor surface. This discharge is accompanied by a hissing sound,
and by the odor of ozone. In the presence of moisture, nitrous acid is
produced. Corona is due to ionization of the air. The ions are repelled
'rem the conductor at high velocity, producing other ions by collision.
The ionized air is a conductor of high resistance and increases the effective
diameter of the original conductor.
If the distance between two insulated cylindrical conductors is small as
;ompared with their diameters, it may not be possible for corona to form, for
IS soon as the dielectric strength of the air is exceeded, it breaks down,
hrowing more stress on the remaining layers of air, which in turn break
^lown, and spark-over results. If, however, a sufficient distance exists be-
ween the conductors (about 15 times the conductor diameter), the undis-
lupted air may be able to support the dielectric stress existing between the
conductors, even although the disrupted air in the neighborhood of the con-
luctors has decreased the effective length of the dielectric path between the
onductors.
'

Corona represents an energy loss, which on a long transmission line may

le substantial. H. J. Ryan, R. D. Mershon, J. B. Whitehead, and F. W.
'eek have made important investigations of corona. Peek's tests were
nade on a line consisting of two transmission spans and having a total length
f about 900 ft., using various conductors, spacings, and at different temper-

turcs, etc. His conclusions are as follows:

The disruptive gradient of the air, go, is constant for all conductors and
equencies at 25 deg. C. and 76 cm. barometer, being 21.1 kv. per cm.
ffective or 29.8 kv. per cm. maximum, and is given by gi, = - ^— _, where
rlog.-
is the disruptive critical voltage in kilovolts to neutral, r the conductor
dius in cm., and S the distance between conductor centers in cm. If
1.1 kv. per cm. is used for go, «„ is given in effective volts.

o
Co = goMorS lege - (29)

e,. affected by the air density-factor S and also by the condition of the
is
ntiuctor surface, which is taken into account by the conductor irregularity,
tor Mo. Mo — 1 for polished wires; 0.98 to 0.93 for roughened or weatthered
>; 0.87 to 0.83 for 7-8trand cable. 5 = 3.926/(273-1-0; 6 = barometric
— ure in cm.; < = temp. in deg. cent.; 5=1 at 76 cm. pressure and 25
_•. cent.; log« = 2.303 logio; values of 6 for various altitudes are given in
ur. 67. The tables in Par. 66 give values of Co. ,,

Br, the voltage at which corona becomes visible is given by:

Er = MvgoSr(l +'^^) log.- kv. to neutral. (30)

^fl = Mo = 1 for polished conductors. When Mv = 0.72, localcorona exists

1along the conductor, and when Mv = 0.52 there is decided corona all along
('conductor for 7-8trand cables.
is always greater than Co.
Et Theoretically no corona loss exists until
is reached, but actually corona loss begins at the lesser value of voltage
due to dirt, irregularities, etc., on the conductor surface. With a truly
lindrical, highly-polished conductor, no loss would occur probably, below
e voltage Ev. The reason that corona does not become visible at the
'Itage eo is due to the fact that the gradient at a finite distance from the
nductor must exceed go in order to give the ions opportunity to attain
locity, and thus produce other ions by collision.
The power loss P in kilowatts per kilometer per conductor is given by
^ = f/"\/^(e-eo)nO-'. (31)

lore k = 344; /is the frequency in cycles per second; e the kilovolts to neutral
951
Sec. 11-65 POWER TRANSMISSION
effective (corresponding to £/o = 21.1 kv. per cm.), In English units tl
power losa becomes:
P = ——f'^^le—123AMorS logio -1' 10-^ kw. per wire mile. (3;

17.91-.&
where = effective volts to neutral S =
e « => 1 at 77 deg. f ahr. and 29.5
459 + t
;

in. barometer; 6 = barometric pressure in inches; r== radius of conducti

in inches; 5 = distance between conductor centers in inches; /=frequen(
in cycles per second; = irregularity factor; Mo = \ for polished wires, et
jVf,,

The above equations show that corona loss is proportional to the frequenc;
This holds true for the range of frequencies used in the tests, 47 to 120 cycl
per second. The law departs from the linear relation at low frequencie
At zero frequency, (that is direct current), the loss is from J'i to J-^ the©
cycle loss for the same maximum voltage. Humidity has no effect on tl
critical voltage or on the loss; smoke lowers the critical voltage and inereasi
the loss; heavy winds have no effect on the critical voltage or on the los
fog, sleet, rain storms, and snow storms all lower the critical voltage an
increase the loss. Snow causes a very marked increase in the loss, as show
by Fig. 26. In calculating foul weather loss, make Co equal to 80 per cent
of the fair weather value.

11

16
15
14
13
12
 POWER TRANSMISSION Sec. 11-66

>6. Corona limits of voltage. Kilovolts between Conductors (three-

phase) at sea level
(Standard)
From formula eo= \^goM„rS log,- where Afo = 0.87

\ WG
Sec. 11-68 POWER TRANSMISSION
M. To decrease corona loss, either the frequency or the voltage may b«
reduced. These, however, are usually fixed. The spacing may be increased
but this decreases the loss but slightly, and the increased conductor spacinj
would increase the line cost considerably. As the meteorological conditioni
cannot be controlled, the diameter of conductor must be increased. This
may be done without increasing the conductor weight by using aluminum
hemp- or steel-cored cable, or hollow conductors. The use of aluminum and
steel-cored aluminum is the most practicable method and in future, it ma>
become necessary to use aluminum for very high voltage lines. Hempi-
cored cable has been tired, but the core soon rots and the conductor strands
becomes disarranged. Hollow conductors reduce the skin-effect, but the
cost of manufacture makes their use prohibitive.
69. Example of calculation of corona loss. Line, 3-phase; length oi
line, 140 miles; size conductor. No. 4/0 A. W. G. std.; 150 kv. between con-
ductors frequency, 60 cycles; spacing, 14 ft. Assume 20 deg. cent., 76 cm,
barometric pressure; coefficient of roughness. Mo = 0.83. S = 3.92 X 76/
(273-1-20) = 1.02; diameter of wire ^Par. 66) 0.530 in.; r = 0.673 cm.; S"
14X12X2.54 = 427 cm.; e = 150/ V3 = 86.6 kv. to neutral; ff« = 21.1 kv.
per cm.; logio S/r = 2.80; e„ = 21. 1X0.83X0.673X1.02X2.303X2.80 = 77.5

kv. to neutral; -P = pQ^60 \^~ (86.6-77.5)2X1.61X10-5 = 1.071 kw,

per wire mile; total corona loss = 1.071 X3X 140 = 450 kw. In practice
this loss would not be permissible,

LINE INSULATORS
70. Requirements. The successful operation of a transmission system
depends to a large extent upon the degree of insulation attained, and the
most important factor is the insulator. Up to a few thousand volts, there
is no difficulty whatever in maintaining good insulation, but as the voltage
reaches higher values, the difficulties increase and factors such as leakage
and capacitive effects, which are entirely negligible in low-tension systems,
become of major importance.
Insulators are made of glass, patented compounds, and porcelain.
71. Glass is cheaper than porcelain and when properly annealed has high
dielectric strength and high resistivity. As it is transparent, flaws can
readily be detected. On the other hand, moisture condenses on its surface
the action of rain destroys the smoothness of the surface and allows particlcf
of dirt to accumulate, diminishing the resistance of the leakage path. It ii
easily shattered. Glass is most commonly used for telephone, telegraph
and low-voltage insulators.
72. Patented compounds are on the market, having mcchanica
characteristics practically as good as either porcelain or glass. It is somewha
doubtful, however, if these compounds can successfully withstand _th'
combined effects of weather and the high electrostatic and mechanics,
stresses incident to high-tension power transmission.
Porcelain gives less leakage trouble, is stronger mechanically tha:
78.
glass, and is less affected by changes of temperature. On the other hanc
it more expensive, and slight imperfections in the glaze are commor
is
In its manufacture, underfiring produces good mechanical properties, bu
tends to cause porosity in the porcelain, which almost always results i
rapid deterioration and failure when in service. Over-firing minimiif
porosity, but makes the porcelain brittle. Clo.se control of the kiln tcmpe)'
ature has greatly improved the quality of porcelain. Porcelain has ,

tensile strength of about 1,500 lbs. per sq. in. and a compressive strength i^

about 40,000 lbs. per sq. in. As porosity and flaws, such as blow-hok .

cracks, and the like, cannot be detected readilv by simple inspection, eat ;;

section should be subjected to a voltage test before and after assemblin,. r

Because of its superior characteristics, porcelain is used almost universal

for high-voltage insulators.
74. Pin-type insulators are designed to operate up to 90,000 volts, i

are seldom used for voltages in excess of 70,000 volts. In the past it 1.

been found difficult to vitrify porcelain properly if the thickness was ti

great. Therefore, high-voltage insulators are made up of shells of modcra

954
 POWER TRANSMISSION Sec. 11-75

.hickness, cemented together with neat Portland cement, as shown in Fig.

:!9, each shell operating at about 15,000 volts.
75. Insulators have appreciable capacitance (of the order of 2X10""
and act like condensers of complicated construction. The dielectric
'i

arad),
s made up of alternate layers of air and porcelain or glass of varying thick-
lesses. Some of the charging current to the pin must pass over the surface
,)f the insulator, which has a very high resistance, so the insulator may be
epresented by a resistance, shunted by a number of small condensers, as
hown in Fig. 27. E is the voltage from the line to the pin, I the total current
aken by the insulator, ic the charging current of each of the shunted con-
1

Fig. 27. — Insulator, equivalent circuits.

enser, the leakage current. The vector diagram merely illustrates

and iV
le theory, and no attempt has been made to give the proper relative values
tlie various quantities.
) As the ohmic resistance of porcelain insulators
extremely high, most of the leakage occurs over the surface.
The minimum arcing distance and leakage path are shown in Fig. 28, as
!B C, and ab, respectively. That part of the leakage path on the top of the
ap and on the outer side of the petticoats often becomes conducting, due
rain, salt fogs, accumulated dirt, etc.
) The resistance is directly pro-
ortional to the length and inversely proportional to the sectional area of the
ith, so that beyond a certain point increasing the diameter of the petticoats

l"i>.-^>_:

IG. 28.
LP
—Arcing and leakage paths.
r
Fig. 29.
8*,-=^

—Pin-type
—-;

insulator.
368 increase the leakage resistance appreciably. Increasing the
not
Lunber of petticoats increases the length of path without necessarily in-
•easing the area, so that a high leakage resistance is best secured by in-
•easing the number of petticoats. The fact that porcelain has a permittivity
between 4 and 5 tends to produce larger proportionate dielectric stresses
1 the air spaces, with the result that corona tends to form, reducing the
cing distance and the leakage path.
7*-. A *high efficiency insulator design has been developed on
ientitic principlesby G. I. Gilchrest. In order to reduce corona, to decrease
*A. I. E. E. Trans., Vol. XXXVII, 1918, page 805.

955
Sec. 11-77 POWER TRANSMISSION
the impulse ratio (see Par. 80), to increase the arcing-over voltage, and tl
mechanical strength under electric stress, the insulator. Fig. 30, is co
-x,, structed with the following features: (1) Surfac
o conform to the flow lines of the electrostat
field; (2) Surfaces b of the rain sheds conform
the equipotential surfaces; (3) Unes of mecha;
ical stress are parallel to the electrostatic stre
lines; (4) the leakage resistance per shell
nearly constant, but is decreased gradually fro
the head to the center shell; (5) the capacitan(
is approximately the same for each shell.
'"'• Suspension insulators under favorab
c?ir~:i:rl
°*~^ conditions can be operated at an average voltai
—
Fig. 30. High eflSciency of about 20,000 volts per unit. They are use
insulator with electrostatic almost exclusively for transmission voltages i

field. excess of 70,000, as the pin-type insulator the

becomes excessively large, heavj', expensive, an
mechanically weak. When suspension insulators are used, the cost an
weight are practically proportional to the line voltage, but beyond a certai
point it is difficult to secure increased insulation even with additional uni:
(see Par. 78). There are two common types: In the Hewlett, or interlinkic
type. Fig. 31(a), the two suspension cables loop through each other and ai
separated by a layer of porcelain. In the cemented type, the porrelai
or glass is cemented into a metal cap, and the pin is cemented into tlj
insulator. Fig. 31(6) shows a one-piece cemented unit and Fig. 32 shows]

Fig. 31o. —Hewlett suspension Fio. 316. —One-piece

lator,
cemented
suspension type.
in
insulator.

two-piece cemented unit. The Hewlett type is used extensively for sti
insulators. It has the advantage of not being cemented in a metal d
The units are joined together by looped cables and by clamps. It is pi
ably more diflScult to replace than the cap and pin type. The cable nl
should be filled with cement in order to prevent water entering and t
freezing. The cemented type has given trouble, due to failures at the I
of the cap, and in design this factor should be carefully considered. !

present tendency in insulator design is toward smaller discs and closer s)

ing. This results in higher puncture strength for a given flash-over voltl
Fig. 33 shows the relation of the sizes and weights of insulators to tl

normal rating.
78. The string efficiency of n suspension-insulator units is the rati
their total flash-over voltage to n times the flash-over voltage of on(
Bulator. Although certain unpublished 500,000-volt tests have shown
ratio to be practically unity, the majority of experiments show thaf

056
 POWER TRANSMISSION Sec. 11-79

iring eflBciency decreases when the number of insulators is increased,

ig. 34 shows the results of the tests made by F. W. Peek, Jr.* This lowering
f flash-over voltage is due to the fact
lat each insulator has a certain capa-
tance to ground, the insulator near-
ut the line carrying the charging cur-
;nt of the whole string of n insulators.
he second insulator carries the charg-

—
FiG. 32. Two-piece cemented
insulator, suspension type.

100

oo

stti
Sec. 11-80 POWER TRANSMISSION
80. 'Effect of high frequency on insulators. Insulators that on]
flashover at commercial frequencies may puncture at the same voltage if tl
frequency be high. This is probably due in part to the altering of strei
distribution caused by the change in the ratio of susceptance to leakaf
conductance brought about by high frequency. It is also due in part to tl
corona not having time to form and relieve the stress by rupture of the ai
To prevent puncture due 1
high frequency disturbance
the ratio of puncture voltaj
to flash-over voltage should I
high.
The ratio of the impuU
flash-over to normal frequent
flash-over is called the in
pulse ratio. If this ratio :

too high, insulators punctui

through the head before flasl
ing over. Because of its hig
corona-forming voltage, tl
Jeffery-Dewitt insulator (Pa
86) has a high arcing-ovc
voltage and a low impult
The unusual thicknei
Fig. 35. —Strain insulator with yoke. ratio.
of porcelain prevents punctui
through the head in this typ
Therefore some engineers favor a high impulse ratio and some rfavor a lo
impulse ratio. Insulators having high impulse ratios should also have hij
puncture voltages.
81. Insulator testing is of two kinds, design tests and routine test
Design tests cover those features that are important to the purchaser, suj
as dry and wet flash-over, puncture voltage, tensile strength, and are usual
made on the assembled unit or string. The insulator should be tested uno
conditions approximatiug those attained in service, such as mounti,
or suspending from a grounded pin and cross arm, well away from otk
objects. The potential should be applied between the pin and a shi
length of cable, representing the line conductor, tied or clamped to <
insulator. The standard wet test is to spray water over the insulator
an angle of 45 deg. and at a precipitation rate of 0.2 in (0.508 cm.) of waj
per min. As results are largely dependent on the electrolytic nature of
water, distilled water is to be preferred, as more uniform results are obtail

by its use. Insulators, under ordinary conditions, flash over before pi

turing, so in order to obtain the puncture voltage, the insulators muaj
immersed in oil.
Routine tests should be made on each part of every insulator befort
sembling, and also on the complete unit. The object is not to flash ovej
insulator but rather to detect existing faults before the insulator i.s p^
service. The parts of pin and suspension type insulators are inverted in i

thus forming one terminal. Water is also placed inside the iiisu
covering the threads in the threaded parts, and from 0.5 to 0.75 in. (1.,
1.9 cm.) deep in the other parts, thus forming the other terminal as she*
a. Fig. 30. Dry tests are often made on the assembled unit, b, c, d, e|
• Imlay, L. E., and Thomas, Percy H. "High Frequency Tests ot
Insulators." Trans. A. I. E. E., Vol. XXXI (1012), p. 2121.

958
 POWER TRANSMISSION Sec. 11-82

() and are necessary on strain insulators and bushings. Free arcing testa
e obtained when the testing transformer has sufficient capacity to maintain
heavy power arc after flash-over occurs. The breakdown voltage of in-
lators is a function of the time during which the voltage is applied, as has
len shown by A. O. Austin.* A higher potential for a short time will
.minate poor insulators in the same manner as a lower potential for a
ager time. Such curves for 100 kv. and 85 kv. are shown in Fig. 37.
iius 100 kv. for one-half minute will eliminate 2.2 per cent., whereas
kv. must be applied 4.7 minutes to produce the same result.

6
Sec. 11-83 POWER TRANSMISSION
are accountable for the greatest number of failures. Some* companie
now use resilient material between the tops of the caps (Fig. 30) and sane

Fia. 38. —Nicholson arcing rings.

Fia. 39. —Arcing rods.

the surfaces between insulator sections in order to reduce these mechani
stresses.

* Austin, A. O. "Present Practice in the Design and Manufacture ki

High-tension Insulators." Trans. A. I. E. E., Vol. XXXVI (1917), p. 6' J
see p. 554.

960
 POWER TRANSMISSION Sec. 11-84

84. Arcing rings. Insulator petticoats are often shattered by the power
ire following a flash-over. At the same time the line conductors may be
burnt off by this same arc. To protect both
the insulator and the line, arcing rings, Fig.
38, arcing rods, Fig. 39, and the Thomas hne
protector. Fig. 40, are used. These devices
hold the arc away from the insulator, and
also prevent its burning off the hne wire.
85. The *Jeflerey-Dewitt Suspension
Insulator, Fig. 41, differs from the conven-
tional types in that the porcelain is in tension
1

rather than in compression and shear. To

eliminate the stresses occasioned by the un-
equal expansion of the metal and the porcelain,
the usual cap is replaced by a semi-flexible,
pressed-steel spider, set into the porcelain and
held by an alloy having practically the same
coefficient of cubical expansion as the porce-
lain. Other features claimed for this insulator
are that the surface gradient is nearly uni-
form, resulting in high corona-forming voltage
(60,000 volts), and high flash-over voltage
(100,000 volts). The thickness of the porce-
lain minimizes the possibihties of the insulator
being shattered by power arcs, or by rifle
Fig. 40. —
Thomas line shots and in addition gives a puncture voltage
of 300,000 volts. By a special process, and by
protector.
the use of a continuous tunnel kiln, it is possi-
ile to produce the thick porcelain of this insulator without
firing cracks,
orosity, etc. The insulator develops a tensile strength of about 9,000 lbs.

letter Pin ft'x li'

pider-Pressed Steel-
llot Galvanized
J.D. Alloy
J.D. Insulating PorceUin
Glazed all Qver
Grey Glaze-Standard
^ocolate Brown GUze-
^^
Special

I
Fig. 41. —Jefferey-Dewitt suspension insulator.

I
SYSTEM CONNECTIONS AND SWITCHING
1
86. System connections should be madein such a manner that
intinuity of service, flexibility, and safety are secured without undue com-
Lieations of wiring and switching.
fW. Duplicate lines are usually necessary, where continuity of service is
bportant. It is customary to run the two lines on the same poles or
iwers, especially if these are of steel or concrete, as the total cost of line
[ipports is th en much less than it would be for two individual pole lines.

rPeaslee, W. D. "Factors Controlling the Design and Selection of Sus-

jasito Insulators." Trans. A. I. E. E., Vol. XXXIX (1920), p. 1645.

961.
Sec. 11- POWER TRANSMISSION
Where the power is especially valuable, the two lines may be run over tw
different routes, removed from each other. This lessens the chance of bot
lines being disabled at the same time by Ughtning or by other natural cause
The cost of two such lines is frequently prohibitive. When it is necessar
to shut down a line for repairs, the service is interrupted if two lines ai
not available. Where the regulation would be impaired, or the overloa
capacity of one line is not sufficient to carry the entire load during such
shut-down, sectionalizing switches may be provided. The section requirin
Loir Voltage Bub Bars

Automatic Oil Switehei

(Bsverse Enerfj Eela;)
Stop Down
Transformer Banks

SlsoonDeoting Bwitchsi

High Tension Bus

Non Automatic
Oil Bwitcbet
l>i8coDneetuig Switohoi

AlumlDum Cell a,
Lljsbtuing Arresters U"
BiscouuMting Switches

Line Beotlon Switches

Section Tie Switches

Line Section Switches

Aluminum Oell
Lightning Arresters
Son Automatic Oil Swltc^s
Blgb Tension Bus
JDiiconnecthig Switches

Step Up
Transformer Banks
-Aransiormer lianas K/\/*Cyl
Automatic OU awltches I Y I

(InvcrM Time Limit Relaj) r~l t

Low Voltage Bus
Automatlo
OU Switches

Power House
Generators
Fig. 42. —Typical system connections,
repairs may be isolated andgrounded, the two lines being in parallel fori
remaining distance. This insures better and more continuous service, th«
frequently theadvantage gained is more than offset by the added expensM
switching complication. Fig. 42 shows the connections for a typical pot
system. ~
_

88. Substation connections are made as shown in Fig. 42 and FigW

and 79. See also Sec. 10 and Sec. 12.
89. Advantages of grounded systems are as follows: (a)
under unusual traiuiieut conditions, the voltage from line wire to
never exceeds the Y voltage, so the line insulation need not have so
factor of safety as with isolated systems; (b) a ground on one wire ope^

962
 POWER TRANSMISSION Sec. 11-90

^breakers and warns the operator of trouble; (c) the dynamic arc to ground has
but little tendency to create high frequency oscillations; (d) disturbancea
to the telephone system due to electrostatic unbalancing are a minimum.
90. Disadvantages of grounded systems are: (a) The line is in-
operative if a ground occurs; (b) the short-circuit current may produce
strong mechanical forces in generator and transformer windings, causing
,serious damage; (c) the dynamic arc may shatter the insulators or burn on
ilthe conductors, because of the large amount of energy available; (d) induc-
I'tive effects of the earth current may affect the telephone and telegraph
r
circuits, though the earth current is practically negligible except in case of an
accidental ground.
91. Conditions of advantageous grounding. A system in excess of
60,000 volts may well be grounded, unless absolute continuity of service is
essential. A line connected as a part of a large system should be grounded.
It will then be automatically disconnected and cannot subject the entire
system to the delta voltage between line wire and ground. A cable system
should be grounded, as oscillations and transients are of common occurrence,
and a ground in one part of the system may otherwise cause a breakdown in
the insulation at some other point. To locate and repair a ground in a cable
system is expensive, requiring considerable time.
92. The ground connection may be made by connecting the neutral
to a copper plate buried in charcoal; by connecting to a metal plate immersed
n a nearby body of water; by connecting to metal work in contact with the
sarth or water; by driving iron pipes of about lin. (2.54 cm.) or so in diameter
ind 6 ft. (2 m.) in length into the earth 6 ft. (2 m.) apart, and pouring salt
*ater around them. To limit the short-circuit current, a resistance may be
iserted in the neutral connection, though to secure one having the necessary
aistance and carrying capacity is expensive. A reactance should not be
ised in the neutral as it may increase the probability of oscillations. The
;round should be made at only one point of the system, at the power-house,
18 otherwise earth currents, particularly those of triple harmonic frequency
md multiples thereof, tend to flow and to disturb telephone and telegraph
ireuits in the vicinity of the line.
93. Ungrounded systems have the following advantages: (a)
n accidental ground does not shut down the system; (b) the earth may serve
IS a third conductor until the damage can be repaired; (c) an arcing ground
nay be cleared by the arcing ground suppressor; (d) under normal conditions,
here is little effect on telephone and telegraph lines.
94. Disadvantages of ungrounded systems are as follows : (a)
Though the neutral of the system should be at ground potential, experiment
as shown that excessive voltage may exist between neutral and ground;
b) the insulation of the system must be designed to withstand the delta
oltage, and therefore must have 1.7 times the insulation for the same factor
if safety; (c) an arc to ground is in series with the line
capacitance, and there-
ore tends to set up destructive high-frequency oscillations; (d) any electro-
tatic unbalancing affects neighboring telephone and telegraph systems.
96. Ungrounded systems should be used where the voltage is mod-
rate; where a shut-down would be a serious matter; where the apparatus may
.ell withstand the full-line potential.

96. Transformer connections may be either delta or star. Trans-

Drmers connected in delta must be able to withstand the total voltage be-
ween lines, hence their cost is greater than for star-connected transformers,
'hey are more reliable than the star-connected, for if one transformer ifl;
isabled, the system will continue to operate connected open delta. Trans-
irmers connected in delta may be heated by the third harmonic circulatory
urrent. The star connection affords an accessible neutral, and the trans-
jrmers need be designed to withstand only 58 per cent, of the line voltage,
here is no third-harmonic circulatory current possible, and any third-har-
,
ionic voltage does not appear on the line. If one transformer goes out, the
,
o'stem must either be operated single-phase, or be shut down, unless a spare
lut is available. Voltage taps are easily brought out from the transformer
,, ending in the star connection. See Sec. 6.
"• Switching a transmission line always gives rise to transients which
-r '^'^^'^y attenuate rapidly and die out without damage to the system.
.
ader favorable conditions, however, transients caused by switching often
!3mt in serious damage to Une and apparatus. The matter is further
963
Sec. 11-98 POWER TRANSMISSION
complicated by the characteristics of the oil switches themselves. When th
switch contacts approach each other on closing the circuit, small arcs (
decreasing magnitude are set up between them. These may result in hig
frequency oscillations corresponding in period to the natural frequency of th
transformer windings. In a three-phase switch the three contacts may nc
close at the same instant which further complicates the problem. Simila
phenomena occur when the switch opens the circuit, the arcs between coi
tacts increasing in magnitude. The maximum possible voltage rise 8
the switch opens is given by

where i is the current at the moment of break and L and C are the circu
inductance and capacitance respectively. The voltage does not usually ai
proach this limiting value, as the arcs formed between the contacts introduc
resistance which diminishes the voltage rise. The switch also absorbs soir
of the energy stored in the line. The voltage rise, under ordinary switchir
conditions, may not exceed the normal operating value by more than from t
to 75 per cent. The excessive rises in potential occur under short-circu
conditions, when the current may reach many times full-load valu'
Aluminum arresters and power-limiting reactances offer the best solutic
of the problem.
98. High-tension and low-tension switching are both extensive
employed, there being no consensus of opinion as to which is more desirahl
The following methods are used in switching on a substation.
(a) Connect the line to the high-tension bus at the generating station, ai
then switch the substation transformers.
(b) Connect substation transformers to the dead line, and then swit^
the line to the high-tension bus at the generating station.
(c) Connect the open line to the transformers at the generating statiti
switch these on the low side, and then connect the substation transformers
the end of the live line.
(d) Connect the substation transformers to the dead line and step >

transformers and switch these latter on the low-tension side.

(a) and (b) come under the classification of high-tension switching ami (

and (d) low-tension switching. The reverse order may be followed, wti
switching off.
(b) and (d) are not desirable methods^, as the potential waves whicli ;

first sent out along the line are reflected at nearly double amplitude a' '

receiving end which puts high voltage stresses across the transformers
other apparatus connected at the receiving end of the line.
Transformer switching may result in abnormal current rushes, if the cii
is closed on a point of the e.m.f. wave which does not correspond to i

residual magnetic state of the transformer.

POWER-FACTOR CORRECTIOK
99. Power-factor correction may often be made on transmission lin ,

whereby the voltage regulation may oe materially improved, thegenerut ;

capacity increased and the copper losses reduced. This correction may )

made by the over-and the uncier-excitation of synchronous apparatus at )

receiving end of the line. When used for this purpose exclusively, si i

apparatus is called a synchronous condenser. This synchronous appara )

may be a part of the receiver and used for further distribution of power, r
it may merely float on the end of the line, its sole function being to retiul i
the power-factor, or the voltage. As synchronous motors are not \v(j> i
for voltages much in excess of 13,000 volts, they must be connected to i
low sides of transformers if the line voltage exceeds this value. When 5
motor is installed solely to improve transmission efficiency, the cost of
power required by the motor, plus its maintenance and fixed charges. ;

not exceed the cost of the power saved, and must be less than the intere
the cost of installing more copper. As the synchronous apparatus m!>>
out of step, or be damaged by surges or short-circuits, it is generally desir
to install copper, which will give greater reliability, and has a better s
value.
When improved is the result desired, the installation of
regulation
chronoua apparatus be justified repardless of the energy saving. V
may
large is impracticable to install synchro
amounts of power are concerned, it
condensers to take care of the entire quadrature current, although they
be used for purposes of improved regulation. In the 150,000 volt, 14(1
line which runs from Big Creek, Cal. to Los Angeles, two 15,000 kv-a.

964
 POWER TRANSMISSION Sec. 11-100

chronous condensers are installed in Los Angeles merely for controlling the
voltage at the receiving end of the line.
100. Calculations for power-factor correction. The per cent, quadra-
ture current required for unity itower-factor at the receiver may be deter-
mined from Fig. 41, or may be calculated for a three-phase system as follows:
^'=3£ (33)
^ P
(34)
where 7i and It are the energy and quadrature components of current respect-
ively, P is the power, in watts, at the receiver, E is the voltage from line
wire to neutral, at the receiver, and d is the angle between the current and
voltage vpntnra
vnlt,n.£rp vectors. It
T+. will Ko
w.-ill be nntaA
noted, f..^.>, 1?;™
from Fig. ^o ii._j.
43 :j.
that it __
requires a
_

much larger synchronous

motor to bring the power-
factor from 95 per cent, to 100
per cent., than is required to
bring it from 90 per cent, to 95
per cent. As a rule, it is not
economy to install apparatus
large enough to obtain the last a
6 per cent. « 100
101. Constant receiver s
Toltage* may be obtained ^^ *"
^
by varying the excitation of £ §0
the synchronous apparatus, ^
either by use of an automatic g
70
regulator which acts on the -v
exciter or by compounding, if § 60
the synchronous apparatus is C^
a motor-generator or a rotary u 50
converter. When the varia- S ,-
tions in voltage are not severe, S,
hand regulation may be em- E on
ployed. Machines cannot <
always be compounded
to give 20
constant voltage at all loads,
though the condition of con- 10
stant voltage may be approxi-
mated. Without any regula-
tion whatsoever, synchronous 10 20 30 40 SO 60 70 80 90 100
apparatus tends to maintain Ampures Energy Current
constant voltage at the end of
a
— line.
t^^ii^. A rise
xi HOC lU
in voltage at
V UltitgC iXb
Fig. 43. —
Energy and quadrature currents.
the terminals causes the current to lag more,
a drop in voltage causes the
current to lead more, etc. As the voltage of a line
may rise on open circuit
to a value m
excess of the generator voltage, due to the line charging current,
the synchronous apparatus must be able
to shift its phase from leading to
Jaggmg current. The power-factor being known, the
quadrature current and
synchronous apparatus may be determined by
nlottiTpL ^7^m^^9°J^
*° ' '''^'' '"''' ^°^ ''''' •=°'"P^^*« ^^^""--^
i"ult'the'bibui?aphy.^
STRESSES IN SPANS
^Mechanical Stresses in a span are produced by: (a) the dead weight
nf ^th!' ^•h/'^h acts vertically; (b) the weight of any ice, sleet or
snow thnt '^"''*°V-
to?.t h •^^. "n"^ \° the wire; and (c) the wind pressure, which is assumed
the^cLX-rri it^s^lfe^^loTdt^ -
'"^ '""^ "'^^- ^'^^ *^« P-^-^^d -- «^
The weights copper and aluminum conductors are given in Par 104
of

sl^WnH i^ " °'' \^f^ "'' ^b °'" ?-.033 lb. per cu. in., and the weight of
'"^

U^iln 1 ?^'1 somewhat less than this. For the average climate of the
^^-27 cni.) thick isassumed to be the worst
conditln^n ^''^'''l^^ '"t^-^ I"- mountainous
'

?.?' ^2"^^'-?^^! regions, sleet may form to a

geater thill
weater thickness than this. The table in Par. 104 gives the ice and conductor
• Bibliography
37.

SM6.
Sec. 11-103 POWER TRANSMISSION^
loads with 0.5-in. and 0.75-in. layers of ice, for both copper and aluminum
conductors.
The wind pressure is a function of the wind velocity and may be ex-
pressed by Buck's* formula
p = 0.0025K2 (lb. per 8q. ft.) (35)
Where p is the pressure in lb. per sq. ft. and V is the actual velocity of the wind
in miles per hr. Fig. 44 shows the relation between velocity and wind
pressure. Buck gives the following as the relation between actual velocity
and that indicated at the Government observation stations.
Indicated velocity. . .
 POWER TRANSMISSION Sec. 11-104

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967
Sec. 11-104 POWER TRANSMISSION

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968
 POWER TRANSMISSION Sec. 11-106

d
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r-li-ie«llN WCCW"**
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 1

Sec. 11-106 POWER TRANSMISSION

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970
 POWER TRANSMISSION Sec. 11-107

107. Calculation of horizontal stress. The foregoing tables give the

factors by which the weight per ft. of conductor may be multiplied, in
order to determine the horizontal stress in the span. Values are given up to
200 ft. (61 m.) spans, and to 20 per cent, deflections. For any span greater
than 200 ft. (61 m.) the table may still be used, if it be remembered that for
a given percentage deflection, the stress is proportional to the span. Thus for
a 1,500-ft. (457 m.) span having 2.0 per cent, deflection, and a total weight of
0.5 lb. per ft. (1.64 lb. per m.) the horizontal stress will be (from 150-ft. span)
< =938X10X0.5 = 4690 lb.
In the same way, the length of this span wire (Par. 106) will be (from 150-ft.
span)
i= 150.16X10= 1501.6 ft.
The tables were computed from formulse given in Weisbach's "Mechanics
of Engineering," page 297 (seventh American edition, translated by Eckley
B. Cox, A.M.)
SX W' = horizontal stress in wire at centre of span (lb.) (41)
S = j/V22+x/6 (ft.) (42)
l = y[l +
(2/J) (x/y)^] (43)
(ft.)

X'=3S -V9S^-3y ^ (ft.) (44)

= \/(32/i-3j/2)/2 (ft.)
J/ _ (45)
where y = one-half the span, = one-half
I the length of the span wire, x =
deflection at centre in same units as y, and if) = dead weight per ft. of wire.
108. Temperature variations will change the length of the span, and as
the sag and tension are very sensitive to changes in the length of span, the
effect of change of temperature must be considered. With a change of
tension, the length of the wire will be changed, due to stretching or con-
tracting. As stretch and temperature change are interrelated and occur
simultaneously, their combined effect must be determined. As an analytical
calculation is difficult to make, the solution is better determined by graphical
methods. For every degree fahr. change in temperature, the length of
unstressed copper will change 0.00096 per cent., and of aluminum 0.00128
per cent.
109. t Properties of conductor materials
Ultimate
Elastic
Mod. Coef.
Copper 3trength per
limit
elasticity, expansion.
sq. in. E
Solid, soft-drawn. 32-34,000 28,000 12,000.00010.0000096
Solid, hard- 50-55-57-60,000 30-32-34-35,000 16,000,000 0.0000096
drawn.
Stranded, soft- 34,000 28,000 12,000,000 0.0000096
drawn.
Stranded, hard- 60,000 35,000 16,000,000 0.0000096
drawn.

Aluminum
Stranded 23-24,000 14,000 9,000,000 0.0000128

(See Sec. 4 for detailed data on Conductors)

110. The maximum stress in a span occurs when it has its greatest load-
ing of ice or sleet, minimum temperature, and maximum wind velocity
blowing at right angles to the line. The loading usually assumed is 0.5-in.
layer of ice at — 20 deg. fahr. ( — 29 deg. cent.) and a wind pressure of 8 lb.
per sq. ft. (at a velocity of about 57 miles per hr.) The load under these
conditions may then be determined from Par. 104, and the stress from Par.
106, or calculated from Eq. 36, Par. 103.
The heaviest loading recommended by the "National Electrical Safety
Code" (third edition, 1920) is H
inch of ice and zero deg. fahr. It is
doubtful however, if these conditions give sufficient factor of safety for those
regions where weather conditions are unusually severe.
111. Example of stress-sag calculation. Problem: Required to
find the proper sag for a 600-ft. span of No. 0000 hard-drawn solid copper, at

• From "Wire in Electrical Construction" by John A. Roebling's Sons Co.

t Report of the Joint Committee on Overhead Construction, N. E. L. A,
May, 1911, Vol. II, page 374.
971
Sec. 11-112 POWER TRANSMISSION
maximum (summer), minimum (winter-loaded), and stringing (unloaded)
i
temperatures.
From Par. 104, for 0.5-in. ice, and 8 lb. per sq. ft. wind pressure, the
total load per lin. ft., w, is 1.57.5 lb. The allowable tension, (, is 4,150 lb.
(corresponding to 25,000 lb. per sq.in.). The sag may be calculated from Eq.
37, Par. 103. d = [(600)2X 1.575]/(8X4, 150) = 17.08 ft. at the assumed mini-
mum temperature. This is the sag under ice load at 20 deg. fahr. —
+
The maximum sag will occur at 120 deg. fahr., the assumed maximum tem-
perature, with no load other than the conductor itself and no wind.
To determine this sag, first consider that all the stress is removed from
the conductor, and determine its length under this condition.
The change of length due to removing the load, Al = tl/EA. (46)
In this expression, ( is the tension in lb., I, the length in ft., E,
the modulus of elasticity, in in. -lb., A, the cross-section of the conductor, in
sq. in. Values of EA
are given in Par. 104.
Theoriginallength,fromEq.38,Par.l03,isZi = 600 + [8X(17.08)V(3X600)l
-601.297 ft. A« = 4, 150X601. 297/2, 0.59,000 = 0.939 ft. The span, then, if
all stress were removed, would have the hypothetical length at —20 deg.
fahr., 601.297-0.939 = 600.358 ft. This often results in a value less than
the span length. At zero deg. fahr., the length would be given by
l = ha+at;') (47)
Where lo is the length at zero deg. fahr., a is the coefficient of expansion, t'
is the temperature injiegjahr., lo = 600.358/[H-0.0000096 X ( - 20)] = 600.473
ft., do- VlBX 600(600.473 -600) ]/8= 10.31 ft. (Eq. 38, Par._103.)
112. To obtain the sag at zero deg. fahr., no ice and no wind load, the
Btress-sag curve ab should first be plotted (Fig. 47), having w = 0.641 lb.
f)er ft.,
weight of conductor with
oadremoved (Par. 104). Thetable
of Par. 106 is very convenient for
this purpose.
Curve ah shows merely the
tension in the unloaded conductor
for different sags. The problem is
to find the sag and tension at
some particular temperature, which
point must lie on curve ab. For a
given temperature, by Hooke's
Law, the length of span changes
8ag-Ieet with the tension. Assuming dif-
Fia. 47. —
Stress-sag curves. ferent values of tension, different
lengths of span are found by equa-
tion 46. Given the span and length of conductor just found, the sag can be
determined, using eq. 38, Par. 102. This sag is plotted against tension
which gives curve cd; where this curve intersects the sag-tension curve ab
will be the sag at zero deg. fahr., when the conductor has no load other than
its own weight.
Thus, at a tension of 3,000 lb.,
ti- 600.473 +[(600.473 X 3,000)/2,659,0001
-600 .473 + 0.678 = 601.151 ft .(from Eq. 46).
d-V'[l,800(601.151-600)]/8= 16.09 ft. (from Eq. 38, Par. 103). From th«
intersections, sag at zero deg. fahr. = 14.4 ft. and tension at zero deg. fahr.
—
2,000 lb.
113. The sag at another tenxperature may be found by increasing
the asbcissas by a distance, determined from Eq. 47 and Eq. 38, Par, 103.
Thus, to find the .sag and tension for 120 deg. fahr. I - 600.473 (1 +0.0000096
,

X 120) =601.163 ft. at 120 deg. fahr. and zero stress; d = 16.18 ft.
The sag and stress should then be computed as in Par. 113, and a new
stretch line c'd' plotted. The maximum sag (assumed at 120 deg. fahr.)
occurs where c'd^cuts ab. It is equal to 18.5 ft., and the corresponding ten-
sion is 1,560 lb.
114. Data used when stringintr. A set of stretch curVBS similar to
those of Fig. 47 for several temperatures should be furnished the foreman
in charge of stringing the wire, in order that he may adjust the sag, or tension
(by means of a dynamometer) to its proper value for the temperature at
the time of stringing. It must be remembered that the temperature of the

972
 :

POWER TRANSMISSION Sec. 11-115

wire, when the sun is shining, may be several degrees higher than that of
the surrounding air.
116. With the supports at
different levels, the line forms a catenary,
the lowest point of which is no longer midway between supports. The
curve can, however, be prolonged until it reaches a point which is at the same
level as the higher support (Fig. 48) and the distance xi to the lowest point
of the catenary will be equal to half the as.<sumed span, S', and may. be
computed.

Xi=S — — (ft.) (49)

Vd-h + Vd

Fig. 48. —Supports at different Fig. 49. —

Condition for upward
pull at lower support.
levels.

where S is the horizontal distance between supports, d the sag measured

from the higher support, t the tension in the wire in lb. at the higher sup-
port, w
the weight in lb. per unit length, h the difference in height of suj)-
ports, all distances expressed in feet.
Eq. 48 is useful when the span and the allowable stress are given; and Eq.
49 when the span and sag are given. Eq. 48 is correct to within 2 to 4
per cent, when neither the sag nor difference in height of supports exceeds
15 per cent, of the span. Eq. 49 has an error of less than 1 per cent, under
these conditions.
The sag d may be computed,
d = <i'(l+jj,)' (ft.) (50)

where d' isthe sag as determined by Eq. 37, Par. 103, for the same span, S, and
the same loading.

Also X2= f (l-^') (ft) (51>

Fig. .50. —Error introduced by assuming constant equivalent span.

Having determined the distance xi, the span may then be treated like a
"span S', where S' = 2xi. From Eq. 51, if h/M' is greater than unity, the
vertex of the line will lie outside the span, and there will be an upward pull
on the insulator. This is shown in Fig. 49 and the span should be so designed
that this condition docs not occur.
Load and temperature changes may be computed as in Par. 112 and 113,
but a certain error is introduced in assuming that the length of equivalent

*Thoma8, Percy H. "Sag Calculations for Suspended Wires." Trans,

A. I. E. E., Vol. XXX (1911), p. 2229.
Sec. 11-116 POWER TRANSMISSION
span remains unchanged. Except for accurate work, this error is negligible.
The error increases or decreases with the difference in height of supports by
an amount, a, Fig. 50. For accurate work, however, the length of line in
the span may be computed from Eq. 38 knowing xi.xzandd (Fig. 48), and the
effects of changes of load and of temperature may also be computed. The
new distance X2 is determined and the new equivalent length of span found.
 POWER TRANSMISSION SeC. 11-117

but the sag, stress and length of wire will be reduced in direct proportion,
The stress for a definite sag is proportional to the weight per unit length of the
wire, including ice and wind loads. The curves, Fig. 51, show the relation
between sag, length of wire and stress, for a 1-ft. span loaded uniformly with
1 lb., and are based on the equation of the catenary. Three sets of curves,
A, B, and C, are given, all plotted to different scales. Curve A is good for
sags from 2 to 15 per cent.; curve B, for sags less than 2 per cent.; curve C,
for very large sags, being especially useful for spans on steeply incUnedslopieB.
The chart in Fig. 51 is too small for accurate work, but the data from which
the curves were plotted may be obtained from the original paper.
117. Use of the Thomas chart. By means of these curves, the sag,
stress, and length of any span may be easily determined. Divide the allow-
able stress in the wire by the span and weight per unit length.
«=—3"^ (lb.) (52)

where tthe tension in lb. in a 1-ft. span; T the allowable ten-

ia
sion in lb. in the actual span; w the weight in lb. per ft. (wire, ice and
wind) S the distance in ft. between supports.
;

From the chart, determine the length and sag corresponding to t, as Ai and
Ci (Fig. 51). Then the sag and length in the actual span will be the values
iust obtained multiplied by the actual span in ft. If the sag, or length, be
jiven, the other quantities ma.v be found by reversing the process.
With supports at different levels, the span may be computed as outlined
n Par. 116, and the chart then used for the total equivalent span.
118. The effect of temperature may
be determined with the Thomas
;;hart by finding the length of wire, with all stress removed, from Eq. 46,
Ill, using the stress in the actual span, and marking this point on the
hart for the one-foot span (as Pi, Fig. 51).
I'ar. The elongation of the wire ia
iroporlional to the stress, so the straight line PiAi will be the stress-length
•r "stretch" line for this load and temperature. If the sag is small. Pi may
« less than unity, but the line may be drawn by determining some other
)OJnt Po (Eq. 46), and drawing Po.4o. To determine the sag and stress at
ny temperature, determine the length of the unstressed wire at zero deg.
ihr. ( — 17.8 deg. cent.) by Eq. 47, Par. Ill, asatPj. For the same loading,
he stress-length line at zero deg. fahr., P2.42, will be parallel to PiAi and At
the length at zero deg. fahr. of the 1-ft. span. Let this be h, and the
orresponding stress and sag be h and di respectively. The values in the
otual span may then be found.
Actual length =SZi (53)
Actual stress =iS<i«) (54)
Actual sag = Srfi (55)
here 5 is the actual span in ft., and 10 the load in lb. per ft. of line.
The length axis may then be marked off in divisions proportional to tem-
oraturea, and parallel lines drawn, from which the lengths, stresses and sags
lay be determined.
119. The effect of ice and wind is determined by use of the
homas chart as follows: Suppose the values in Par. 118 to be
amputed for maximum loading (ice and wind). When these loads are
moved, the weight per ft. is reduced to Wo (the weight per ft. of the wire
ad the stretch in the wire will be — of what
w
it was before, for a given alone
ress in the 1-ft. span. Therefore, along the line A Ai make AD/ A At
and drawPiBi through D. The intersection of this line with the length
irve will give the results as obtained in Par. J.18, substituting Wo for to.
he temperature lines may be found as before, PaSa being drawn at 120 deg.
hr. (49 deg. cent.) and parallel to P?S!.
ISO. Example of calculation, using Thomas chart. Consider the
oblem of Par. Ill, where S = 600 ft., w= 1.575 lb., 7 = 4,150 lb.
S is the distance between supports; w is the weight (including wire, ice,
d wind) per unit length; T is the allowable tension.
The tension in a 1-ft. span, having a 1-lb. load, will be < =4, 150/(1. 575X
0) =4.395.

975
 ..

Sec. 11-121 POWER TRANSMISSION

From curve B, the sag will be 0.0286 ft. (Ci) and the length 1.00215 ft. (Ai).
The true sag and length will be Sdi =600X0.0286 = 17.16 ft. Sii = 600X
1.00215 =601.290 ft. The length, unstressed, may be found (Eq. 46, Par. 111).
Al = (1.00215 X4,150)/2,659, 000 =0.00156 ft.
ii = 1.00215-0.00156 = 1.00059 ft.

A line PiAi is drawn from Pi (length = 1.'00059) to Ai, the original point on
the length curve. The length at zero deg. fahr. is found from Eq. 47, Par.
111. ?o=1.00059/[l+0,0000096X(-20)] = 1.00078 ft. A line PiAs is drawn
(where Pa = 1.00078) parallel toPiAi. At zero dog. fahr., with wind and ice
loads,

Chart Actual

Length. 1 0022 1 ft.

. 6a0 X1 . = 60 1 344 f t.
00224 .

Stress. 4.21b. 600X4.2X1.575 = 3,965 lb.

Sag. . . 0.0295ft. 600X0.0295 =17. 70ft.
To find the length, stress and sag when the loads are removed. At zero deg.
fahr.,no ice, and no wind, liio =0.641 lb. At the stress as now shown on the
ohartof4.2 lb., the stretch will be (1.00224-1.00078)0.641/1.575 = 0.00059,
and the length 1.00078 + 0.00059 = 1.00137. Draw P2B2 through 1.00137 at
the 4.21b. ordinate (at D). Graphically
AO/AAj =0.041/1. 575
Then, at zero deg. fahr., no ice or wind.
 .

POWER TRANSMISSION ScC. 11-122

122. Short-circuit due to unbalanced

ice loads. * Ice loads on wires
may drop from all suspension insulators are u.sed and the
but one span. If
lines are arranged in a vertical plane, this span, aided by the longitudinal
deflection of the suspension insulators, will sag heavily and the adjacent spans
will be drawn up, as shown in Fig. 53. The phase wires may readily ap-
proach within easy arcing distance of one another and all three conductors,
even, may touch, thus, causing a short-circuit. Also, if one wire alone loses
its ice load, its whipping up may cause short circuit. This may be partially
overcome by the use of shorter spans, more anchor towers, or better, by
offsetting the middle conductor, thus making an isoseles triangle arrangement
(see Fig. 67, isosceles triangle)

I
STRENGTH OF SUPPORTING MEMBERS
123. Insulators and pins must be designed to withstand the weight
bf conductor and any ice, sleet or snow load; the wind pressure acting on the
ponductor, and any other transverse force produced by a change in direction
i)f the line; the longitudinal force due to unbalanced horizontal stresses in

idjacent spans; the longitudinal stress occasioned by the breaking of a line

!onductor. It is desirable that they withstand a stress equal to the elastic
iniit of the conductor, when exerted in any direction in a plane perpen-
•licular to the axis of the pin.
124. The cross arms must be designed to withstand the resultant of
he forces of Par. 123, and the dead weight of insulators and attachment.
n addition, the cross arms must be secured to the pole so that they will
lot be wrenched loose by the turning moment which follows the breaking
'f one or more conductors on the same side of the pole. The results of
Strength Tests of Cross Arms," made by T. R. C. Wilson, are published in
J. S, Government Forest Service Circular 204.

125. The supportingr structure may be considered first as being a

iniple column and therefore must be designed to bear the compressive
rn ss, due to its own weight and that of conductors, loads, insulators,
ros arms and attachments. Also it may be considered as a cantilever and
s svich must be designed to withstand the shear and bending momenta
ue to the transverse forces of the wind on conductors and supporting struo-
arc and also those occasioned by change in direction of the line; the longi-
iilinal stresses due to unbalanced horizontal stresses in adjacent spans;
:' •'PS caused by the breaking of one or more conductors. In addition,
tructure should be able to withstand the torsional stresses which result
the breaking of conductors on one side of the structure.
\'t uoden, steel, or concrete poles, designed to withstand the moments due
) the horizontal forces, will have the necessary compressive strength, to
l\u- the vertical loads. With towers of the light \^•ind-mill type, this matter
lotild be carefully considered. Where extreme rigidity at small expense is
^ired, the structure must be made of many light members, resulting in a
ore complicated tower, and a shorter life, due to the greater proportionate
>rr(jsion. A less rigid tower made of fewer but heavier members, will
eciuently answer the purpose, will be less expensive and of linger life.

Fig. 53. — Ice loading on single span.

126. The transverse force due to the wind on the conductors should be
iumed as 8 lb. per sq. ft.f of the projected conductor and ice area. A
'-U1.(1.27 cm.) layer of ice is usually assumed. Values of the resulting
;ssure may be foun d in Par. 104. The pressure on the pole or tower may be
*Oreisser, V. H. "Effects of Ice Loading on Transmission Lines."
A. I. E. E., Vol. XXXII (1913), p. 1829.
'ins.
Report of the Joint Committee on Overhead Line Construction, N. E. L. A.
ly, 1911, Vol. II, p. 374.
077
Sec. 11-127 POWER TRANSMISSION
assumed to be 13 lb. per sq. ft. on one and one-half times the projected area
of latticed structures. (Also see Sec. 12, Par. 166.) The overturning moment
may be greater without the ice load. 13oth conditions should be calculated.
The stress due to an angle in the line may be readily computed by a simple
resolution of the maximum stresses already calculated for the spans. The
longitudinal forces, due to unbalanced horizontal stresses in adjacent spans,
should be small in a well designed line, and may be determined if the stresses
in each span at different temperatures are known. There is some question
as to how many conductors may be assumed to be broken at one time. If
a line is carefully strung, with no kinks or abrasions in the wires, and if the
ends of the insulator clamps are well rounded, there is small chance of a line
conductor breaking under ordinary load conditions. As an extra precau-
tion, however, anchor towers are used at frequent intervals, and are so de-
signed as to safely withstand the simultaneous breaking of several conduc-
tors. Where suspension insulators are used, the insulator string is thrown in
the unbroken side of the span, and the increased sag decreases the ultimate
pull. The force due to the jerk at the time of breaking is quite severe, and
no reduction in the allowable stress should be made even if suspension in-
sulators be used. The line structures should have a factor of safety of
from 2 to 4, according to the importance of the line, the assumptions made
in the design, and the local conditions.
127. A wooden pole should be a cubic parabola, to use the material to
the best advantage. As this would be impractical, a truncated cone, having
the diameter of the top two-thirds of that of the bottom, is the best approxi-
mation. With this shape, the pole will break theoretically at the ground line.
The allowable horizontal pull, P, on the pole may be calculated
p=- ^!^ (Ib.-i for a round pole. (56)

P = —n —6t
r; (lb.) for a square pole. (57)

assuming that ds, the ground diameter in inches, is one and one-half times the
top diameter. In Ihese formulas n is the factor of safety, I the length of th(
pole in inches, and T the tensile strength or modulus of rupture of the pol<
material, values of which are given in Sec. 12, Par. 164. The factor of safety
should be at least 5 or 6 for wood.
1S8. The stresses in steel poles cannot readily be calculated, duo to the
complications introduced by lattice work, cross bracing, etc., and the enginee;
is more or less dependent upon actual tests and manufacturers' guarantee;
for data relative to the load that a given structure may be expected to carri'
safely. Steel poles, for the same weight and material, have much les
torsional strength than steel towers. Although they may be satisf actor
under normal conditions of balanced load, their factor of safety may be muc!
reduced if one or more wires on the same side of the pole should break.
129. The stresses in concrete poles may be computed approximately
knowing the moment of inertia of the top and bottom sections, the cros*
section and tensile strength of the reinforcing steel, and the compressiv :

strength of the concrete. Up to the present time, however, very little ha ;

been done along this line, and purchasers and manufacturers h.we bee:'*
dependent upon actual tests of full-sized poles. The usual mixture c
Portland cement (1 2 4, cement, sand and gravel) has a compressive strengt
: :

after 7 days of 900 lb.; after 1 month, 2,400 lb.; after 3 months, 3,100 lb \

after 6 months, 4,400 lb. all in lb. per sq. in.

;

180. Stresses in guys and anchors may be readily computed if th :

magnitude, direction, and point of application of the resultant force actin

on the pole are known. The position of the anchor is determined, and th
stress in the guy and anchor can be calculated by the well-known law
governing the composition and resolution of forces. The table in Par. 10
gives the diameters, strengths and weights of 7-strand galvanized steel wip
such as would be used for guys (also see Sec. 4). When guys are iised wit
wood or other poles, or towers capable of considerable deflection befoi'^
failure, they shall be able to support the entire stress in the direction in wmc|
they act, the pole serving simply as a strut. The guy should be attaohel
to the structure as near as practicable to the center of the conductor 108|
to be sustained. Anchor rods shall be so installed as to be in hne with tJ |
pull of the attached guy when under load, except in rock or concrete, J
S
978 S
 POWER TRANSMISSION Sec. 11-131

131. The stress in towers may be computed by the well-known laws

of statics, provided the tower is statically determined. Towers are usually
constructed of four main angle members, cross-latticed and braced the entire
length of the tower. These members must not only withstand the total
compressive load of a simple column, but the members on either side of the
tower may be subjected to additional compression due to the fact that the
tower is also a cantilever. As steel fails in compression, the strength of
unsupported compression members should be carefully checked, using well
known column formulas. The following formula for ultimate strength, T,
(lbs. per sq. in.) is commonly used.
T= 'Q'T
1
,. (58)
1 + 16,000 '
11
r«
where I is the length of unsupported column member and r is the least
radius of gyration of the column cross-section. A factor of safety of 2 or
2.5 customary.is
R. D. Coombs* shows, in the following table, that by using a different
Jangle iron of less eross-sectional area, the strength of the main compression
.members is nearly doubled. Because of corrosion, this should not be carried
too far, if a reasonable life is expected. It is generally conceded that } in.
for the legs and in. for the secondary members should be the minimum
A
^nesses of metal.

Breaking i ,
^°,*^'
Area, Length, ^^^^^^rng
Section l/r strength^
sq. in. ft.
Ib./sq. in.

1
4 in. by 4 in. by \ in. angle 5.44 13 202 12,000 65,200

;5 in. by 5 in. by -fg in. angle 5.31 13 159 16,000 85,000

1 6 in. by 6 in. by ^ in. angle 5.06 13 131 20,000 101,200

Except in very short members, angle lacing (and bracing) is preferable to

lat lacing (and bracing), as angle members are stiffer and better able to
^st tension and compression than are flat bars. Also, if the flat bars are
lightly bent on handling, they are practically -worthless as compression
lembers.
I
As transmission towers are usually assembled on the field, bolts are used
the joints rather than rivets. About 12,000 lbs. per sq. in. can be used
|ithe working shearing stress for such bolts. bolted joint is much less A
ficient than a riveted one, as the friction between adjacent surfaces cannot
depended upon for holding. With time, the tower vibration due to wind
jten causes the nuts to work loose. Therefore, during erection the nuts
.ould be gone over carefully, tightened, and the threads upset.
The calculation of the forces in the tower members due to torsion, partic-
arly if the tower faces are battered, is difficult. Towers which are care-
Uy designed rarely fail from such torsional forces alone. When designing
ower, it is not sufficient to use merely the assumed steady horizontal forces,
allowance must be made for the forces caused by the sudden jerk when
iiductor breaks, particularly if the suspension string is thrown into the
roken line.
132. The stresses in tower foundations are produced by the vertical
Is V V, Fig. 54, due to the dead weight of the tower and its column
ling. These forces must be opposed by the vertical resistances V'V,
lie base of each of the foundation members. To obtain the requisite
1 ing area, a flat grill work is usually riveted to the foot of the foundation,
ss a concrete foundation is used.
'
(See Fig. 60.) The horizontal force
resulting from wind, unbalanced span tension, etc., produces a couple HX
;
ich must be resisted by a couple at the foundation. BY
The couple HX
I
reases the vertical load on the foundation members which are on the
inpression side and tends to produce an uplift in the anchor on the other
'
Letter to Elect. World, Vol. LXII (1913), p. 544.

079
Sec, 11-132 POWER TRANSMISSION
side. This uplift is resisted by the weight of earth above the grill work.
It is usually assumed that this weight is that of the earth included within
a cone whose sides make an angle of 30 deg. with the vertical. The weight
of earth is usually taken as 100 lbs. per cubic foot. A
frequent cause of
towers overturning is the lack of holding power in the freshly-tamped earth,
and the softening of the earth resulting from rains, floods, etc.
The entire shear pro-
duced by H must be trans-
mitted to the foundation,
and be resisted in the earth
by horizontal resistances
H', //'. Resistances H', H'
are distributed forces and
the point of application of
their resultant is not
known. Unless the rela-
tion between the magni-
tudes of the forces W, H'
and their centers of ap-
plication be known, or
assumed, the tower is
statically indeterminate.
In the A frame (a), Fig. 54,
the horizontal shear is
entirely transmitted to the
Fig. 54. —Stresses in towers, unbalanced
spans, etc.
foundation through longi^
tudinal stresses in the
main angle members
Practical considerations, such as the attaching of cross-arms, usually pre-
clude the use of straight A frames. In (6), practically all the shear must b(
transmitted through the member Z to the foundation at point P, where thii
foundation is usually bolted to the tower. Unless the point P has some specia'
support, serious transverse stresses ^re developed in the tower leg and in thi
foundation member and a tendency to buckle results. Towers, after havim
successfully passed tests on rigid foundations in the shop, often fail at tuf

^-^
: spans adjacent
the standard length (125').
spans adjacent to the angle
pole shall be reduced to the di8tance"S "given in table.

Angle
a
 POWER TRANSMISSION See. 11-133

133. Location of poles and side guys may be determined by use of the
table given with Fig. 55 The term "pull" refers to the deviation of the
line and is equal to the distance from the pole to the straight line joining
points on the line 100 ft. each side of the pole.
134. Flexible towers are used with a view to decreasing the line cost.
Their design is based on the fact that with equal spans and sags on both sides
of the tower, the stresses in the direction of the line are balanced. The towers
are not intended to carry longitudinal stresses, but are designed to withstand
any transverse stresses that may occur. They are held in position by the
conductors, if pin insulators are used. When suspension insulators are
used, a heavy steel galvanized ground wire is necessary to keep the towers in
position. If a conductor breaks, the tower will deflect until the increased sag
in the conductors and ground wire on the other side of the pole compensates
for the unbalanced forces due to breaking. The towers should be designed
to deflect from 12 in. to 24 in. without being permanently deformed. The
unbalanced pull will not only be taken up by the tower at which the break
occurs, but will be gradually absorbed by the other structures in the line.
If a tower is actually pulled over, it is not a very serious matter because of
its low initial cost, and ease with which another may be erected. About
every mile there should be an anchor tower. Methods of computing the
iefiections and stresses in flexible towers have been published (see Bibliog-
raphy 45 and 47) Such towers should be designed to carry from j\s to j",
.

the load for rigid towers and with this load should not be stressed beyond the
slastic limit. The two legs or main members are usually made of channels,
whereas in anchor towers the legs are usually made of angles. (See Fig.
50.)
135. Anchor towers, when used in connection with flexible towers,
i.hould be designed to withstand the stress produced by the breaking of all
he conductors on one side, even when the line is loaded under the most
infavorable conditions. Under these circumstances, there should be no
idelding of the foundations, and the tower should not be stressed beyond the
(lastic limit. With a line constructed entirely of rigid towers, these condi-
iions may be somewhat modified, as the intermediate towers themselves are
v.esigned to take care of one or two broken conductors.

i'TJNDAMENTAL CONSIDERATIONS OF LINE OONSTEUCTION

I
136. The line location should in general be direct. Detours are often
[ecessary, to avoid sections subject to severe lightning, to avoid country
[hat may be inaccessible, to avoid swamps or hills that will make the con-
truction difficult and costly. It may be necessary to pass near towns or
illages where connected load may be profitable. However, angles in the
ne should be avoided whenever possible, as the unbalanced horizontal
Tesses require a stronger and more costly tower than the ordinary straight
ne tower.
The most direct right of way cannot always be obtained at a reasonable
gure. County plat maps or U. S. Topographical Survey maps should be
irefully studied with special reference to the villages along the route, the
roiimity of roads, hence accessibility, and the topography that will permit
andard structures and spans. When the location is roughly determined, a
nail surveying party should go over the route, make a profile, locate swamps,
reams, railroads, other power, telephone or telegraph lines, and should note
'le character of ground and probable location of supports. Profiles should
} made 100 ft. on each side of the centre line, as well as at the centre line,

Qce a supportiiig structure might bo advantageously located a short distance

om the centre, if an abrupt change in profile made an increased height of
ructure necessary to secure the proper clearance.
137. A private right of way is necessary for most high-voltage transmis-
)n lines, as the risk to life and property from high voltages is too great to
rinit circuits to be carried along highways. The width should be so
IS' n that no tree or other object located
outside the right of way can fall
- lines. Where very tall trees do occur, they should be bought and
'•(1. It is advantageous to secure the right of way near a highway, as
i.struction materials can be easily hauled to the tower locations. The
will also be more accessible for repairs, and patrolling is facilitated.
licro the line must pass over private property, if possible it should follow
; division lines.

981
Sec. 11-138 POWER TRANSMISSION
138. The proper form of contract should be executed, * when the con-
sent of the proper parties is obtained. In many cases, as in sparsely settled
districts, the land may be bought outright. The best practice, however, is to
acquire perpetual right under easement, or for a term of years, with the right
to renew the contract at the expiration of this time. Legal questions o)
importance should be settled by counsel.
139. The conductor material will usually be copper, aluminum, o*
steel-reinforced aluminum. The relative advantages and disadvantages
of these are described in Par. 61 to 64 inch
140. The spans for any line will usually vary in length. For level
or undulating country, a standard span ranging from 100 to 800 ft. may be
used. In hilly or broken country, the support must be erected at advan-
tageous points regardless of the varied length of span that may
result. With increased length of span, the number of structures and
insulators (hence maintenance charges) is decreased, but the height of
tower is increased. The cost of the tower may vary as the cube of the height.
Other things being equal, the span should be so selected that the total line
cost is a minimum. (See Par. 236.)
141. Extra long spans must be anchored at each end. To secure
sufficient tensile strength in the insulator, it is often necessary to connect a
number of strings of suspension insulators in parallel. In order that each
string may take its own share of the load, a strain yoke (Fig. 35) is used.
142. The conductor spacing should be such that the wires cannot awinft
within arcing distance of one another in the span. When suspension in-
sulators are used, the wires at the insulators should not be able to swing
within arcing distance of the
pole or tower. Allow a 45-deg.
deflection from the vertical for
copper and (iO-deg. deflection
for aluminum under the worst
conditions of loading. Assum-
ing one of tlie phase conductors
to hang vertical and the other
to swing to the above angle, no
two conductors must come
within arcing distance of each
other. Fig. 56 shows the usual
spacings employed.
143. fWeighted conduc-
tors. Where small conductors
are used with suspension in-'
sulators, it may be impractica-
S S s 3 §gh\e to increase the spacing by
an amount sufficient to prevent
PrcsBure between WiresCKilovolts)
the wires swinging more than
FiQ. 56. —
Approximate conductor spacing. CO deg. By hanging a weight
on the end of the insulatoi
string, the maximum swing may be kept within this limit. Such weights
tend to prevent the propagation of mechanical waves longitudinally.
144. The type of line construction should be decided upon after the
location of the lino has been determined. The choice lies between wooder
poles, steel poles, concrete poles, rigid steel towers, and the flexible towei
system.
When selecting the type of line, the locality through which the line passes
the initial cost, the reliability, the ultimate life, and the maintenance shoulci
all be carefully considered.

•Croswell, S. G. "The Law Relating to Electricity."

Joyce, J. A. and H. C. "A Treatise of Electric Law."
Tiffany, H. T. "The Law of Real Property." Chap. 12 (Eu.-,. m, ..u,
Chap. 24 (Prescription for Incorporeal Things), Chap. 30 (Appropnatioi;
under Eminent Domain). _ ^

tBuck, H. W. ''Practical Operation of Suspension Insulators. ' Trant

A. I. E. E,, Vol. XXXIII (1914). p. 131.

982
 POWER TRANSMISSION Sec. 11-145

146. The poles or iowers should be staked out by the surveying

party; following should come a digging party provided with a steel or wooden
teniplate by which the corner holes may be located. This party should
be followed by another to install the concrete foundations, if such are to
be used, and then by the erecting gang.
POLES
146. Wooden poles,
though apparently the cheapest form of construction,
should seldom be used, except on short or relatively unimportant lines. The
life of untreated poles (Par. 147) ranges from 6 to 15 years, depending on the
I
type of wood and the climatic conditions. When treated, their life may reach
20 years or more. Though wooden poles and cross arms give better insula-
tion (per pole) to the system, they may be charred or badly burned by leak-
age currents or by conductors that fall from insulators. Although less likely
'
to be struck by lightning, they are usually shattered or badly damaged
1 when struck. The large number of poles required per unit length of line,
decreases the (total) insulation of the system and increases the number of
insulator troubles in direct proportion.
Wooden poles are still used to a considerable extent in transmission.
Sixty per cent, of the wooden poles used in the United States are cedar and 20
per cent, are chestnut. On the western coast, redwood is used to a great
extent; other woods, such as pine, cypress, juniper, Douglass fir, tamarack,
and oak are occasionally used. Cedar, owing to its lightness and to its long
life, which varies from 10 to 30 years depending on the climate and soil,
is the rnost common pole timber, although the supply in the eastern states
'is practically exhausted. Chestnut, though heavy and not as long-lived aa
3edar, is used in the eastern and middle states. Redwood poles have
i long life, and are usually sawed from large trees. Pine, though heavy in
'•esinous products, rots very rapidly and does not last more than 4 or 5
years unless treated. Cypress stands very well in its native climate, but is
short lived in the north. The other woods are used only occasionally,
hough the present methods of pole treatment will widely increase the
imber available for poles.
,^ 147. Average life of untreated poles.
Iledar 15 years Juniper 8.5 years
^Jhestnut 12 years Pine 6.5 years
,;;ypress 9 years
148. Preservative treatment of poles is attracting much attention
;mong large users, as the available supply of timber is constantly decreasing
nd the price rising. Two preservatives are in general use: creosote
nd zinc chloride, though copper sulphate has also been used to some extent.
•'reosote, though expensive, is the most satisfactory preservative, as it
'oes not contain water nor is it affected by water, and has valuable anti-
ijptic properties. Zinc chloride is far cheaper, but as it is carried into the
.ood poles in a water solution, the water must be dried out again, and the
ole will readily absorb moisture later.
149. Brush treatment of seasoned poles consists of two applications
f hot creosote (220 deg. fahr.) about 24 hr. apart. The treatment should
jctend at least 2 ft. above the ground line, and the pole should be very
iry at the time of application. This is the simplest form of treatment; it
38ts from 15 to 40 cents per pole, and increases the life 2 to 3 years.
150. In the open tank method of pole treatment the dry pole butts are
laced in tanks containing hot creosote at 220 deg. fahr. (105 deg. cent.), for
otn 4 to 8 hr., and are then allowed to stand in a "cold" bath between 100
ad 150 deg. fahr. (38 and G6 deg. cent.) from 2 to 4 hr. Where the top
the pole is subject to rot, as in the south, the whole pole may be treated
Y this process. The penetration is about three times as great as with the
ush treatment. The estimated increase of life is 20 to 25 years.
161. In the full-cell (Bethel) process of pole treatment, the poles are
aced in an iron cylinder, about 125 ft. long and 8 or 9 ft. in diameter. Live
earn at 20 lb. pressure is admitted and maintained for several hours.
he steam is then blown out of the cylinder, and pumps exhaust as much of
,e air as possible. At the end of the vacuum period, the preservative at
lOut 150 deg. fahr. (66 deg. cent.) is admitted and is forced into the wood
>aer pressure. This insures a deep penetration of the preservative and a

983
 t

Sec. 11-152 POWER TRANSMISSION

long life to the pole. No data as to the life of such poles are available, bu
poles in England under similar treatment are still in service at the end of 6(
years.
152. The burnettized creosoted butt process of pole preservatloi
issimilar to the full-cell method, except that zinc chloride is always used in thi
tank. The butt, to a foot or two above the ground line, is then impregnate(
to a slight depth with creosote under pressure. This prevents the zini
chloride from leeching out, and is much cheaper than a complete treatmen
of creosote.
163. Tabulation of pole cost, per-annum pole cost, and cost o:
butt treatment western red cedar* —
Based upon present market prices (Oct. 1, 1920) delivered Central Statei
rate of freight

8 in./ 8 in./ 8 in./ 8 in./ 8 in./

Size of pole
si'f 40 ft. 45 ft. 50 ft. 55 ft. 60 ft.

Price delivered, Central

States S17.75 $18.55 $27.15 $28.50 $34 50 $39.25 .

Cost in place, shaved but

not painted or stepped,
based on wholesale new
construction 8.90 14.55 16.55 18.75

Total cost in line. $26.65 $29 65 $39 80 $43 05 $51.05 $58.00

. . .

Using average of 13J.^ years

life; per annum cost 2.20 4.30

Cost of butt-treatment:
Specification A 2.25 2.70 3.30 4.00 4.80 5.55
Specification AA 1.90 2.10 2.55 2.90 3.30 4.00
Specification B 3.45 4.00 4.35 4.80 6.00 7.20
Guaranteed penetration
process 3.80 4.40 5.30 7.90

Added necessary to pay

life
entire cost of treatment: Years Years Years Years Years Years
Specification A 1.14 1.22 1.12 1.25 1.28 1.3
Specification AA 0.96 0.95 0.86 0.90 0.87 0.93
Specification B 1.76 1.81 1.47 1.50 1.58 1.67
Gruaranteed penetration
process 1.92 2.00 1.62 1.66 1.74 1.83

Specification A provides for a continuous submersion of that part o

the pole to be treated, in high grade Carbolineum, for a minimum of fifteer
minutes. Specification A A provides for a continuous submersion of tha'
part of the pole to be treated, in high grade Creosote, for a minimum o
fifteen minutes. Specification li provides for an alternately hot and cole
submersion in Creosote for a minimum of six hours. The guaranteed pene
tration process quarantees one-half inch penetration in every portion of the
pole in that area between the plane designated as the height of treatment t<
a plane one and one-half feet below the standard ground line, unless the s?ip
wood is less than one-half inch in thickness, in which case the impregnatioi
is to the full depth of the sap wood.
164. Char and tar the butts of poles before setting if they are no
creosoted. This is done by placing the pole upon a skid over a slow fire
gradually revolving it until tlie butt to about 1 ft. above ground levi'
thoroughly charred. While hot, it is given two or three coats of tar wii
stiff brush and is then set. This will increase its life perhaps a year.
166. Wooden pole specifications. Each polo should be of good quality c,
live growing timber, free from knots and shakes, and sound in all respects; th,
grain should be close and hard, with the annular rings closely pitched am

Page & Hill, Minneapolis, Minn.

984
 POWER TRANSMISSION Sec. 11-156

with a sound heart. Each pole should be straight and well proportioned,
free from all objectionable bends; should have the natural butt of the tree
and should be squarely sawn, without trimming. Poles should vary in size
by lengths of about 5ft.; they should be cut between the first of November
and the first of March, and after being felled they should be carefully trimmed,
the bark removed and the butt squared. The poles should be piled with
open spaces between, raised from the ground and allowed to season for at
least a year or more. After seasoning, the top of each pole should be roofed
and the suitable number of gains cut for the cross arms. The specifications
vary with the kind of wood.
156. *Depth of wooden poles in the g^round

Depth Depth, curves, n„ iU t J Depth, curves.

Length for
corners and
Length Depth for ^i;„ '
„„H
corners„ and
over all straight over all straight
points of extra points of extra
(ft.) line (ft.) (ft.) line (ft.)
strain (ft.) strain (ft.)

30 5.0 6.0 60 7.0 7.5

35 5.5 6.0 65 7.5 8.0
40 6.0 6.5 70 7.5 8.0
45 6.5 7.0 75 8.0 8.5
50 6.5 7.0 80 8.0
55 7.0 7.5

167. Wooden-pole settings. All holes should be dug large enough to

idmit the pole without forcing, and should have the same diameter at the top
iS at the bottom. The pole may be "piked" into position, but it is usually
nuch cheaper to employ a gin wagon, and to use the team for raising the
>ole. Forty to fifty poles per day can be thus raised, with only two linemen
nd a teamster.

Fig. 57.— Pole

repairing at
^'""''^ "'''•
Fig. 58.-Tripartite steel pole. 3^

il68. Crib-bracing can be used, where the poles are set in loose, or marshy
.Is. For further discussion see Sec. 12, Par. 173.
169. The sand barrel is a u.seful expedient in digging holes or setting
les in sandy or loose soils. See Sec. 12, Par. 173.
160. A concrete foundation may be used for wooden poles where
' eptional stabihty is desired. This concrete filling should extend at least a
Report of Committee on Overhead Line Construction, N. E. L. A.
y, 1911, Vol. II, p. 374.

985
Sec. 11-161 POWER TRANSMISSION
foot from the pole on all sides, should be carried above the ground line and
bevelled to shed water, and should consist of one part Portland cement, three
parts sand, and six parts broken stone or clean gravel, mixed wet. (See
Fig. 47, Sec. 12.)

161. Special pole setting's. In marshy ground, more elaborate devices,

as shown in Fig. 47, Sec. 12, are often required for a satisfactory foundation.
162. Pole repairs. Wooden poles usually fail .by decay at the ground
line. If they are long enough, they may be sawed off and set again. A very
satisfactory way of repairing such poles without disturbing
them is to drive U-shaped rods in the poles at the ground
line, as shown in Fig. 67, and fill the space with concrete.
Poles reinforced in this way are said to be stronger than when
new, and their life is greatly prolonged.
163. Steel poles cost but little more than wooden poles,
when the erection and labor costs are considered, require no
assembling at the point of erection, are not injured by fire,
birds and insects, and are not damaged by lightning. Their
field is the moderate line, with spans from 250 to .350 ft. in
length, running along roadways or where space is limited.
Their life is from 25 to 50 years, and even more depending
upon 'their upkeep.
164. The tripartite steel pole, shown in Fig. 58, consists
of three continuous Uparts, held together by "spreaders" and
"collars" bolted together. The strength and rigidity of the
pole can be increased by increasing the number of these
members, and the pole is everywhere accessible, so that it can
be readilj^ painted and inspected. Tripartite poles may be
shipped either assembled or "knocked down," and are there-
fore well adapted to the lighter lines, particularly where trans-
f)ortation is difficult. They can be assembled by unskilled
abor. In ordinary soil, and with a concrete foundation, it
has been asserted that the poles need only be buried for one-^
tenth their length. |j

166. The Bates' expanded steel truss pole, Fig. 59, is

made from rolled H
sections. The web is sheared longi-
tudinally by a rotary shear, leaving intact portions at fixed
intervals throughout the length of the web. The intact
portions are staggered. The section is heated to a cherry-
red color and is then expanded by a special machine which
grips the flanges through its entire length and expands the
section to the desired dimension while hot. This creates a
series of triangles in alignment, thus forming a one-piece
steel truss. The manufacturers claim greater strength, lower
cost and maintenance, and lighter weight than fabricated
Fig.
Bates ex-
59. — poles, or tubular poles. These poles may be used as mem-
bers of A frames, anchor towers, special structures, etc.
panded steel They are also well adapted for use as flexible towers in this
pole. type of transmission line design.
166. Steel poles should invariably have a concrete foundation,
in order to obtain adequate bearing area. Steel-pole foundations are shown in
Fig. 59.

167. Concrete poles are coming to be used for high-voltage transmission.

Their maintenance is very low, they are not injured y the attacks of insects,
fire, etc., and, apparently, are not damaged by Ughtning. They can be
used in the most acces.siDle places only, as they must be construct ed,_ in
most cases, when erected. Their weight results in high transportation^
costs. Though there are as yet no data regarding their life, it is probably^
long. Two poles, 150 ft. (45.8 m.) high. 11 in. (28.0 cm.) .<:nuare at the
31 in. (78.7 cm.) square at the bottom, and capable of withstanding, withouW
guys, a 2,000-lb. horizontal pull at the top, have been successfully install
by the Hamilton Power, Light and Traction Co., at the Welland Can
Crossing.

086
 POWER TRANSMISSION^ Sec. 11-168

StEEL TOWERS
168. Advantages. Steel towers in the open country, and for trunk
ines of large capacity and long spans, are unquestionably the best type of
;onstruction. The two systems, the rigid and flexible, are both in general
ise, and the latter is becoming more used. The flexible system compares
avorably even with wooden poles, as far as first cost is concerned, since

27/|22
A 4J1O
SECTION K-K'^
C 18

SECTION B-a

FACES B & D
FiQ. 60. —Rigid steel tower.

Eat of the work on it can be done by unskilled labor. The flexible towers
i rule come all assembled.

69. The design of a steel tower is largely the work of the structural
Orineer, but the electrical engineer should be able to specify the various
8 sses that the tower must withstand, the height, length of cross arm, etc.,
* be able to check the design by calculating the stresses in the various
(See Pars. 131 and 132.) Towers made with members which are
deteriorate very rapidly when corrosion once begins, and the cost of
ti. ,

987
Sec. 11-170 POWER TRANSMISSION
painting such towers, should this forin of protection be found necessary, will
be high. Members should never be much less than J^^g in. (0.48 cm.) thick.
Fig. 60 shows a standard tower, Alabama Power Co., designed for two
110,000- volt circuits and two ground wires. Members 1 and 2 and channel 3
below the ground line are part of the foundation and are designed to transmit
the horizontal shear. (See Par. 132.) Fig. 61 shows a flexible tower.
170. Protection against corrosion is obtained by painting, galvan-
izing and sherardizing. For proper protection, paint must be applied
every 2 or 3 years, and if the tower consists of a large number of small mem-
bers, the expense of painting may be prohibitive. Where the structures
consist of a few members, painting may b(
economically used. One coat of hot dip gal-
vanizing, well applied, offers protection foi
perhaps 30 years, except at the ground line
A shell of concrete at the ground line ma>
materially increase the life of the tower
Sherardizing or "dry galvanizing," gives s
uniform coating at a low cost, and offers s
high resistance to wear and abrasion. If th«
zino is removed by abrasion or bending, th«
zinc-iron alloy still offers protection.
171. Erection of the tower is ordinarilj
by gin poles or by shear poles. The formei
device consists of a wooden mast or a frame
which must be set outside the tower base
The butt must be firmly anchored, and th(
l>ole strongly guyed, especially in the direc-
tion of the back line.

Elevation

61. — Flexible tower. Fio. 62. —Concrete anchor for steel tower.

The shear pole supports the raising line and affords a means of raisinj
the tower by a straight away pull. The straight shear pole has a groove aj
the top, over which the rai.sing line passes. The shear pole maybe lowered
to the ground when the raising line clears the top.
Heavy towers must often be braced at the base by some form of strut,
to reinforce the tower against the stresses duo to erection.
172. Special structures are often required for transpositions, and »1
points where the line crosses a river, a bay, or a railroad. They are alsc.
used where the line makes a sharp angle; where the line is dead-ended; anc
to allow the installation of line switches, protective apparatus, or outdooi
sub-stations or switching stations. Special structures are usually very ex-

988
 POWER TRANSMISSION Sec. 11-178

pensive as compared with the standard towers, and where one of the latter
will answer the purpose, it should be used.
173. Steel towers may be set directly in the ground, in which
case the steel should be well protected by galvanizing. The footings are
usually made by bolting an angle or channel iron directly to the bases of
the anchor stubs. For the heavier structures, a built-up grillageis necessary.
Fig. 62 shows a concrete anchor.

POLE ACCESSORIES
174. Wooden cross arms may be of either Norway or yellow pine, long-
leaf yellow pine, Washington fir, though other woods such as cypress, oak,
spruce and cedar are used to a limited
extent. Long-leaf yellow pine, and Wash-
ington fir are the best woods for high-class
construction, the average life untreated
being 8 and 11 years. Wooden cross arms
are being used in connection with steel or
concrete poles. In certain localities, cross
arms are being treated to prevent decay.
The full-cell treatment (.see Par. 161) is
usually employed, although the initial
; treatment by live steam is found un-
, necessary if the arms have been well sea-
soned. Cross arms should be seasoned for
: at least 3 months and painted with two
I coats of white lead paint, unless properly
. treated with a suitable preservative. For
the voltages employed in transmission
work, there has been no standard size
of cross arm adopted. In the lighter con-
struction, the standard electric light cross
arm, 3} in. X4i in. (8.25 cm. X 10.8 cm.)
often answers the purpose. For heavier
work, siaes ranging from 4 in.X5 in. (10.2
cm. X 12.7 cm.) to 5 in. X 7 in. (12.7
;
cm. X 17.8 cm.) are used.
Cross arms should be snugly fitted into
'

a 0.75-in. (1.9 cm.) gain. Unless the pole

previous to erection has been treated by
some preserving process, the gain should
be given a good coat of mineral paint.
Cross arms maybe secured to the pole by
two lag bolts, though in the best construe- |
lion the cross arm is supported with a 5

through bolt and braces. The cross arms

jn alternate poles should face in opposite Ground Wire CoU
iirections. »tBMeofPoie
176. Cross-arm braces are discussed _. /.o ttt-
n Sec. 12, Par. 177 to 179. 63.—Wish-bone cross arm.
-^i"-
t i.

176. Double cross arms should be used where very large stresses may
)ccur such as at line terminals, corners, curves, and where extra precautions
igainst life or property hazard are required, as at railroad, highway, or low-
'oltage line crossings. See Sec. 12, Par. 178.
177. The wish-bone and bo-arrow cross arms, made of angle iron, are
ised for wooden-pole, single-circuit construction. The ground wire is
arried on the bayonet, at the tip of the pole. See Fig. 63.
178. Insulator pins are made of wood, of steel and of steel in combina-
ion with porcelain. Although the wooden pin adds to the insulation, the
ielectric stress in the insulator is so localized, especially in wet weather, that
ttle gained; wood deteriorates rapidly, being carbonized by leakage
is
urrents, and eaten by nitric acid which forms in the presence of high voltages.
^ ''irthermore, a wooden pin is weaker mechanically than a steel pin, hence
•squires a larger hole in the cross arm, and thus decreases the mechanical
rength of the arm. Wooden pins should be used only for the lightest
instruction, and with voltages not exceeding 20,000. They are made from
98»
 — —

Sec. 11-179 POWER TRANSMISSION

locust, oak, maple, hickory and eucalyptus, and should have a fine straig
grain, free from knots.
179. A wooden pin with a centre bolt is common. bolt serves as The
cross-arm fastening and the wooden portion holds the insulator. TJ
advantage of this over a straight wooden pin is that a much smaller cros
arm hole is required.
180. Steel pins may be of steel, malleable iron, cast iron, cast steel,
combinations of these. They are much stronger than wood pins, and whi
well galvanized have a much longer life. They are either cemented direct
into the insulator, with Portland cement, or capped with either a wooden oi
lead thimble, which is screwed into the porcelain.
181. Clamp pins are designed to eliminate the weakening of the cro
arm, due to removal ofvaluable material when holes are drilled for the ins
Eins. Furthermore, they reduce the concentration of leakage current, ai
ence the burning and charring of the wood.

Top Tie showing; tfae use of flat armor idre

No.2 D.i 8. Tie WJpe .

-Pig-tail or Iloldlng-ilown Tie.
.
1
. > Fyr Aluminum Couductor use Strauds of 214,000 CM,
J
/.^_J^_JS. Aluminum Ci,Uo t»i Iloldiu; Dgwn Tie.
XT iT^'^, Fm Copper Conductor use No. 10 S.n.8..Aajualfd Telephone Wire or
Meranon lie- AimailedStr»nd»otNo.OU Copper CebW A tKnit4^ ft..'f wire Neceasag

Fig. 64. — Insulator ties.

182. Insulator pins with a porcelain base (lead or wood thimb!

prevent an arc striking from the conductor to the pin, have a long h'
and are mechanically strong. Even tliough the porcelain cracks, t
pin will only bend and the insulator will not fall.
183. Method of hanging suspension insulators. When suspensi
insulators are used, the breaking of a conductor pulls the string into
nearly horizontal po.sition. The string should be able to swing freely
line with the unbroken span and the tower connection at the top of the sv
pension string should be made as snug as possible to the under side of the cr<
arm, to avoid torsion on the arm.
184. A tie wire or a clamp may bo used to fasten the conductor to t
insulator. The main function of a tie is to hold the conductor securely
the insulator, and prevent it from creeping from one span to the
ne;

Its form depends largely on the type of insulator used. Aluminum i

wires should l)e used with aluminum conductors, as contact with ott
metals may form a galvanic couple and produce corrosion. Furthertno)
a harder metal will injure the soft aluminum. A large bearing area
mv
f) be allowed where aluminum is used, as it is softer than iron or copp*
alun
No. 2, No. 3 and No. 4 A.W.G. have been found most satisfactory for
nam ties. A few typical insulator ties are shown in Fig. 64, and Fig.
hows two Clarke insulator clamps.
990

I
 POWER TRANSMISSION Sec. 11-186

Owing to vibrations in the span, which are reflected at the points of support,
aluminum strands tend ultimately to break.at the tie when pin-type insulators
are used. To prevent this, flat aluminum armor wire, usually 0.30 in.
(0.76 cm.) wide and 0.05 in. (0. 127 cm.) thick, is first wrapped around the
conductor and the tic then made outside the armor as shown in Fig. 64.
Flat armor wire is also used with suspension insulators, but the effects oi
vibration with this type of insulator are much less than with the pin type.

Fig. 65. —Insulator clamps.

185.Cable clamps for suspension insulators may be designed either
.0 allow the cable to slip through and equalize the horizontal stresses in
idjacent spans, or to holci the cable to approximately breaking loads, in case
if a broken span. The clamp should be designed with a liberal cable seat
.ad long, free, well-rounded approaches, so that the conductor will not be
.lermanently injured if a span breaks, and the string is thus thrown tempo-
I
arily into use as a strain insulator.
186. Suspension strain or anchorage clamps should admit the wire
.:om the span without producing any kinks, or sharp bends, and should have
long, liberal bearing surface. The cable should not be held by such
Bvices as Uor J bolts, but rather by flat smooth surfaces.

POLE BRACES, OUYS, AND ANCHORS

187. Pole braces consist of shorter and lighter poles bolted against
|,ie main t>ole. They are sometimes preferable to guying, especially where
; narrow right of way does not allow a guy wire to be used. The brace
hn be designed to take tension and compression; assist the main pole to
IfiiBt the stresses in the direction of the line, and is not easily damaged
I'aliciously. Owing to the increasing cost of poles, the cost of erection, and
^.e liability of destruction by grass fires, guys are ordinarily to be pre-
rred. Fig. 66 shows standard methods of bracing. The bearing area of
le soil can be increased by fastening planks to the base, or by placing a
fit rock under the butt. A log bolted to the butt also permits the brace
take tension. An A frame or double-pole, shown in Fig. 66b, may be
[betituted for the braced pole.
188. Quys are necessary to assist the supporting structure in resisting
[eh unbalanced stresses as are produced at angles, terminals or on sloping
|3Und. They are also used to give the line increased stability in places
\\<ite a failure is very undesirable, where a hazard to life or property must

nan
Sec. 11-189 POWER TRANSMISSION
be avoided, as at a railroad crossing, or where a line runs parallel to or cross
a highway. Steel towers are seldom guyed, their resistance to overturnii
being sufficiently large (also see Par. 133 and Sec. 12, Pars. 174, 176, 176).
Well-galvanized steel strand should be used for guys. See table Par. 10
189. Straight-line guying is used to give increased stability to thelin
Approximately every twentieth pole should be guyed, in the direction
the line, either by head or anchor guys, and, if possible should be si(
guyed as well. Head guys should be used when a line runs over abrupt
sloping ground, in order to give the line increased longitudinal stability.
190. Guy anchors are necessary where there are no trees, poles, or rod
to which the guy line may be conveniently attached. The simplest ai
most reliable form of anchor is the so-called "dead man, " which consists

;;OB^

Log About 5 Long

)> >• 14"Diaraeter

Fig. 66. —Pole brace. A-frame.

a log, 8 to 15 in. (20 to 38 cm.) diameter and 5 to 12 ft. (1.5 to 3.7 m.) Ion
A guy rod is passed through and held by a nut and washer. The log ,

buried to a depth of from 4 to 7 ft. (1.2 to 2.1 m.), depending on theloadj

must carry, and the character of the soil. Malleable iron plates may seri
the same purpose. j

191. Patent anchors. The many types of patent anchors depend a

their holding power upon projections that are brought into play upJ
reversal of stres.s. The anchors are placed in position by being drivq
screwed, or buried in the ground.
192. Rock anchors are often desirable where ledges or large bould
are encountered. They are made by setting an eye-bolt into the rock w
or without cement, depending upon the character of the rock.

CONDUCTOR CONSTRUCTION
193. Wire stringing may be accomplished either by securing the end
the wire and carrying the reel forward, or by maintaining the reel station^
and carrying the end of the wire forward. The former method is
adapted to light construction and long lengths, whereas the fixed reei
best adapted to heavier construction and shorter lengths. The conductj
are drawn up by means of a team, and when the proper sag and tension |

obtained, the wires are attache<l to the cross arms by snub-grips, thus mak
temporary dead-ends which remain until the lineman can attach the clai
or make the tie. Where flexible or light structures are u.sed, those must
guyed temporarily until a permanent line anchorage is made.
194. Phase wires may bo arranged (Fig. 67) (a) in a horizontal pi
(b) in a vertical plane; (c) at the vertices of an e<iuilateral triangle; (<f
the corners of a square (quarter-phase) and (e) at the corners of an isa
;

992
 POWER TRANSMISSION Sec. 11-195

triangle. Only in (c) are the conductors symmetrical with respect to one
another. In the other cases, except (d), the inductive drop and charging
current are unbalanced, but these effects are so slight that they can be neg-
lected. The arrangement of circuits on a pole will be determined by mech-
anical considerations and the type of construction employed. When
making inductance and capacitance calculations, the average distance between
wires, or the cube root of the product of all three of the actual distances
may be used. Either method intro-
duces only a slight error. For spacing
and clearances see Fig. 56.
196. Cable splicing. The insula-
p
J_ 1 _1
tion should be carefully removed from
the ends of the cable to be spliced, Horizontml Place
Horitontal Plare
close attention being given to getting Equal bpaciug
Cnequal Spacing
the copper perfectly clean. A
copper
sleeve of the proper size may be used
to make the joint. The joint should
be left smooth and free from any little
points of solder or sharp edges, as
the.se factors tend to produce ab-
normal dielectric stress.
All burned or imperfect material in
the insulation should be removed.
The braid and tapes should be taken
back far enough to allow the splices to
be completed without touching them;
this is very necessary owing to their
low insulating properties.
The insulation should be beveled
down to a very thin edge until it has
the appearance of a well-sharpened
ead pencil this bevel or taper should
;

oe very gradual. If the taper is too

ihort, it will be difficult to put the
splicing compound on with sufficient
Tensity where the insulation stops at
he joint, or at the end of the scarf. ! laoacelei Eight Irlanflt
More high-tension joints break down Isosceles Eight TriaDzle*
t this point than at any other one ,, „» ^^ , -l

jlace. The remedy is a very long, t la. 67.— Grouping of phase wires.
;radual taper or scarf.
'^ When possible, a good rubber cement should be used, smearing the taper
,8 far up on the insulation as the splicing compound is to go, keeping it
i^'ff the copper. The cement should be allowed to dry out until all moisture
]p(iia8 disappeared, leaving it firm and sticky. Enough pure rubber should
;( '6 put on to cover the copper, running about one-third of the way up on the

Rper. This should be covered with a good rubber splicing compound until
is somewhat larger than the rest of the cable. Care should be taken to
.• as much tension on the splicing compound as it will stand, in order to
t it on tight, to exclude all air and make the whole a solid, dense mass.

.a the case of submarine cables, the vulcanizing of all patches and splices
recommended.
I
On
small stranded joints, which must be kept flexible and which cannot be
ad|)ldered,a layer of tin-foil over the joint is recommended; this should be laid
before the rubber is applied, and will prevent any corrosive action of the
laiia

bjilphur in the rubber on the unsoldered joint. (Also see Sec. 12, Par. 216.)
196. Joints in transmission lines are seldom made up from the con-
'letor itself but are almost entirely patented devices. Aluminum is not
adily soldered and hard-drawn copper becomes annealed when soldered.
Western Union joint is used only for small wires. The so-called dove-
splice is made by fitting the strands of one cable between those of the
• r and wrapping one strand at a time tightly around the_ others and

ind the cable. The parallel-groove clamp is used where a jumper con-
t.on or station connection is to be made.
j.97. The Mclntyre joint is used chiefly on small sizes of cable, although
has been used on sizes as large as 650,000 CM. It is made of seamless

993
Sec. 11-198 POWER TRANSMISSION
copper or aluminum tubing, oval
in section, into which each conductor ii

pushed from opposite ends, until the conductors project about 2 in. beyonc
the ends of the sleeve. The tube is then twisted three or four complete
turns by special tools. This joint is eflBcient both electrically anc
mechanically.
198. For steel-reinforced aluminum, the simple Mclntyre joini
can be used in sizes up to 4/0, and develops about 80 per cent, the entire
strength of the cable. For larger sizes, a 2-piece compression joint, usinj
a steel Mclntyre joint for the core of the cable, is recommended. Th(
aluminum part is threaded together in the middle and the ends are com
pressed on to the cable by means of a portable hydraulic jack. Anchori
should be of thoroughly galvanized malleable iron clamps, which hold th(
aluminum and steel core separately.
199. Ground-wire construction. See Par. 60, 91. Ground wires an
designed primarily to protect the line from lightning disturbances, am
should be placed well above the line conductors. With wooden poles, thi
so-called "bayonet" shown in Fig. 63 is commonly used. This may bi
a piece of angle iron or a pipe properly drilled and fitted to be fastenec
to the pole top to receive the ground wire. Where steel towers or poles
and consequently long spans, are used, the ground wire is often depende<
upon to take up some of the unbalanced stress due to the breaking of i

line conductor. This is especially true when flexible towers with pii
insulators are used. A ground wire is absolutely necessary to hole
these towers in the correct longitudinal position, if suspension insulator
are used. Some companies mount the ground wire on insulators as an extri
conductor during the winter. The ground wire should be held securely U
_

the pole top by a clamp which is slightly flexible, has a grip of several inches
and flaring, well-rounded approaches. Taps to ground connections shouU
not be soldered, but rather fastened by well-designed clamps. The win
should be grounded at every steel pole or tower by contact with the meta
work. If the metal work is completely imbedded in concrete at the base
the ground should be made by driving an iron pipe, about 6 ft. (2 m.) loni
and 1 in. (2.5 cm.) diameter, into the ground, and connecting it to the meta
work with a copper wire.* If the soil is dry, the ground can be made mon
permanent by pouring salt water around the pipe. When wooden polei
are used, the ground connection should be made at every pole, by running i

copper wire down the pole and grounding to a pipe driven in the ground
or by coiling the wire (bare) in a flat helix and placing it under the pole
butt.
200. Transpositionsf are made to eliminate electrostatic and electro
magnetic unbalancing of the various phases; to eliminate mutual inductioi
between parallel lines; and to prevent disturbances in neighboring telephom
and telegraph circuits. When used solely to improve operating condition
of the power line, the distance between transpositions may vary in differen
lines from 2 to 40 miles. When used to reduce disturbances in ncighborint
telephone and telegraph circuits, the distance between transpositions i

determined by the irregularities of the parallel, the characteristics of th

telephone line, etc. Generally it is of the order of magnitude of one milt
Fig. 68 shows the transposition of a section of three-phase line and a tel«
phone circuit.
201. Transpositions axe commonly made by rotating the delta; b;
gradually changing the relative positions of the wires; by dead-ends an
jumpers, similar to the method employed in telephone work. The firs
method requires special structures that are usually interspersed between th
standard towers. When the wires are arranged at the corners of a trinngli
the delta is rotated through 60 deg. in one span, and through anoth(
60 deg. in the next span. This is shown in Fig. 69 (o). When the wires a
lie in the same plane, resort to an intermediate triangular arrangeinei

* Creighton, E. E. F. "Ground Connections in Lightning Protedn

Systems/' G. E. Review, 1912, pages 12 and 66. ^
t Fowle, Frank F. " The Transposition of Electrical Conductors." Trmn
A. I. E. E., Vol. XXIII (1904), p. 659. |
Osborne, Harold S. "The Design of Transpositions for Parallel PoW'l
and Telephone Circuits." Trans. A. I. E. E., Vol. XXXVII (1918), p. 89;
 POWER TRANSMISSION Sec. 11-202

must be made, as shown in Fig. 69 (6). Both of the above methods require
special structures, and the transposition spans are usually about one-half
the length of standard spans, in order that proper clearance between con-
ductors may be maintained. The jumper method, shown in Fig. 69 (c),
requires only a standard strain tower, which may be slightly modified if the
conductors happen to lie in a vertical plane. It is frequently possible to
affect transpositions using only standard towers and spans.
202.A telephone line is essential to the satisfactory operation of every
transmission system, as a means of communication between generating
stations, sub-stations and patrolmen. When possible, the telephone wires
should be run on a separate pole line to eliminate disturbances and trouble
caused by the high-tension circuit. The cost of an extra pole line is often
prohibitive, so it then becomes necessary to carry these wires on the power

1 !
Sec, 11-204 POWER TRANSMISSION

Standard Tower

Transposition Tower

Standard Tower

( a) Single Circuit Construction-Symmetrical Spacing

Standard Tower

Transposition Tower

Standard Tower

( b) Vertical Spacing

Standard Strain Tower

(c) Dead-end Jumper Metbod

Flo. 69. — Methods of transposition.

006
 —

POWER TRANSMISSION Sec. 11-205

205/ Extra precautions in overhead-crossing construction.* No

allowance shall be made for deformation, deflection, or displacement
of the supporting structures. In computing the longitudinal stresses
upon conductors and their supports, ancl the sags corresponding to given
limiting stresses in conductors, the loading shall be assumed as one of the
following, according to climatic conditions of the locality: Heavy loading;
conductor plus 0.5 in. (1.27 cm.) radial thickness of ice and horijsontal
wind pressure of 8 lbs. per sq. ft. wind pressure. Minimum temp. 0° F.
—
Medium loading 2/3 heavy loading, but in no case less than 25 per cent,
Minimum temp. 15° F. Light loading
in excess of weight of conductor.
2/3 medium loading, but in no case less than ^5 per cent, in excess of weight
of conductor. Minimum temp. 80° F.

Telephoi

_Cylindcr Gap
0£0 Arresters

^ ^-i,
^ Horn Gaps
Line Entrance Bushings
""^ly~ "
_V»ouum Gap.
Arresters

J
0£0t
Expulsion Fuses
Cylinder Gap Arresters
" D.P.5.T.
_gn_ ,
S.P. Vacuum Gap ArreBter
i ^
Choke Coils

1:1 Insulating Transformer

D.P. Vacuum Gap Arreater

^1:1 Insulating Tninafonner

^ Low Toltag« Arrester

Intermediate Station

-Terminal Station

(O)Without Drainage OoilB (6) Witli Drainage Coils

FiQ. 70. —Telephone protection.

Under the preceding loads assumed, the calculated stresses in the steel
embers and in the guys shall not exceed the following values:
ructural steel
Tension 27,000 lbs. per sq. in.
Shear 24,000 lbs. per sq. in.
Compression 27,000 L/r
)lts, rivets, pins
Shear 24,000 per sq. in.
lbs.
Bearing 48,000 per sq. in.
lbs.
Bending 36,000 per sq. in.
lbs.
Guys One half the ultimate strength.
towers supporting the crossover spans of overhead supply lines
Poles or
railways shall, unless physical conditions or municipal requirements
2r
^vent, have side clearance not less than 12 feet from the nearest track rail,
'^ept that at sidings a clearance not less than 7 feet may be allowed.
The clear space between the lowest overhead supply line conductor or
'
e and the heads of rails above which the former cross shall not be less than
> following at 60° F., with no wind, where the conductor or wire has fixed
* ports and the span does not exceed 150 feet and where men
are permitted
< cars.
00 volts to ground to 15,000 volts, 28 feet.
5,000 volts to 50,000 volts, 30 feet.

National Electrical Safety Code, Third Edition, 1920, p. 139.

997
Sec. 11-206 POWER TRANSMISSION
For longer spans they shall be increased 1 inch for each 10 feet of the excess
between 150 and 300 feet and by 1 inch for each 20 feet of the excess beyond
300 feet.
HIGH-TENSION CABLES
206. Undergrround and submarine cables are often used for trans-
mission purposes. Pressures up to 60,000 volts are successfully employed.

(a) Round Type. (b) Sector Type

Fig. 71. —Cross-sections of high-tension cables.

207. There are two common types of high-tension cables, thi

round type, shown in Fig. 71(a), and the sector type, shown in Fig. 71(b)
For the same copper and thickness of insulation the sector type has th'
smaller diameter, as shown iJ
-96 the plot. Fig. 72. The relatioj
1
of copper areas in the tW'
^g,.90
types, for fixed diameters au'
thickness of insulation, J

shown in Fig. 73 ( Simple

2 sn Wire and Cable Co.).
208. The essential chd
^ acteristics of high-tensio
Fig. 72.—Comparison
sector and round types
of outside diameters,
of high tension cables,
cable insulation
insulation
arc:
resistance;
hig'
hij
dielectric strength; low permil
and low dielectric loss.
tivity or dielectric constant; '

Insulating Materials. Three types of insulation are in common vui

(a) rubber compounds; (6) varnished cambric; (c) impregnated paper.
209. Rubber compounds consist of Fine Para or Smoked First L«t
 POWER TRANSMISSION Sec. 11-211

repelling, insulating conipound, and has a dielectric constant practically

equal to that of the varnished cloth it prevents the tapes from unwrapping
;

when cut, and is of such a nature as to allow the layers to slide upon one
another when the cable is bent. The varnished cloth is apphed in the form
of tape wound on helically, the filler being appUed between layers.
Varnished cambric has high dielectric strength, is not affected by ozone or
corona, and is not easily overstressed. It is well adapted to high tension
work. Varnished cambric cables are more flexible than paper cables, more
easily jointed and can be installed at lower temperatures with less risk of
injury. They can be submerged several hours without absorbing moisture.
This allows them to be used extensively with a braided covering only. They
ire well fitted for service where the temperature is so high as to make
•ubber insulation unsuitable, or where surges in the voltage takes place.
SV^hen lead-covered and armored, they make excellent submarine cables.
*11. Impregrnated paper insulation consists of manila paper apptied
firmly and evenly to the conductor and then thoroughly impreg-
lelically,
»ted with an insulating compound. Before impregnation, the paper
OBulation must be thoroughly dried.
The value of the paper as a dielectric depends mostly upon the composition
if the impregnating compound. It should have high dielectric strength,
ow dielectric constant, low dielectric loss, should retain its insulating quali-
les at high temperature, should be sufficiently viscous at high temperature
o prevent flow from one part of the cable to another, and sufficiently fluid
.t low temperatures to allow bending of the cable.

I
Cables insulated with impregnated paper usually have high dielectric
strength, and have lower capacitance and lower dielectric loss than cables
osulated with either cam-
bric or rubber insulations.
mpregnated paper can be
perated safely at higher
amperatures than the other
irpes of insulations. Paper
ables require a lead sheath,
nd successful operation de-
,ends upon the integrity of
le sheath.
i tl2. Dielectric loss is an
iiergy loss which occurs in
le dielectric of a cable. In
(ibles for voltages less than
fiOO volts, this loss is negli-
|ble. Fig. 74 shows the
feet of dielectric loss on the
irrent-carrying capacity of
cable. The allowable
pper loss is the difference
tween the heat dissipating
of the cable and the
'ility
lectric loss.
Hclow are given what are considered as normal values of no-load power-
tor and dielectric loss per foot of cable at different temperatures for 3-
iiductor cables operating at 13,000 volts and higher. Dielectric loss data
'
meagre and little has been done as yet in the matter of standardizing
loctric losses in cables.
 : :

Sec. 11-213 POWER TRANSMISSION

213. Maxizuum temper attire. As recommended by the A. I. E. E.,
the maximum safe temperatures in degrees cent, at the surface of the con-
ductor in any cable is
For impregnated paper insulation (85 — B)
For varnished cambric (75 — E)
For rubber insulation (60 — .B/4J
where E is the operating phase voltage in kilovolts.

214. High voltage cable testing. * High voltage tests should be applied
between conductors, and between conductors and sheath. The test voltage
E is determined by the ioTrnxila. E ~ Kd logic D/d where D is the diameter
over the insulation, d the diameter of the copper, and K a constant depending
on the dielectric strength of the insulating material.
216. Electrical disadvantages of a cable system. A cable system
differs from an overhead system in that the capacitance is much greater
while the linear inductance is neghgible. Hence the charging current
may be equal to or even greater than the load current itself. Surges and
transient phenomena are much more common than in an overhead line of
the same length.
216 Underground cables for high-tension work are ordinarily installed
in standard ducts (see Sec. 12). All underground cables should be lead
covered. The rubber covering may last for years after the lead sheath
has been eaten away by electrolysis or has been injured mechanically.

SUB-STATIONSt
217. The building is intended to shield the apparatus and equipment
from the weather, as well as to furnish a shelter where repairs may be
quickly made. A low-voltage station may have a fairly low initial cost.
On the other hand, the large clearances required by overhead bus-bars,
connecting-leads, arrester equipment, etc., make the high-voltage sub-station
a rather expensive afifair.

218. The transformers should be installed in separate fireprool

compartments which should be of such construction as to prevent buniinj
oil from flooding the station, in case of trouble. Provision should be niade
for ea.sily moving the units, so that repairs and replacements can be quicklj
made. Each transformer is often installed on wheels and rails, and truckf
are provided in order that the largo units may be readily moved.
219. Protective' equipment is often placed indoors. The largei
sizes of aluminum arreHtors and the largo overhead clearances required foi
the horn-gaps often necessitate that these, as well as the aluminum arresters
be placed out-of-doors. Where there are no overhead busses or inflamniabk
material, the following clearances from the top of the horns should w
allowed: for pressures up to 16,100 volts, 3 ft. (1 m.); from 16,101 U.
At
37.900 volts, 4 ft. (1.2 m.); from 37,901 to 70,000 volts, 6 ft. (2 m.).
nressures above 70,000 volts, the horn-gaps should never be placed indoors
The auxiliary charging gaps for the aluminum arresters, when charging
should always be in sight of the operator.
220. Choke coils are often mounted on post insulators on the outsidi
of the building, especially where very high voltages are employed. For
thi

lower voltages they may be conveniently installed on the inside wall, o

directly in the switch leads.
221. High-tension bus bars are hung from the ceiling by suspensioi
insulators, are suspended by ceiling insulators, or are mounted on post in
sulators. Owing to their low cost it is desirable to utilize su-spensioi
insulators whenever possible. Fig. 75 shows typical high-tension bu
construction. (See Sec. 10, Par. 869.)
222. Entrance and outlet for lower voltages are as shown in Fig. 7t
Plate glass with a central hole, sjightly larger than the conductor, is ofte
• Middleton and Dawes. "Voltage Testing of Cables." TraHi.'A. 1. 1

'Vol. XXXIII (1914), p. 1185.

t See Sec. 12, Par. 51.

1000
 POWER TRANSMISSION Sec. 11-223

ised, as it keeps the weather out. Where high-voltage must be carried into
I station, great care should be used in the design and selection of suitable
jushings. A simple entrance for a 110,000-volt line consists of a 5-ft.
'1.5 m.) slab of glass or marble, with a small hole sufficient to admit the
jonductor without undue corona discharge. In Fig. 77 are shown typical
yall bushings.
223. The condenser type * of bushing: is built up by placing thin layers of
;in foil between concentric layers of insulation, and making the areas of the
oil equal, irrespective of the diameter, thus giving uniform potential dis-
iribution. Such a bushing is shown in Fig. 77 (c).

"'J'-yfjW/M'/li>J«t»

Fig. 75. —Typical sub-station.

SS4. Roof entrances and horn-gap outlets require a petticoated
isulator in addition to a wall bushing in order to prevent trouble which
^ight arise from rain and condensed moisture. The ratio of wet to dry
ash-over should be very high. Fig. 134, Sec. 10, shows a typical roof in-
ilator, and Fig. 78 shows standard roof construction.
225. A Sub-station wiring diagram is shown in Fig. 79, and Fig. 80
;iows a typical instrument panel. Instrument leads A and B (Fig. 80) corre-
pond to instrument transformer leads A and B (Fig. 79).
226. Outdoor switching stations are often installed at points where
le amount of switching actually done does not warrant the expense of a
uilding for housing the equipment. In such cases, a safe and economical
instruction is to erect a platform on a special structure, upon which the
ivitch-handles, transformers and other equipment are placed.
• Reynders, A. B. "Condenser Type of Insulation for High-tension
•erminals." Trans. A. I. E. E., Vol. XXVIII (1909), p. 209.

1001
Sec. 11-226 POWER TRANSMISSION

Fig. 76.— 80,000-volt entrance.

( C) Condenser Tyi
Bushiiut

( b) 80.000 Volts
FiQ. 77. —High-tension biuhingn.
1002
 POWER TRANSMISSION Sec. 11-226

Mild Steel Strap

No.2 Solid,
Conductors)

'la. 78. —Typical roof construction showing horn gaps and roof insulators.
.-•r-OutgolDg Feeders

lecml Power n Q U^tlag Oabinei

Kwv^vw^InAaI Local Serrloe

r'~T-''^T^ Transformert

wndiit 110,000' Vdt Liu

FiQ. 79. —Sub-station wiring.
1008
Sec. 11-227 POWER TRANSMISSION
227. Outdoor sub-stations are rapidly coming into use, since the largi
clearances necessitated by high voltages would require a very large build
ing. They are also used where small loads are tapped from the main line
requiring only one transformation from line to consumer. Switches
arrester equipment, power and instru-
ment transformers have been de- fotentiol Current
veloped to such a point that little de-
terioration occurs due to the weather.
The outdoor equipment should be
installed on paved, well-drained
ground, and should be enclosed by a
fence to exclude intruders. A small
building may be necessary for making
repairs, as well as to protect the oper-
ator and the switchboard and meter
equipment. Climate, location, com-
parative costs of building and ground,
voltage and method of operation, are
factors which largely determine the
type of station. The transformers
and arresters should be shielded from
the hot sun, and in winter the electro-
lytes and cooling water must be pre-
vented from freezing. Painting the
arrester tanks white tends to prevent
the absorption of heat and cold.
Transformer oil thickens and loses its
insulating properties under conditions
of extreme cold. An outdoor sub-
station can be enlarged or modified
with but little expense.
OPERATION
228. A chief operator should be
In absolute control of the system
and should have direct telephone con-
nection with every part of it, not only
over the company's private line, but
over a leaded wire as well, as in times
of emergency the private telephone
line may be crippled. Likewise the
chief operator and the sub-station
operators should be in telephone con-
nection with all linemen and patrol-
men. In the chief operator's ofBce
there should be a dummy board
showing the position of every line and
switch on the system and whether A Ammeter
each switch is opened or closed. No V Toltraeter
switch should be operated, no genera- l.W. Indicating Wattmeter
tor connected to or disconnected from W.H.M. Watthour Meter
the system, no water taken from a B.L. Inverse Time Limit Bell^^
flume, unless the chief operator is noti- T.C. Trip Coils
fiedand sanctions the operation. All
communications should be repented to Fia. 80. — Instrument panel for 4
I

the sender in order to prevent any sub-station. i

misunderstandings and should be written in the log book to reduce mistnk

to a minimum.
229. A complete log should be kept, not only by the chief operator, b
by switchboara operators as well, of every transaction, loads carried, shu
downs, causes of trouble, and times of connecting or disconnecting mote.
and generators on the system.
A multi-recorder* for lightning and switching phenomena has been devise,
•Creighton, E. E. F., Nichols, H. E. and Hosegood, P. E. "MxiV
Recorder for Lightning Phenomena and SwitchitMt." Trans. A. I. E. I
Vol. XXXI (1912), p. 825.
1004
 POWER TRANSMISSION SeC. 11-230

whereby the exMt times of switching, shut-downs and disturbances are auto-
matically recorded.
230. A periodic line inspection should be maintained over all lines
the frequency of mspection dependinR on the country and the importance of
the lines. A patrolman should be assigned to about 20 miles of line,
as one man is then always within 10 miles of each section
of the line
1 he patrolmen may cover the ground on foot, on horse-back, with a horse
and team or an autornobile, depending entirely upon the nature of the
right
of way, his duties and the distance he must travel. The pole switches and
line sectionahzing switches should be inspected at least
once a month to
lasure proper ahgnnient of parts and proper operation in times
1 he patrolman should be held responsible for the proper operation
of n^.
' of bxM
particular section of the Une.
Defective insulators which cannot be detected by inspection may
be
located by the use of a megger. A sound insulator should have a resistance
greater than 1,000 megohms, whereas, if the porcelain or glaze
is injured or
cracked, the resistance will drop below 500 megohms. Other methods such
as the buzz stick," "spark stick," etc., may be used to locate defective
insulators, even when the hne is in service. (See Par. 82.)
repairs and replacements are often made only after the line
•

18
^V" I"^^^ The lineman
dead.' or patrolman should notify the chief operator when
a particular hne or section is desired. The line should then be cleared not
merely through the oil switches, but should be opened by disconnection
switches as well Before a lineman is allowed to work, the line should be wet
grounded, m
order to eliminate the electrostatic charge. If the line closely
parallels another power hne, both ends should be
grounded to eUminate any
dangerous induced potential.
In order to make repairs and replacements without interrupting the
service, special tools, mounted on the ends of wooden sticks, have been
devised whereby insulators may be replaced, conductors spliced, etc., while
the hne is alive.
232. Aluminumarresters* should ordinarily be charged at least once a
day, under normal conditions of temperature. In hot weather, or if exposed
to a higher temperature, they should be charged two or
three times a day
After passing a heavy discharge, and undergoing a high temperature rise, they
charged intermittently while cooling, in order to re-form the
u"l dissolves
which i?®
very quickly when the temperature is above normal
film
charging current should be about 0.4 amp. The
The auxiliary or charging gap
should be closed three or four times or until the arc ceases to flare
jacks are. now available for convenience in measuring
Ammeter
the
An abnormal charging current may denote trouble within charging current
the arrester, such
as carbonized oil between the cones. It is desirable to charge the arresters on

om'^'o'J
'^ ^^^ °°* ^^^ ^* *^® ^^™^ t™®- (^'so see Sec. 10, Par 862.)
"^^'^ ^^^ ""^ "^^^"^ * ^^'^t'oa is provided with
antnm JrhrM""*'"**w^^^
breakere. Where non-automatic switches are used; the operator
f^ Ti !i
"'•«%% the voltage, rather than open the circuit, waiting for the
fco f
line to clear If the line does not then clear, the load
should be thrown over
Z^ Ih^u . k"*-'
^^P*""* "5" ^^ '"*'*« "^^^"^ '*• is essential that the ser-
^® interrupted, resort may be had to such expedients as
^pr«t;^; o^° I

irnormll conlutfon""'' "' ^

^°"°^ '""'"'"• '''• "°*^' '^' "°^^ ^«*'° '>
TRAKSMISSION ECONOMICS
234. ,T
o,.. ,
Value of continuity of service.
No system should be equiDped
"'""^'"^ ^^^'=«?' duplicate lines. liberM^ective
e^iiom?nT'J^^^'°'^''*'"
generating plants in order to insure continuity of ser-
S^^Z^^hT'^'°^Pf'l
o
^th tL
s,',oh .Tr.ft.1
P ^
J}"^
r
TK^ hne'"te"'^Ption
or a shut down justifies the expenditure
should be constructed as cheaply as is consistent
standard of service, without endangering'^life or property!
Fi^thpr TTr'^ should not be
extended to a distance greater than tfiat at
whioh [htf^c'''"'
prospect of selling sufficient power to pay the
develonmpnt
PS£^^"d L^
'^'"'^l-^'''
operating costs of the extension.
MR
reUahili^^
reua ^^A °A
biuty desired,
^^^ °^"^* ^® decided upon after considering the
the character of the country, transportation facilities.

^^'"^'^"^ Aluminum Lightning Arresters."

'^"IfJj^r'lfis^ p^-248.'^''*
''^
Is;
Sec. 11-236 POWER TRANSMISSION
availability of timber, etc. Although steel construction, as an engineering
proposition, is far superior to wood, there are many instances where the low
first cost of wood alone makes a transmission project economically feasible.
236. The length of span should be so chosen as to have the line cost a
minimum. As the length of span increases, the number of supports and insu-
lators decreases, but the height of the support and the conductor spacing
must be increased to allow for the greater sag. The effect of these changes
on cost for steel towers is shown in P"ig. 81. Under these conditions, the most
economical span for steel towers is about 700 ft. Other factors, such as the
decreased cost for pole or tower rights on private right of way, the lesser
number of insulators, with the increased possibility of failure with the longer
span, should receive due consideratiop.
3000

700 800
Spsn-Feet
Fig. 81. —Span length and cost.
80

16
 POWER TRANSMISSION Sec. 11-240

the criterion adopted by engineers. An 80,000-volt line presents no greater

operating difficulties than a 30,000-volt line. Surge voltages are, however,
dependent upon the current and systems have been designed to operate at a
tiigher voltage than is economically demanded, in order to secure greater
"reedom from surges.
60

40 60 go 100 120 ]

Nominal Rating-Kilovolts
Fig. 83. —Cost of station insulators.

COST DATA
240. The trend of construction costs from 1914 to 1920 was con-
nuously upward, and in the latter year peak prices of unprecedented
laracter were reached for both labor and materials. The peak has now
;«n passed and the trend is downward, but stable conditions have not yet
;«a established. These important facts should be kept in mind in making
!e of the figures which follow, acknowledgement for which is due to the
>hn F. Vaughan, Engineers, of Boston, Mass.
S41. Kstimated line costs per mile

COSTS PER MILE

Typical Lines in New Jersey
Estimate from actual construction records for cost per mile of 13.2 kv.
5oden pole lines using1914, 1918 and 1920 prices, open country. No
lecial construction.

1914 1918 March, 1920

One One One One One One

add. add. add.
circuit circuit circuit
circuit circuit circuit

Poles (45 ft.) $1,200 $ 1,500 $2,000

pross arms, insulators
[and ground wire
I Bupports 900 500 1,100 600 1,500 650
liuying 400 500 600
Itiipt of way 200 300 400
150 M.c.ni. wire (3). 2,500 2,500 5,200 5,200 4,200 4,200
Ilround wire 300 500 500
[fobor string wire. . . 200 200 300 300 500 500
acidentale 800 500 1,000 600 1,000 500
Totals. $6 500
, 3,700 $10,400 6,700 $10,700 5,850

1007
Sec. 11-242 POWER TRANSMISSION

29-3 ^
05* 3 g «
— o ^S
i-iOCn^
• to 2

CO. 2 ooi-N a
lo a.-

05_e.'S iS

S O »0 00 "t* «c »*<

t> -<J" * M 05 1^ IN
A
n
^ "<-S§;s Sax
*»
03

»1j 3^4, Tl

— « <" _
O
lO 00 OC ;C «5 (N
M O
« M O
(3 (V •<j<0 • tn Tf •* >0 05
££;
t3 ^ CI- Ct^ C .O?
00 <)* .-1 CC IN >H .-lOJ rtN-(
-IN a'^ f S cf^ i

4» 03

O M

*OOOpN
O +^ TS CO ^* -^ • 05 COC^I^
- ^::2 ej*; ciN
O Oofe.S"" ;

H-o

23O
3
ti 03

13 »,
03 o i

03 £ 01 oj C ij J.

=EE — T) —
. • 5J S n tn
U o fl'2
*^ o ri
oj 5
*^ |m
nO. O"- rt bC c si's i'^
i^ ojS 6C ol3r5
hr o^
^ i s "•mats 0? ^ga|-
bf "^ r w
t=
.i S "" °— ^
ji »}•'- flj

oosSs'^a 'ao , <« o" °a^.S3jg>e33-2

OoOScoK^OWccCuO
 POWER TRANSMISSION Sec. 11-243

O oo O t-

o •
z «-=»= a
-o -w
0X302
So a
0'-<'0 O
I

0(N-*(NOCO<0
CO o>
es CO
X
CO CC
0.-1
O i-c

t»OcDi-<OiO
<0 * h- Tt< >}< .-H

K-

O -"S W!= ft

oootDom
oic a)
OOr;
owea
,-1=*=
- -P o I a

ot- a 'OO) V
I

1 coj-s .-1=*= a
- >°
WO!M o I ft
i
<-<co o

:-

c-r)

^S '^ ei5 O t4 (u ©
Sec. 11-244 POWER TRANSMISSION

OK5 <»-^S_„-S oc« Ng* o o o 00 « m i-

to • »>-''*=o"*'S* S ° C! d • ?f^«2» '-<''2

"3-
•a

to • IB—''•=o^'3'-' fe ° fl fi
•
^j, O ira t~ t- rH K5

""S

.E C3^ g-S TO Tj" in N CO to lO

.

COOO (p^^ i-< —1^ or»(NOiMC<3>0

0-*= giN

ft
c •S-Sos o
tOb- «j-<^
-I°
"3
Occ U O5oo •

o . a* 2
S
^
£
g
o S o 6:2 . M* *0 •-* CO 03
d "Si

«[^ L20 0.

^ Oitc I

) 4,1-1*
j
•S CoiTttr-

^ a
-1 o 5 OS

s-g 1.H
ti'"' - OS'S o flt-t-o3
o ^
a„
c<5.2_««
CO o
•§ '
Sooa" l>V
ft-° coco fi.

a
O a 2 2^0
5 OcfeO o

* coco

^^
rt •

a
a >.T3
05 ea

a^-£
d o o
^- ^
2-a ° 5-*

d h - ^"C'd
-d _ 1«
3c2 o -S • a >> ® Si

o S >) « o S O'-
oa,»; ' »-a iS os I- d— . f»
 POWER TRANSMISSION Sec. 11-245

.-I . S(NCO "O

5 C 00-.
(DO tf 5
O - H -

ooo

_> &0-.0 >B.S 3 3 g r Ml - -

o® ]

d '
2 M
Ol-HlO S e o M. - - -

o a a

DO ft

®i<3 CC t. 03-3
ONoi oo^» :::*c>
f- 2
Sft o>m a g gS
Mb "
d o
PA
Sec. 11-246 POWER TRANSMISSION
246. Cost of cables per 1,000 ft.

2/0 stranded, —
3-conductor lead covered
(Simplex Wire & Cable Co.)

Volts
 POWER TRANSMISSION Sec. 11-251

2S1. Insulators
—"Practical
25. Nicholson, L. C. Method Protecting Insulators from
of
Lightning and Power Arc Effects." A. E. Vol. XXIX (1910),
Trayis. I. E.,
,p.573.
Peek,
26. W., —"Electrical Characteristics the Suspension In-
F. Jb. of
eulator." Trans. A. I. E. E., Vol. XXXI (1912), p. 907.

System disturbances
—252.
" Transient Electric Phenomena and Oscillations."
27. Steinmetz, C. P.
28. Creighton, E. E. F., and Spronq, S. D.
—
"Surges on a Cable System
with an Aluminum Surge Protector." Trans. A. I. E. E., Vol. XXVIII
(1909), p. 805.
29. Faccioli, G.
—
"Electric Line Oscillations." A. I. E. E., Vol. XXX
(1911), p. 1803.
30. Still, Alfred. —
"Standing and Traveling Waves on Overhead
Transmission Lines." Elec. World, Vol. LXI (1913), p. 779.
253. Protection
31. Creighton, E. E. F. and Whittlesey, J. T.
—
"Application of Local-
zers of Faulty Feeders and an Arcing Ground Suppressor to the System of
he Public Service Electric Co., and Descriptions of Several Experimental
Studies."
32. Creighton, E. E. F.
— XXXI
Trans. A. I. E. E., Vol. (1912), p. 1881.
"The Multi-Recorder." G. E. Review, XV
912, p. 434.
33.
—
Hewlett, E. M. "Characteristics Protective Relays."
of Trans,
Vol. XXXI (1912),
i. I.
34.
E.E.,
Elden, L. —"Relay Protective Systems." Trans. A. E.
L.
p. 175.
I. E., Vol.
<CXXI (1912), p. 1911.
254. System connections
35. Steinmetz, C. P.
—
"The Grounding of Transmission Lines." G.E.
leview, XVI (1913), p. 370.
36. Lincoln, P. M.
—
"Transposition and Relative Location of Power and
Telephone Wires." Tra?is. A. I. E. E., Vol. XXI
(1903), p. 245.

265. Synchronous condensers

37. Laycock, H. a.
—
"Automatic Regulators for the Control of Syn-
hronous Condensers in Power Systems." G. E. Review, XVI (1913), p. 428.
266. Mechanical design
38. Lundquist, R. A.
— "Transmis-sion Line Construction." McGraw-
mi Book Co.
39. "Report Committee on Overhead Line Construction,"
of the Joint
A. Convention, May, 1911, Vol. II (also 1912 and 1913 Reports).
•I. E. L.
40. Buck, H. W.
—
"The Use of Aluminum as an Electrical Conductor."
41. Bl.vckwell, F. O. —
rans. International Electric Congress, St. Louis, 1904, Vol. II, p. 313.
"Conductors for Long Spans." Transactions

42. Still, Alfred. —

uternational Electric Congress, St. Louis, 1904, Vol. II, p. 331.
"Sags and Tensions of Overhead Conductors." Eleo.
Vorld, Vol. LIX (1912), p. 1021.
43. Pender, Harold .««> Thomson, H. F.
—
"The Mechanical and Elec-
ric Characteristics of Transmission Lines." Trans. A. I. E. E., Vol.
ZK.X (1911), p. 2241.
44. Pierce, C. A., Adams, F. J. and Gilchrist, G. I.
—
" Theory of the
Ton-elastic and Elastic Catenary as Applied to Transmission Lines." Trans.
.. I. E. E., Vol. XXXII
— (1913).
45. Brown, R. S. "Stresses Produced in a Transmission Line by the
ireaking of a Conductor." Elec. World, Vol. LXI (1913), p. 673.
46. Winchester, L. S.
—
"Experimental Determination of the Strength of
Elec. World, Vol. LVII (1911), p. 667.
'ull-sized Telephone Poles."
47. Still,
—
Alfred. "Flexible Supports for Overhead Transmission
ines." Elec. World, Vol. LX
(1912), p. 97.
48. "Concrete Poles for a Transmission Line for 30,(X)0-volt System at
Eng'g Record, vol. 61, page 668 (May 21), 1910.
arseilles."
49. Still, Alfred. —
"Reinforced Cement and Concrete Poles for Over-
sad Electric Lines." Elec. World, Vol. LX
(1912), p. 658.

1012a
 Sec. ll-2r)7 POWETt TRANSAflSSIOX

257. Operation
50. Wood, R. —"Transmission
J. C. Systems from the Operating Stand-
point." Trans. A. E. I. XXX
— "Continuity
E., Vol. 835.(1911), p.
51. Crawford, Magnus T. of Service Transmission
in Sys-
tems." Trans. A. I. E. E., Vol. XXX
(1911), p. 1049.
52. Steinmetz, C. P.— "Notes on Control and Operation of High Volt-
age Transmission Systems." G. E. Review, XV, (1912), p. 342.
53. Dewey, H. H. —
"The Operation of High-voltage Power Systems."
O. E. Review, XVI, (1913). p. 35.5.
54. CoLLBOHM, Max. H. —
"Servioe Continuity in Grounded Transmis-
sion Systems." Elee. World, Vol. LXIII (1914), p. 870.

10131)

I
 ?.l

SECTION 12

DISTRIBUTION SYSTEMS
BY HARRY BARNES GEAR, A.B.* M.E.
of Distribution, Commonwealth Edison Company, Fellow of the
American Institute of Electrical Engineers and Member of the
Western Society of Engineers
Author of "Electric Central Station Distributing Systems"

CONTENTS
{Numbers refer to Paragraphs)

Classification of Systems 1 Special Methods of Transformation 119

jeneral Applications 7 Protective Apparatus 129
"ypes of Circuita 1.4 Overhead Construction 155
)esign of Circuits 24 Underground Construction 194
ubstationa 51 Distribution Economics 220
Regulation
'ressura 86 Bibliography 237
ooondary Distribution 96

1013
 SECTION 12

DISTRIBUTION SYSTEMS
CLASSIFICATIOK OF SYSTEMS
1. Distributing circuits may be classified as to the nature of tl
— —
current direct or alternating; as to method of connection series or multipl
and further as to phase, number of conductors, voltage and frequenc;
The following is a statement of the field of application of the princip'
kinds of distributing circuits.
2. Direct cturent i3_ best adapted to use: (a) -where the distances a:
small, (b) where there is variable-speed machinery, and (c) where thei
is an area
of congested load for which storage-battery reserve is necessai
to insure continuous service.
8. Alternating current is best adapted to use where the distances ai
greater and the density of the load not sufficient to justify low-tensio
distribution without transformation from a higher voltage.
4. The use of series systems is limited almost entirely to street and oth(
lighting which is all in use at the same time. These systems are inherent!
high-tension in character and are, therefore, not suitable for gener:
purposes. They are operated by direct current or alternating current at
constant current of 5 amp. to 10 amp. in American practice. In Euroj
there are several direct-current series power transmission systems in open
tion utilizing a series of motor generators as the converting medium (Sec. 11
6. Multiple or parallel systems are used for general purposes almoi
exclusively. When direct current is used a nominal voltage of 110, 221
or 550 is employed, the last named being used only for power distributioi
The Edison three-wire system at 220 and 110 volts is common in larj
installations.
When alternating current is used, the primary mains are operated at
nominal voltage of 2,200. Single-phase, two-phase, and three-phase circuii
are in general use, with frequencies of 25 or GO cycles. In general, singli
phase distribution is used for lighting and small power service, and two-phas
or three-phase distribution is used for larger power loads.
Frequency. Twenty-five cycles is standard where most of the energ
6.
isconverted to direct current for lighting and railway service or other pui
poses. Sixty cycles is standard where the energy is delivered for reta
consumption as alternating current. Other frequencies such as 30, 33, 4(
60 and 133 cycles are in use in some of the older installations in Americ
and in Europe. Sixty-two and one-half cycles is used in some moder
systems where the supply is derived from a 25-cycle system, this frequenc
giving a better design of frequency-changer apparatus.

GENERAL APPLICATIONS
_
7. The single-phase system, requiring only the simplest form of electri
circuit, has the aavantage of a minimum number of conductors, and henc
the minimum first cost for distributing mains. The feeders, however, n
quire 33 per cent, more copper than equivalent three-phase feeders. SingU
phase motors are more complicated and cost more than polyphase moton
and usually produce more disturbance of pressure, in starting, than three
phase machines. The distribution of energy by single-pha.se circuits ii

therefore, usually limited to motor units of less than 10 h.p., although motoi
up to 35 h.p. are used in single-phase systems with good success. Thi
system is used very generally for lighting circuits, in both single-phase ani
polyphase systems.

1014

f>
 DISTRIBUTION SYSTEMS SeC. 12-8

8.Two-phase systems. Two-phase distribution is effected by the use

)f two single-phase circuits in a quarter-phase relation, making a four-wire
lystein; or by means of a three-wire system in which one conductor of each
ihase is common.
The four- wire systeia is substantially the same as a single-phase system,
ixcept that two-phase motors may be used. The principal advantages of
.wo-phase systems are that there are only two phases to keep balanced and
)nly two transformers are required to supply polyphase energy to motors.
In a three-wire, two-phase system, the current in the common or
leutral conductor is 1.414 times the current in the outer conductors, with
lalancod load. When all conductors are the same size, the copper required
3 75 per cent, of that needed for a four-wire system. When the neutral is
per cent, larger than the outer conductors, the amount of copper required
i 85 per cent, of that needed for a single-phase system or a four-wire, two-

-ihase system. In the primary mains, which are all the same size, the three-
rire two-phase system is as economical of copper as the three-wire, three-
hase system. The line drop in this system is such that even with balanced
)ad the drop in the two phases is not the same, making voltage regulation
ifficult, unless line-drop compensators are employed. The three-wire
ircuit cannot bo used where the mid-points of the quarter-phase generator
indings are tied together, as is the case in some machines.
9. Three-phase, three-wire system. This system is commonly
mployed for general distribution, since it is readily derived from a three-
hase transmission system; it is also well suited to power distribution, and
;quires but 75 per cent, as much copper in the feeder system as an equivalent
ngle-phase system. The three-wire distributing mains are usually carried
nly where motor service is required, the lighting service being taken on
ngle-phase branches from the three-phase main. Users of small motors,
3 to about 5 h.p., are generally supplied from a single phase; while the larger
otors, up to 30 h.p. or 40 h.p., are supplied from two phases with the open-
^Ita connection.

10. Three-phase four-wire system. In primary distribution this

stem usually operated at 3,800 volts between phase wires and 2,200 volts
is
tween any phase wire and neutral. This gives the advantage of 3,800-
ilt distribution in the feeder system and permits the supply of energy over

radius about twice as great as with 2,200-volt systems, with the same regula-
)n. Standard 2,200-volt transformers and other accessories are used, and
e lighting branches are single-phase. The unbalanced load is carried by
e neutral wire, and with the use of line-drop apparatus, good pressure regula-
m is possible with any proportion of unbalanced load.
The four- wire distributing mains are carried only where there are motors
large loads to be served, and but three wires are needed for installations
less than .30 to 40 h.p., which may be served by two transformers connected
open delta. The wide range permissible has led to the adoption of this
stem in many of the larger cities of the United States. It is also well suited
. the supply of suburban districts and rural communities, where double-
iltage, 4,400-7,600 volts may be used to supply a group of towns and
,'lages, the pressure being regulated independently on each phase at the
urce of supply.
11. Direct-current low-tension systems find their principal field of ap-
cation in important parts of cities where the protection of the storage bat-
y reserve is of great value, and where there are many elevators, printing
esses and other variable-speed machines, and where space for transformers
i)uld be difficult to secure in public thoroughfares. The principal limitations
direct-current distribution are the small radius of distribution, and the
<cessity for rotating machinery to transform the energy from an alternating-
rrent source of supply. This requires a greater number of substations to
ver a given area, and these are more expensive both in first cost and opera-
n than alternating-current substations.
la. Two-wire, 600-volt, direct-current systems are operated in some
ies where they were originated to supplement single-phase systems in the
'•ly period of development. The duplication of mains necessitated by a ,

uarate power-service results in an excessive investment and 500-volt

litems are being eliminated wherever possible.
13. Combination systems. Various combinations of alternating-cur-

1015
 ;
:

Sec. 12-14 DISTRIBUTION SYSTEMS

I
rent, and direct-current, or 25-cycle and 60-cycle systems, are necessary in th
larger cities. The direct-current supply is usually derived through syt
chronous converters or motor-generators from an alternating-current general
ing system. The 60-cycle supply is sometimes derived from a 2o-cycle syi
tern by the use of synchronous motor-generators called frequency changer!
In some cases both 25-cycle and 60-cycle generating systems are maintainec
and the frequency changers are used as a connecting link between the tw
systems.
TYPES OT CIRCUITS
14. Series circuits. Two general types of arrangement are employed i
laying out series circuits, the "open loop," and the "parallel loop." I
the open-loop circuit (Fig. 1) the lamps are connected by following th
shortest available route, without reference to
the separation from
the return conductor.
This permits a minimum
length of circuit, but
makes it a break, or open
difficult to test for
circuit in the line. In alternating-current cir-
cuits it also tends to increase interference with
—
telephone systems.

r X *

[ ;

Ji k

—
1 II 1

Fig. 1. —Open-loop
series circuit.
Fig 2. — Parallel-loop
series circuit.
Fig. 3. —Tree-system of
distribution.

The parallel-loop circuit (Fig. 2) is laid out in such a way as to be nea

the return conductor at many points. This affords frequent opportunity fo
test and minimizes inductive disturbances, but usually requires a greate
mileage of conductor than the open-loop circuit. A combination of paralle
loops with small open loops may often oe used to advantage.
16. Multiple circuits. The arrangement of multiple circuits may tak^
any one of a number of forms as conditions require. The simplest and leas
expensive circuit is that commonly known as the "tree" circuit (Fig. 3)
it is thus named because it is branched off in various ways, and has its heavies
branches nearest the source of supply. The tree system is not adapted t<
supplying a uniform distribution pressure and is only suited to short branchei
and those branches in which the current values are small as compared witi
the conductor capacity.
IS. A system of feeders and mains is the arrangement most co^monl:
employed in city distribution for lighting and power-service. This takes tbi
form of a network in low-tension systems (Fig. 4), and an isolated or dead
ended main system in primary distribution (Fig. 5). In the low-tcnsioi
network the system of mains is designed to be of such capacity as to carri
the load units which are tapped off from house to house, and the fcrder
are provided in such number, of such size and at such points as will maintaii
an even distribution of pressure, within a few per cent., over the entin
system of mains.
1016
DISTRIBUTION SYSTEMS Sec. 12-16
 Sec. 12-17 DISTRIBUTION SYSTEMS

17. Primary- main systems are usually supplied by a feeder at a centri

of distribution, this point being a junction from which the load is distrib
uted in four or more directions. These mains are not interconnected
because it is not practicable to provide fuse protection
and in most cases not much is to be gained by sue!
connection.
18. The loop feeder (Fig. 6), is used where the loac
is distributed in a long continuous line with few sid(
branches. This arrangement distributes the pressun
more evenly along the line than is possible with othei
types of circuit.
19. Ring feeders. Where it is desired to proyidi
emergency supply to units of load in one general direo
tion from the point of supply, the most economics
means often consists of the type of feeder known as t

ring circuit (Fig. 7). The capacity of the ring mustb<

sufficient to carry the combined load of all the units, ii
case either of the links adjacent to the point of supplj
should fail.
20. Urban transmission systems. In cities hay
ing too large an area to permit an economical distri
bution of electrical energy from a single point, it he
comes necessary to transmit energy from a generatin(
station (located at a point convenient to coal anc
water supply) to substations centrally located witl
reference to the districts served. This transmissior
system, in the larger cities, becomes practically a bulk
supply distribution system. The same condition exist!
where hydroelectric energy is brought from a distano
for distribution in a large city. These urban transmis-
sion systems are universally three-phase; where two-
phase energy is generated, it is converted to three
phase energy for transmission.
21. Pressures and frequencies in urban trans-
mission. The pressures in common use are 6,600
9,000, 12,000, and 13,200 volts, and the standard fre
quenoies are 25 and 60 cycles. The use of 25 cycle
Fig. 6.—
is preferable where the principal portion of the energ:
Loop feeder. is converted to direct current for lighting and railwa;
service, because the synchronous converter is men
economical in operation and in first cost, at 25 cycles, than at 60 cycles
The use of 25-cycle energy for general lighting purposes is not satisfactory
and the transformers, motors, etc., are more expensive; hence it is necessar;
to convert the retail supply of alternating cur-
rent to 60 cycles, to put it into form which is
readily saleable.
The use of 60 cycles is desirable where the
major part of the energy is to be distributed as
alternating current. This permits the use of
transformer substations, instead of frequency-
changing motor-generators which are necessary
for securing 60-cycle energy from a 25-cycle
Bupply.
22. Underground urban transmission.
Urban transmission lines are necessarily placed
underground to a large extent. This involves
the use of paper-insulated lead-sheathed cables,
which are made up with the three conductors of
the circuit under one sheath. With standard
3.5-in. ducts, the largest size of cable which
can be drawn into the duct is about 3 in. with
Fig. 7. — Ring feeder.
circular shaped conductors the largest size of ^J
conductor, of which three can be placed within a 3-in. lead sheath, is 350,00r
cir. mils at 6,600 volts, or 300,000 cir. mils at 13,200 volts. With sectc
shaped conductors, it is possible to use three 500,000 cir. n»il conductors a
1018

I
 DISTRIBUTION SYSTEMS Sec. 12-23

.3,200 volts within a 3-in. sheath. This fixes the maximum load which can
>e carried continuously on such cables at from 4,500 to 8,000 kv-a.
In the larger cities where certain substations distribute loads of 8,000 to
.5,000 kw., several cables are required to sup-
each substation, and it is desirable to have

:
)ly
the maximum size.
lables of
SS. Seserve cables.
provided
A reserve cable must
for use in case of the failure of any
=1
fie
'if the cables which normally carry the load,
^his reserve may be secured by having a spare
able direct from the power-station, or by means 1

11
o
ei a tie line from a neighboring substation, or
i'j the use of a ring system. When substation
^lads are small as compared with the cable
apaeity, the ring system is often found to be
Sie most economical (Fig. 7). After the com-
iined loads of the substations exceed the
(apaeity of one side of the ring, additional
apaeity may be secured by adding radial
eders (Fig. 8). This is the situation in the
irger cities where substation loads run from
',000 kw. upward.
. Fia. 8. — Radial feeders.

DESION OF CIKCniTS
24. General. The function of a conductor being to convey electrical
lergy from the source of supply to the consuming device, it must be of such
ze that it will not absorb too great a percentage of the energy or become
.•erheated. The problem of designing a circuit is, therefore, one of deter-
ining what size of conductor should be used to limit the loss of voltage to a
lecified amount, when distance and current-strength are known, and also
;tormining whether the size needed for the specified voltage drop is sufficient
carry the current safely.
26. Direct-current circuits. In direct-current circuits the current and
le resistance are the only factors affecting the drop in voltage. The re-
Uunce of a mil-foot of pure annealed copper at 68 deg. fahr. being
.4 ohms, that of a conductor D ft. long and M
cir. mils in area is
= {D X 10A)/M. The drop with current /, therefore, is

E = IR = -^ (volts) or Af = ^;
(cir. mils) (1)

both conductors are of the same size the total drop is twice the drop in one
nduetor, as found by Eq. 1; if they are not of the same size, the drops in
c different sizes must be computed separately and added together.
Example. A two-wire circuit is to carry a load of 100 amp. a distance of
10 ft. with a drop of 5 volts. What size of conductor must be used?
M-
2DX^X10A 2X300X100X10.4 =
124,800 cir. mils.
E 5
No. 2/0, A.W.G., which should be used.
ue nearest size.is
28. The calculation of direct-current drop at any load is readily
termined, where the size of the conductor is already fixed, by the use of the
rmula, £ = 27Dft/ 1,000, in which R is the resistance per 1,000 ft. of c6n-
.ctor. The formula gives the total drop in the two wires of the circuit.
-Example. A circuit of 4/0 cable, 500 ft. in length, is to carry a load of
amp.; what will be the line drop? The resistance of No. 4/0 conductor
0.049 ohm per 1,000 ft. (Par. 31); Z) = 500 ft. The drop is

£ = 2X190X500X0.049 = 9.3 volts.

1,000
27. Three-wire direct-current circuits. In making calculations for a
ree-wire Edison circuit, separate computations are made for each con-
fitor if the load is appreciably unbalanced.
Example. A circuit having two No. 4/0 A. W. G. outer wires and a No.
leutral, 1,000 long, carries a load of 150 amp. on the positive side and
ft.
amp. on the negative side; what is the drop on each side of the circuit?

1019
Sec. 12-28 DISTRIBUTION SYSTEMS
The resistance of 1,000 ft. of No. 4/0 = 0.049 ohm, and that of No. 0=
0.098 ohm, per 1,000 ft. (Par. 31).
JS-/ft = 150X0.049 = 7.36 volts drop on positive wire;
JB = /i2 = 110X0.049 = 5.4 volts drop on negative wire;
J5 = /J? = 40X0.098 = 3.92 volts drop on neutral wire.
The drop in the neutral wire is added to the drop on the heavy side and sub
'

'
'
'

tracted from that on the "lighter" side, making the total drop 7.35 + 3.92 =
11.27 volts on the "heavy" side, and 5.4 — 3.92 = 1.48 volts on the other side
28. Alternatingr-current circuits. In an alternating-current circuit
voltage drop is caused by the combined effect of (a) resistance, (b) indue
tance, and (c) capacity. The component of drop due to resistance i
governed by the same laws which govern direct-current circuits, and is ii
phase with the current. The component due to inductance (react
ance drop) is a counter e.m.f. set up by the magnetic field and is a quarter
cycle behind the current wave. The resistance drop and the reactance drop
may be represented, therefore, by two sides of a right triangle. The capacity
of a circuit causes a charging current which is however of importance only at
the higher voltages. See Sec. 11.
The inductive reactance of a circuit is wL, where ai = 2irn and n =
frequency in cycles per second; L = inductance in henrys. The inductance
|8 a measure of the number of lines of force per ampere linked with the circuit;
It increases, therefore, as the separation of the conductors of the circuit ie
increased, or with the introduction of iron into the magnetic field, since either
of these increases the n\imber of lines of force linked with the circuit.
29. Table of wire resistance and reactance. The table in Par. SI
g^ves the reactance drop in volts per amjjere, for 1,000 ft. of conductor, foi
the distances of separation and sizes of wire commonly used in transmission
and distribution work. It should be noted that the reactance increases oi
the separaiion is increased. ;

80. Example of calculation of resistance and reactance drops. A

single-phase circuit 10,000 ft. long operates at 60 cycles and carries a load of
100 amp., with No. wires 12 in. apart. What are the values of the inductive
and the ohmic components of drop, and the impedance drop? The react-
ance per 1,000 ft., per amp. per wire, for No. wires 12 in. apart is X
»= 0. 1043.
The resistance is 0.098 ohm. per 1,000 ft. The inductive component of the
impedance of the circuit is
X-.2Z)X/X0.1043/1,000 = 2X 10,000X100X0.1043/1,000 = 208.6 volts.
The ohmic component is R = 2X 10,000X100X0.0981/1,000= 196.2 volts.
The impedance drop in the circuit is
\/(209) ''+1196)2 = 286 volts.
The length of the line OA in Fig. 9 is proportional to the resistance compo-
nent, that of AB represents the inductive component and OB the resultant
of the two. If the circuit consisted of two No. 6 wires the resistance com-
ponent would be 788 volts, the inductive component 241 volts, and the
impedance drop would be
V(788)» + {241)««824 volts.

/ft-196V. Jl A'
Fia. 9. — Resolution of ohmic drop and inductive drop to obtain
impedance drop.
total or

The e.m.f. diagram for the latter case, in Fig. 9, is OA'B'. It is apparent
that the ratio of resistance to inductance decreases as the size of wire i«
increased, so that innreasing the size for the purpose of reducing the pressure-
drop becomes less effective in the larger sizea, It is preferable to install an
additioQal oirouit if faoilitiea will permit.

1020
 DISTRIBUTION SYSTEMS Sec 12-31

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oooooo ooooooo
O.-ii-i!N(N(N(NWC0->J<T)<i0i0

OOOOOOOOOOOOO
C<5TO'J<C0OtO(N05<0Q?C^'C00

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-*^iOTt<—it^COOt^OCOtOffi
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t>.ooo30iO)OOOOi-<(Npqeo
OOOOOrtr^M.-ll-l,-(rt-H
OOOOOOOOOOOOO
or~t~ooooooWCTi050;00"-i
OOOOOOOOOOi-Hi-n-H
OOOOOOOOOOOOO
^p i— y^ u-i »ij I'- (i'j i^j tv i

OOOOOOOOO!
OOOOOOOOOO
TO Ol 50 05 <N "O 00
'OooOTO'o«roo5-*05 ^,
OOOOOOOOOO
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'K<'-<r»Tt«.-it^o«t^
05(N'*1>0(NOOCOOO'*
OOOOOOOOOO
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CO 1^ O C5 t^ 00 r-l b-
OOOSOOrHt^OOCO^W-^t^t"
•3ap 89 '»'' "»;
000' T Jsd stHi^o
OOOOOOO'H'^MWO®
OOOOOOOOOOOOO
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OOO't-^OOONrtiMC^roO
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000' I -lad -qi

«5
OiOOOOOONOsmOCDOSCTi-^
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Sec. 12-32 DISTRIBUTION SYSTEMS
88. Besistance and inductance factors. The reBistance factor ol
a circuit is the ratio of its resistance to its impedance. Likewise the induct-
ance factor is the ratio of the inductive reactance to the impedance. Th«
square root of the sum of the squares of these two factors is equal to unity.
The values of inductance factor which correspond to various common values
of resistance (or power) factor appear in the following table:

Resistance (or power) fac-

 DISTRIBUTION SYSTEMS Sec. 12-35

•8 .9 10 20 30
Load Power Factors Drop in Percent of E.M.F. Delivered

11.— Mershon chart for calculating drop in alternating-current lines.

Sec. 12-35 DISTRIBUTION SYSTEMS

The net line drop is, therefore, 127 volts or 5.8 per cent, of the receive;
voltage.
If a lighting load of 100 amp. at 100 per cent, power-factor were bein^
carried, the inductance factor ER would be zero and ON
would be
\/(2,288)2 (94)2 = 2,290 volts.
+
At 100 per cent, power-factor, therefore, the drop is 90 volts.
36. Mershon diagram. R. D. Mershon has devised a diagram by mean:
of which line-drop calculations, which do not involve charging-curren
effects, may be made with facility and yet with sufficient accuracy for al
ordinary purposes. This diagram,* Fig. 11, is based on the principles of thi
diagram of Fig. 10. The concentric circles are described about a centre
to the left of the diagram, which corresponds to the point O in Fig. 10. Th'
divisions are made in percentages so that the scale may be applicable to any
voltage. The use of the chart may be illustrated by the example of the cir
cuit of No. wire carrying a load of 100 amp. at a distance of 4,500 ft
(Par. 34). The ohmic drop is 88 volts, or 4 per cent., while the inductivi
drop is 4.3 per cent. The power-factor is 0.8. The base of the 0.8 power
factor line in Fig. 11 is the point R in Fig. 10. The point where the 0.!
power-factor line intersects the first circle is the point E in Fig. 10. Passini
from this point to the right, 4 divisions, and then upward, 4.3 divisions, ii
point is reached which is a little below the 6-per-cent. circle; this point iij
equivalent to the point P in Fig. 10. The net line drop is 5.8 per cent. o|
2,20Q= 128 volts, compared with 127 volts by calculation. j
If the load on the circuit has a power-factor of 100 per cent., one begin
at the base of the 100-per-cent. power-factor Hne, passes to the right 4 divi
sions and then up 4.3 divisions. Th
drop is found to be about 4.1 per cent,
or 90 volts, as compared with 90 vol^*
calculated.
36. Two-phase line drop. In th
case of a two-phase four-wire circui
the drop is computed for each phase in,
dependently, using the method given i^
Par. 33 and Par. 34, or the Mershon dia-
gram. Par. 35.
In a two-phase three-wire systen
having the load connected between th
outer phase wires and the neutral »
common phase wire, the inductive d-
on the neutral produces an unbahn
pressure at the load or receiver <
This condition is illustrated in the '

gram in Fig. 12. The ohmic and inil

tive drops on the outer wires are ri'i
sented by the trianglesXYZ and Ji
ON represents the phase of the neir
current and OCD represents the oh:
and inductive drops on the neutral (' :

Fig. 12.— Diagram of potential drop ductor. The power-factor is assunx

on two-phase three-wire circuit. ^t 90 per cent. The voltage nece.ssnr
to maintain normal pressure at th
feeder end is represented by line DZ on one phase and by DT on the othc^
phase. The net line drop is the difference between DZ and OX in one phast
and between DT and OR in the other. It is evident from the diagram tha;
the drop on one phase is considerably greater than on the other. The differ
ence varies with the power-factor and the size of the wire, being grcntr
with larger sizes of wire. No simple rule can belaid down for calculnt
such problems, when the load is not equally balanced between phases, :

a graphical solution is usually the most practical.

37. Drop in three-phase three-wire symmetrical circuits. Ii

three-phase three-wire circuit with conductors symmetrically arranged

carrying a balanced load, the inductive effect is the same in each wire

* American Eleetrieian, June, 1897.

1024
 DISTRIBUTION SYSTEMS SeC. 12-38

the calculation of drop may be made exactly as it would be for a single-

phase circuit carrying one-half the load.
As the currents in the three wires are 120 deg. apart in time phase, the
jhmic drop for the two wires making up any one phase is not twice that of one
wire, as it is in a single-phase two-wire circuit, but is 1.73 times this drop,
rhe inductive component of drop is also 1.73 times that of a single wire, for
the loop. If the load on a three-phase circuit were the same as on the single-
phase circuit in the previous example (Par. 34), the current per wire in the
three-phase circuit would be
100X1.732 ^„,
^ = 57.7 amp.
rhe drop at 100 amp. on the three-phase circuit would be (5.8/2) X 1.73 =
5.0 per cent., and at 5S amp. the drop would be 58/100 of 5 per cent., or
i.Q per cent. The single-phase drop at the same load was found to be 5.8
per cent., or twice the three-phase drop.
Therefore, for the same load and equal line drop, the size of the con-
ductor in a three-phase circuit may be one-ha,lf that of a single-phase circuit,
rhere being three wires in the three-phase circuit, it follows that the weight
>f copper which is required for a three-phase circuit is three-quarters of that
e^uired for single-phase transmission, with equal pressures between phase-
vires, equal loads and equal line drops.
38.Drop in three-phase three-wire unsymmetrical circuits. When
.he arrangement of conductors is not symmetrical, the inductive component
iif drop is different among the different pairs of wires, on account of the differ-
i-nt distances between centres. The most common case is that in which the
Uires are arranged on a cross-arm in the same horizontal plane. In such
fases the equivalent of a symmetrical arrangement can be secured by trans-
|>osing the conductors at proper intervals. This is not necessary in 2,200-
olt distributing feeders which are equipped with line-drop compensators.
is they can easily be adjusted to correct the unbalanced conditions.

The calculation of drop in an unbalanced three-wire three-phase cir-

uit is somewhat" complicated and such problems are most readily solved
•raphically. Loads which are not unbalanced more than 10 per cent, to
6 per cent, may usually be averaged and considered as balanced for practical
urposes. In systems where the lighting service is all on one phase, and the
lird phase wire carries a small scattered load of three-phase motors, the
ghting phase may be considered as a single-phase circuit in computing the
cop. However, as the motor load increases, the drop in the lighting phase
scomes less for a given current value, until, when the current in the other
aases equals that in the lighting phase, the drop in the latter is but 86.6
3r cent, of what it would be with the same current carried for lighting ser-
es only.
89. Drop in three-phase four-wire circuits. The pressure at the
ansformer.on such systems, is the pressure between phase wires and neutral;
hen the latter is 2,200 volts, the pressure across phase wires is 2,200 X 1.732
3,810 volts. With balanced load the neutral conductor carries no cur-
,t and the drop is that in the phase wires only. The resistance drop at
) amp. on a No. circuit 9,000 ft. long is 100X9X0.0981=88 volts.
is is 4 per cent, of 2,200 volts. Assuming a 12-in. spacing, single-phase,
g inductive component of drop is 100X9X0.1043 = 94 volts, or 4.3 per
t. At 80 per cent, power-factor, by the Mershon diagram (Fig. 11), the
-' drop is 5.8 per cent.
The size of wire for a given load and drop, three-
, is one-half what it would be for a single-phase circuit, or, assuming
of equal size, the distance may be doubled for the same drop as com-
with a single-phase circuit.
n the case of an unbalanced four-wire circuit, which is the more usual
idition, the effect of the drop on the neutral wire must be taken into con-
sration. In general, the effect of the unbalance is to increase the drop
the more heavily loaded phases and decrease it on the lightly loaded
aaes, in comparison with the drops at balanced load, as shown in the case

Ki^
*^'"*'^^i''e two-phase circuit above. A graphical solution of the
>blem of determining line drop in unbalanced three-phase four-wire circuits
ihowninFig. 13. This diagram is constructed on a principle similar to
W used in Fig. 12 for a two-phase circuit.
pile load on A phase is heavier than that on B and C, and the drop OE due
Sec. 12-40 DISTRIBUTION SYSTEMS

to the neutral current is added almost directly to the drop XZ on the A-phase
conductor.
The net drop on A phase is EZ-OX, that on B phase is ET-OIl and on I
phiise it is EW-OU.
Where line-drop compensators
axe employed in each conductor,
only the individual calculations for
the four conductors are required, as
the compensator corrects for the
effect of the neutral drop.
40. Skin effect is an alternating-
current phenomenon (Sec. 2, and
Sec. 4), which materially affects
cables of large cross-section, due to
the fact that the currents passing
through the strands around the
outer surface of the cable encounter
less inductance and impedance than
the strands near the centre, thus
causing the outer strands to carry -'
more current, proportionately, than \
the inner strands. It is desirable, *'

therefore, to build up large cables

about a core of non-conducting
material. Cables of over 500,000
cir. mils are often made in this
manner where they are to be used
in 60-cycle systems, and cables Fio. 13. — Diagram drops
of in a three-
of more than 1 ,000,000 cir. mils for phase four-wire circuit.
25-cycle systems.
The increase in effective resistance due to skin effect is approximately
proportional to the product of the frequency and the circular mils, as shown iu
the following table in Par. 41.
41. Table of Skin-eSect Coefficients

Cir. mils X
frequency
 DISTRIBUTION SYSTEMS SeC. 12-42

42. Effect of electrostatic capacity. At ordinary distributing voltages

and frequencies the capacity effect is too small to be of any consequence in
the solution of line-drop problems and need not be considered. At the
higher transmission voltages it is a matter of considerable importance in
many cases (Sec. 11). The electrostatic capacity of an overhead circuit is
fixed by the distance between the conductors and by their size; with insulated
conductors (aerial or in cable), the capacity is further affected by the die-
lectric const.ant (Sec. 4), of the insulating material. The mutual capacity
of a single-phase uninsulated circuit strung in the open air, per 1,000
ft. of circuit, is given by
_
C= —
0.003677 , . ,
J .
(microfarads) (2)
log-
r
where d the distance between centres of conductors and r is half the diam-
is
eter (radius) of the conductor. The logarithm used is the common logarithm.
43. Charging current. The charging current of a single-phase circuit
8 given by

^=
1,000,000
^'*'"P-> (3>

vhere D
is the length of circuit in thousands of feet, n is the frequency,
\1 is the capacity in microfarads, and E is the effective voltage between con-
jluctors. The chargijig current of a symmetrical three-phase circuit, between
i'hase wires, is 2/\/3 = 1.155 times that of a single-phase circuit with equal
I
pacing between phase wires.
i When an inductive load is carried on the line, the lagging component of
Ihe load current tends to offset the leading current required to charge the line,
he tendency of the charging current to raise the power-factor of the line
urrent thus results in a corresponding tendency to reduce the line drop where
>e load is of an inductive character. (For full treatment of the effect of
ijpacity on line drop, see Sec. 11.)
44. Electrostatic capacity of cables. In underground cable work
»e effect of charging current is greatly increased by the reduced separation
{ the conductors. The charging current cannot be determined by direct
ilculation, however, since the dielectric constant of the insulation must be
iken into account. The mutual capacity of a three-phase three-conductor
ible between conductors, per 1,009 ft., is given by
_ 0.00735 K , f A^
(microfarads) ,A^
(4)
I 3a^ (fl^-a') 3
^^ r2 (ft«-o«)
"hen K the dielectric constant, a is the distance from the centre of the
is
toBs-section of the cable to the centre of the conductors, R is the radius of
e inside of the lead sheath, and r is the radius of the conductors. The
mmon logarithm should be used.
45. Dielectric constant. The value of K, the dielectric constant, varies
th the character of the paper and oils used and increases as the temper-
are increases. It must therefore be determined for each cable by measure-
snt at the various temperatures of operation. The charging current is
O affected by the dielectric loss in the cable insulation, and with cables
igned for operation at voltages above 13,200, this becomes an important
tor since it tends to reduce the current-carrying capacity of the cable
adding heat, which contributes to the temperature rise. Also see Par. 48.
*. Current-carrying capacity of conductors. The energy absorbed
a circuit, I'^R, is dissipated in the form of heat, and tends to raise the
iperature of the conductor. The maximum current-carrying capacity of
inductor is dependent upon whether it is installed in open air, in conduit
mderground. The character of the insulation is also a factor, since certain
da of insulation may be safely operated at higher temperatures than
lers.
I?heinsulation of rubber-covered conductors should not be operated regu-
y at temperatures above about 50 deg. cent. (122 deg. fahr.). Weather-
of and other fibrous types of insulation may be operated at temperatures
ligh as 65 deg. to 70 deg. cent. (149 deg. to 158 deg. fahr.). Conductors
d inside of buildings are subject to the requirements of the National

1027
Sec. 12-47 DISTRIBUTION SYSTEMS

Electrical Code, which limits the current in rubber-covered cables to values

such that the temperature rise will not exceed about l.") deg. cent. (27 deg.
fahr.)- This represents a temperature of about 40 deg. cent. (104 deg. fahr.)
during summer months, or in parts of buildings such as engine rooms which
are normally above outside air temperature. Slow-burning insulation is
accordingly required in places where the temperature is likely to be above
45 deg. cent. (113 deg. fahr.).
47. Table of Current-caxrying Capacity of Wires and Cables Under
Various Conditions
Lead-covered cables
National electrical
code Single conductor
Size, Three con-
A.W.G.or Paper or ductor paper
Slow- Rubber cambric, ins. 45 deg.
cir. mils Rubber burning 30 deg.
ins. 40 deg. cent. rise,
ins. cent, rise
(amp.) cent, rise (amp.)
(amp.) (amp.)
(amp.)

14 15 20
12 20 25
10 25 30 20 22
8 35 50 30 34 26
6 60 70 50 56 48
4 70 90 78 87 68
3 80 100 98 110 81
2 90 125 121 134 93
1 100 150 145 160 110
125 200 169 187 132
00 150 225 192 210 150
000 175 275 245 270 190
0000 225 325 285 315 225
250,000 235 350 320 360 255
300,000 275 400 370 415 300
400,000 325 500 460 515 370
500,000 400 600 550 605
750,000 525 800 750 830
1,000,000 650 1,000 900 1,030
1,,500, 000 850 1,360 1,200 1,450
2,000,000 1,670 1,400 1,590

48. Underground cables. The carrying capacity of lead-covered cables

in underground conduit has been studied bv various investigators but
no complete study has been made of the various factors involved. The
radiation from a duct line varies with the character of the soil, size and shape
of duct line and with the presence of other heat producing elements such as
steam heating mains and other conduit lines. The radiation from the
cables in the inside ducts is materially less than from those in the peripheral
ducts, a difference of 15 per cent, having been noted by Fisher in a p-ducj
line and 40 per cent, in a 16-duct Une when all ducts are occupied by loaded
cables. .
v 11 xi, '

With oiled paper cables the maximum temperature is limited, by tne'

Standardization Rules of the A. I. E. E., to 85-E deg. cent., where fiisj
the pressure in kilovolts.
This limit is fixed as a basis of continuous operation, but low-tension'
direct-current cables have been operated at temperatures of 100 to 120.
deg. cent, for several hundred hours without showing perceptible damage.
With high-tension cables the limit should not be exceeded matonally
since the dielectric loss increases with the temperature and adds to the heat
generated as the temperature increases. At voltages above 10,000 the die-
lectric loss may be sufficient to reduce the carrying capacity of the
cable.i

Attention has been given in recent years to the compounds used in sir
'

cables, and it is found that the use of resin oil, the predominant element boi
made up of mineral compounds, should be limited if the dielectric los^^
Atkinson and Fisher. Trans. A. I. E. E.; Vol. XXXII, 1913, p. 327.

1028
 DISTRIBUTION SYSTEMS See. 12-49

to be kept within safe limits. The tendency of the loss to increase as the
temperature produces a condition of cumulative heating which may-
rises
progress in a few hours to a point where the cable is destroyed.
'
49. Temperature of conductors. The temperature of the conductor
may be determined from observation of the temperature of the cable sheath
by a formula derived by Atkinson and Fisher, which is of value since it can
easily applied to working cables, without taking them out of service.
f

Ibe The fall of temperature from conductor to sheath is

jin which D is the diameter (in.), outside the insulation, d is the diameter
(in.) of the conductor, I is the current (amp.) and if is a constant which is
determined for each type of cable. The common logarithm, base 10, should
be used. The values of K
are as follows: for single conductor cable, 0.15;
for two-conductor cable, 0.35; and for three-conductor cable, 0.52.
With multiple conductor cable the value of D is taken over the outer belt
3f insulation and d is that of the individual conductors.
50. Multiple conductor cables. The carrying capacity of multiple
!onductor cables is less than that of single conductor cables of the same
)izp of conductor, since heat is generated in two or more conductors and the
noroase in radiating surface is not proportionally greater. This effect is
urh that for duplex cable the temperature rise is about 10 per cent, greater
hau for a single conductor cable, making its carrying capacity about 10 per
out. less. For three-conductor cable the carrjfing capacity is about 75
)er cent, of that of a single conductor cable.

SUBSTATIONS
61. The function of a substation is to convert energy received from a
'ulk-supply system, at the transmission voltage and frequency, to energy
uitiible for distributing purposes. The energy distributed may be
1 the form of direct current at the voltage at which it is utilized, or in the
:irm of alternating current at a voltage suitable for general distribution
hrough step-down transformers located at suitable points in the district
jrved. The expense of installing and operating a substation must be
istified by the saving made by the shortening of distributing feeders and
je reduction in feeder losses incident thereto.
62. Substation location. The distance between substations
eponds upon the voltage of distribution and the density of the load. The
lerage length of the distributing feeders should be such that the total invest-
lent in feeder conductors and substation equipment is a minimum.
In low-tension systems it is usually found desirable to locate substa-
ons approximately 1 mile apart, except in very congested districts where
iiiy are sometimes located less than 0.5 mile apart, on account of the very

FKc loads to be carried.

In 2200-volt alternating-current distribution, substations may be
..'iced from 2 to 3 miles; in four-wire systems operating at 2,300-4,000 volts,
( y may be located from 4 to 6 miles apart, in scattered districts. In the
It lying parts of the larger cities they are usually found from 2 to 3 miles
lart on account of the density of the load.
53. Substation classification. Substations may be divided into three
incipal classes: (a) those in which tran.sformers change the pressure from
at used in transmission to the distribution voltage; (b) those in which
quency changers convert energy from one frequency to another and
)rn the transmission voltage to the distributing voltage; and (c) those in
lich the transmitted energy is converted by synchronous converters to
iitinuous current at low voltage.
64. Oeneral features. Each of these classes of substations (Par. 63)
s certain elements which are common to all. Each is served by incoming
nsmission lines which are terminated in oil switches and connected thence
high-tension bus system. One side of the converting apparatus is con-
ed to the high-tension bus and the other side to two or more distributing
'

-ies. From these busses the outgoing feeders are taken off through suit-
i e feeder switches, in conjunction with regulating apparatus.
>5. Substation building. The size of the lot and the dimensions of
'9 building should be such as to permit an arrangement of apparatus
" ii'h will not be unduly crowded, and which will permit the installation,

Fisher, H. W. Trans. A. I. E. E.; Vol. XXII, 1903, p. 440.

Sec. 12-56 DISTRIBUTION SYSTEMS

repairand maintenance of the equipment at minimum cost. Where further

growth is probable, due regard must be had for subsequent extensiona
of building and equipment. Fireproof construction is warranted where
continuous service is important.
B6. Bus-bar arrangement. Fig. 14 shows a simple arrangement for a
substation having one main
line and one reserve line.
Feeder
Distributing Where the load is such that
Feeders several direct lines are re-
Switches quired, a transfer bus (Fig.
15) is very desirable. This
permits the operation of any
machine from any line and
makes the reserve line avail-
able in case of the failure oi
any of the main lines.
57. Duplicate distribut-
Transformer ing busses are provided
Switch both as a means of operating
the longer feeders at a higher
High-Tension bus pressure, and as a means
Line Bus of facilitating repair and
Lino Switch maintenance work without
interrupting service.
68. Ill continuous-cur-
Beserve (Xie-llne) rent systems, two busses
Main are required in practically
all cases for pressure con-
Fig. 14. —High-tension
in
bus arrangement
a small substation.
trol during the heavy-loan
period, and in the largoi
substations it is sometimes
necessary to provide three busses to take care of certain feeders which .ire
exceptionally long or very short.
69. Transformer substations. The simplest type of substation if
that which transforms alternating-current energy from one voltage to anothei

Transformers

Bus arrangement in a large substation.

and requires, therefore, only transformers for the converting equipment'

Both oil-cooled and air-cooled types of transformers are used for this purpose
with either single-phase or three-phase units. Oil-cooled units are prefcTabl
where the substation may be left without attendance during certain hour
1030
 DISTRIBUTION SYSTEMS Sec. 12-60

of the day. Oil-insulated, water-cooled transformers are used quite generally

where there is an ample supply of cooling water.
Single-phase units are commonly employed where capacities of less than
1,000 kw. are required, although there is no settled practice in this regard.
Three-phase units are less expensive than single-phase units, particu-
larly in the larger sizes, and require considerably less floor space.
60. Frequency-changer substations. Where the transmitted energy
'is converted to another frequency, the equipment consists of a motor
generator, usually of the synchronous type; the motor is usually wound for
the transmission voltage, to avoid the investment in transformers, where tho
Voltage is less than 15,000 volts. This type of apparatus requires an exciter
^quipmeut, which may be driven by the machine itself, or by a separate
iiotor. There should be at least one separately driven exciter equipment
n a station where the exciters are direct connected.

Sectioa ArA. incoinijig Line

Fig. 16. —Synchronous converter substation.
|61. The synchronizing equipment of frequency-changer sets mu.st be
arranged that synchronizing can be done at both frequencies. When the
tchine is brought into step on the transmission side, the arrangement of
i poles is such that the generator end is held with a fixed angle of phase
placement from the supply system, except for one particular (and correct)
iition of the motor fields. In a 25-cycle to 60-cycle frequency changer
[ring ten and twenty-four poles respectively, there are five positions in
ich. the 25-cycle machine may. come into synchronism, only one of which
1 permit the 60-cycle (generator) end to be synchronized with another
jijuency changer already in operation. The 60-cycle end must be syn-
I'tibized by slipping poles until it comes into phase. Where the frequency
.i^er is being synchronized with a generating system, it is necessary to
Ince or retard the phase of the 60-cycle generators.

1031
Sec. 12-62 DISTRIBUTION SYSTEMS

62. Continuous-current substations. A continuous-current suppl;

is usually derived from transmission systems by the use of synchronous coii
verters, or motor-generators. The synchronous converter is universal];
employed where the transmission system is operated at 25 cycles, as th'
converter is less expensive in first cost and more efficient in operation than
;

motor-generator. Converters have been little used in 60-cycle systems unti

recent years. The development of the interpole converter has minimizei
the tendency of 60-cycle converters to hunt and flash over.
Where motor-generators are employed both synchronous and indue
tion types of motors are in use. The induction motor has the advantagi
of greater stability than the synchronous motor in times of disturbance ti
the frequency or the voltage of the system. The induction motor, how
ever, has a power-factor (lagging) of about 85 per cent., whereas the syn
chronous motor has an adjustable field and may be operated (overexcited
with a leading power-factor, thus raising the power-factor of the generatini
system. It has become customary, therefore, to employ both synchronou
and induction types of motors in converting 60-cycle energy to continuous
current energy, in order to secure the advantages of both.
Efficiencies and first costs of motor-generators and synchronoui
converters at one-half, three-quarters, and full load appear in the foUowini
table (Par. 63). compiled from a paper read by E. W. Allen before the Asso
elation of Edison Illuminating Companies, 1908.
63. Tables of Efficiencies, Cost and Floor Space of Synchronoui
Converters and Motor-generators
Efficiencies

Rating,
 DISTRIBUTION SYSTEMS Sec. 12-66

66. Connection of neutral for three-wire continuous-current

system. — The six-phase type of converter, wound for 250 volts, with a
diametrical connection in order to provide for the neutral conductor, Fig. 17,
is commonly employed for machines of 1,000 kw. and larger. Motor- _

generators are also designed for 250 volts, a small balancer-set being used
to take care of the unbalanced load.
67. The regulation of pressure on the bus supplied by a synchro-
nous converter is accomplished by the use of an induction regulator placed
between the transformers and the converter. Some variation in pressure
can be secured by manipula-
tion of the converter field-
rheostat, but this affects the
power-factor and it is not
depended upon for pressure
control.
68. In the split-pole type LtUJUUUUJ
of converter, which has been
I h ri
Uttoindi)) U!iM42ilMJ

.introduced in recent years,

I
considerable range of pressure
regulation may be secured
by variation of the field rheostat
rTLm To-Neutral

without serious interference

'with the power-factor, and
with this type of machine reg-
ulators are sometimes omitted.
69. Synchronous con-
rerters may be started in
irarious ways, and it is usual to
provide for at least one method Converter
)f starting from both the alter-
Slip Rings
lating-current and the con-
jnuous-current sides. The
lonverter may be started from
continuous-current side by Fig. 17.
he use of a starting rheostat
—
Six-phase diametrical connection
for synchronous converter.
practically the same man-
^ler as that used in starting a continuous-current motor.
The converter may be started from the alternating-current side with
_

[he field open, by impressing approximately half the normal pressure, derived
|rom a starting compensator or half- taps on the secondary of the transformer.
.'he latter method is usually preferable. After the machine has come up
|r) speed, the fields are excited and the polarity corrected, if necessary, by
eversing the field, and slipping back one pole.
The current required in starting from the alternating-current side is
rem one and one-half to twice full-load current, while 25 per cent, to 30
|er cent, of full-load current is sufficient for starting from the continuous-
rent side. The normal method of starting is, therefore, preferably from
|afi continuous-current side.

70. Low-tension switchboards. The operation of distributing systems

It low pressure involves very large currents and for that, reason the most
Inportant part of a low-tension switchboard is the arrangement of heavy bars
li copper, 3 in. to 6 in. wide and 0.25 in. to 0.5 in. thick, required for the
life handling of such currents. The important features of the design are to
liaintain sufficient clearance between bars of opposite polarity and to make
Tje connections as short as possible consistent with accessibility for repair
\i maintenance work.
871. Feeder panels. The switchboard shown in Fig. 18 is based upon a
Jirtical arrangement which permits ample separation of opposite polarities
hd minimum length of the bus-bar copper per feeder. Each vertical section
Ijmprises a set of switches and instruments for one three-wire feeder, the
futral not being brought into the main board. The neutrals are commonly
ied to a separate bus in the basement, where they are connected without
^connecting switches other than removable copper links.
178. Switchboard voltmeters. It is customary to provide a single
||Hmeter with a multiple-point switch so arranged that one voltmeter can

1033
Sec. 12-73 DISTRIBUTION SYSTEMS

be used to take the pressure readings on the pressure wires of any of the
feeders. Separate voltmeters are provided to give continuous indications of
the pressure on each bus.
73. Switchboard ammeters are provided in each side of outgoing feeders
*in order to give an indication of any excessive unbalance of the load. These
are also required for each machine.
74. Number of sets of busses. Two sets are commonly required for
proper distribution, one bus being operated at a higher pressure than the
other. In the large substations it is sometimes desirable to operate as many
as three busses.

76. Knife switches. Single-pole, double-throw knife switches are pro-

vided for the control of the feeders, each feeder being so arranged that it
can be thrown to either of two busses. This permits the longer feeders to
be put on a higher-voltage bus at the time of the heavy load, thus maintaining
an even pressure throughout the network.
76. Boosters. It is often necessary, in substations near the edge of the
system, to maintain boostcr-,sets which can be put in series with extra
long feeders in order to maintain pressure at the distant end. Similarly,
very short feeders are sometimes provided with re.'jistances (equivalent to
negative boost) to absorb part of the pressure. These resistances are made
adjustable for two or three values, and must have ample radiating capacity
to avoid overheating at full load. Strips of galvanized sheet-iron have been
found very satisfactory for this purpose.
77. Storage-battery reserve. One of the principal advantages of con-
tinuous-current distribution is the po.ssibility of having a storage-battery
reserve. In order to be of the greatest value, the battery reserve should
be distributed in a number of individual units located at central points in th(
system, so that it can act as a reserve in case of the failure of the supply n
any part of the system.
78. Battery rooms. On account of the evolution of gases, and th<.
presence of acid vapor, it is necessary that the portion of the building occu-
pied by the battery be provided with ample ventilating facilities and that aJ
metal work be covered or painted as well as possible.
1034
 DISTRIBUTION SYSTEMS Sec. 12-79

79. End-cell switches for battery reserve. The tendency of the

battery pressure to fall off at the time of discharge is provided for by the
use of end'cell switches which are under the control of the operator, so that
additional cells can be connected in series in sufficient number to hold the
pressure up to the desired value. Normally, the end-cell switches are set
so that the battery floats on the system. In any emergency which causes
the bus pressure to drop, the battery immediately begins to supply energy,
thus tending to main-
'tain the bus pressure.
A diagram of abattery,
equipped to act as a 'li|i
reserve on two sets of
busses, is shown in
Motore ^I. olQ Motois
Fig. 19.
80. High-tension
switchboards (up to
16,000 volts). In the
design of high-tension
iwitchboards, the
space required for
oroper separation and
nsulation of the bus
jars, and for the in-
itallation of oil- -^Auxiliary
witches, necessitates + Main
in arrangement in — Neutral
ihich the busses and
il-switches are in-
— Main
tallod in some remote
--Auxiliary
jcation such as a
asoment, the control
Fig. 19. —
Arrangement of battery end-cells.
anels being located at a point convenient to the operator.
Ammeters, voltmeters and wattmeters are operated with series'

current) and shunt (potential) transformers, and oil-switches are usually

f the remote-control type, so that the switchboard panel carries only low-

^nsion apparatus. In smaller substations and in cases where only a few

ivitches are installed, hand control is sometimes employed for the oil-
vitches on outgoing feeders.
81. High-tension bus bars com-
monly consist of cable or copper
A. r 1 >sdB tubing mounted on suitable insulating
I I (Ol supports, carried on a skeleton frame
of pipe or angle iron. Oil-switches for
distributing feeders are commonly
mounted on the same framework in such
a way as to provide an orderly system
of connections from the busses to the
switch terminals. Bus bars operating
at voltages of 6,600 and upward are
TR commonly installed in compartments,
so arranged as to reduce to a minimum
the probability of an arc between con-
ductors of opposite polarity; this is
very important where large amounts of
energy are available to supply a short-
circuit in case it should occur.
82. Disconnect-switches should be
~ , . ... . , provided to permit oil-switches to be
10. 20.- -lank-type of oil-switch. taken out of service during repair and
maintenance work. •

83. Two general types of oil-switches are employed, the tank type
.nr. 84) for distributing-feeders and for the control of converters or trans-
•mers, and the compartment
type (Par. 86) which is used for the control
transmission lines and at other points in the transmission system where
: switch may be called upon to open automatically under short-circuit.

1035
Sec. 12-84 DISTRIBUTION SYSTEMS
84. The tank typo of oil-switch, Fig. 20, ia made in single-pole, two-
pole, or three-pole construction, with individual tanks which separate the
opposite polarities.
86. The compartment type of oil-switch, Fig. 21, is made on a very
much larger scale, each pole of the switch being enclosed in a separate
compartment of brick or con-
crete. The front of the com-
partment is closed by fire-
proof doors which are hinged
at the top to permit heated
gases to escape readily, in case
they should be liberated in
connection with the operation
of the switch on a very heavy
short-circuit.

PRESSURE REGULATION
86. Potential regulators.
The distributing feeders should
be equipped with potential
regulators in order to provide
proper distribution of pres-
sure. Two types of potential
regulators are in general use,
one of which consists of a
transformer with a switch in
the secondary so arranged that
approximately 10 per cent, of
the bus pressure may be added
to, or subtracted from (step by
step), the bus pressure. In
another type, the secondary of
a transformer is mounted on a
movable core (Sec. 6), so
arranged that more or less of
the magnetic flux may be
passed through the secondary
winding, and the pressure thus
raised or lowered by inductive
action. The latter called
Fig. 21. —Compartment type of the induction regulator and
oil-switch.
is

preferable to the other type

is
on account of the absence of sliding contacts, which are disposed to be
troublesome in operation.
Regulators may be controlled by hand, by motor-drive from hand-
operated switches, or by motor-drive from automatically operated switches.
The extra expense of automatic control is justified, in important substations,
by the improved service given.
87. Line-drop compensators. The use of pressure wires to indicate
the pressure at the end of a feeder is not necessary on alternating-current
feeders, since they can be regulated by the use of line-drop compensators.
The length of alternating-current feeders is usually so great that the cost of
Fressure wires is more than the cost of the compensator equipment,
n principle, it consists of a miniature circuit containing the same propor-
tion of resistance and inductance as the feeder circuit which it regulates.
The drop in this resistance and inductance is inserted in the voltmeter
circuit in such a manner as to reduce the voltmeter reading by the amount
of the feeder drop. The amount subtracted from the voltmeter reading
the line-drop compensator is directly proportional to the load carried by
the wrcuit and to the power-factor, so that the voltmeter gives a correct
indication of the pressure at the feeder-end at all loads, when the line-
drop compensator is once properly adjusted.
88. The Westinghouse line-drop compensator, Fig. 22, is designed
to provide for a drop of 24 volts with a load of 100 amp. The current from
the secondary of the series (current) transformer S passes through the induo-
103G
 DISTRIBUTION SYSTEMS Sec. 12-89

tive section B and the non-inductive section A in proportion to the load on

the feeder. The secondary winding is divided into four sections of 5 volts
each, and four sections of 1 volt each. The 5-volt terminals are connected
to the contacts numbered 1, 2, 3, 4, and 5, and the one-volt terminals to the
contacts numbered 6, 7, 8, 9, and 10. The arms may be independently
adjusted, thus permitting any setting from 1 volt to 24 volts. The current
from the shunt (potential) transformer C passes through the feeder voltmeter
and the two movable arms to 3, thence through the portion of the non-
inductive section, which is included between 3 and 5, and the portions of the
inductive section between 6 and 9 and between 4 and 5, back to the trans-
former C. In completing this circuit, the impressed pressure has been op-
posed by a counter-e.m.f. of 10 volts in the non-inductive section and by
8 volts in the inductive section. The reading of the voltmeter is thus made
100 Amp,

Volts

Fig. 22. —Circuits of Westinghouse line-drop compensator.

the same as it would be at the end of a feeder (in the secondary) having a
resistance-drop of 10 volts (secondary) and a reactance-drop of 8 volts
(secondary) at 100-amp. load.
89. In the Oeneral Electric line-drop compensator, Fig. 23, there
lis but one movable arm on each section, with eight points per section.
Each point represents 3 volts when 1 amp. is flowing in the compensator
loireuit. The compensator shown (Fig. 33) is set so as to introduce in the
Ivoltmeter circuit an inductive counter-e.m.f. of 9 volts and a non-inductive
[oounter-e.m.f. of 12 volts, when the feeder is carrying 100 amp.
90. Calculation of compensator setting for a single-phase feeder.
3iven a 60-cycle feeder of No. A.W.G. copper wire, 5,000 ft. long, single-
*
ase, wires 12 in. apart, series (current) transformer ratio 100 amp. to 5
ap., shunt (potential) transformer ratio 2,200 volts to 110 volts, how should
liecompensator be set?
The resistance drop on No. wire, from Par. 31, is 0.0981 volt per amp.
lier 1,000 ft.;hence the drop at 100 amp., for 5,000 ft., will be 2X 100X5X
1)4)981 = =
98 volts 4.5 per cent. The inductive drop of No. 0, at 12-in.
l$Jacing, being 0.1043 volt per amp. per 1,000 ft., the drop at 100 amp. will
tl| 2X100X5X0.1043 = 104 volts = 4.7 per cent. The resistance and the
[•eactance should each be set at 5 volts ( = 0.045X110), to give constant
pressure at the end of the feeder at all loads.
91. Calculation of compensator setting for two-phase feeders. In
[he case of a two-phase, four-wire feeder, the method of connection is

1037
Sec. 12-92 DISTRIBUTION SYSTEMS
similar to that used for a single-phase feeder, except that separate equipment
is required for each phase, and hence the calculations are similar.
A two-phase, three-wire feeder, with unbalanced load requires one
compensator in each wire, with connections as shown in Fig. 24. The values
of resistance and inductance per 1,000 ft. used in the case of a single-phase
feeder are based on the use of two wires, whereas in a three- wire feeder each
compensator corrects the drop in one wire only.

Fig. 23. —Circuits of General Electric line-drop compensator.

Calculation of compensator setting for three-phase feeders.

02.
In the case of a three-phase, three-wire feeder carrying unbalanced load,
a compensator is required in each wire. For instance, if the feeder previously
used for illustration were a three-phase, three-wire feeder (with symmetrical
spacing of phase wires) carrying 100 amp. per wire, the ohmic drop in each
wire would be 5X100X0.0981=49 volts, and the inductive drop 52 volts.

Phase .A

Fi(i. 24. —Compensator connections for two-phase three-wire system.

These values are respectively 3.8 per cent, and 4.1 per cent, of the pressui'
to neutral, 1.270 volts ( = 0.577X2,200).
In a three-phase, four-wire feeder operating at 2,200 volts between
phase wires and neutral, the method of calculating the drop is as follows:
Oiven a feeder of four No. wires (12-in. spacing) running 5,(X)0 ft. from the
station as a three-phase feeder, the drop in each phase wire at 100 amp.

1038
 DISTRIBUTION SYSTEMS Sec. 12-93

will be 49 volts, ohmic, and 52 volts, inductive. The working pressure being
2,200 volts, this is about 2.5 per cent. If the entire load of the feeder is de-
livered from this centre of distribution, the compensator on each phase wire

Phase A

Fia. 25. —Compensator connections for three-phase four-wire system.

hould be set at 2.5 per cent, on each dial; that on the neutral should be set
t 2 per cent, on each dial, to take care of unbalanced load. If, however,
he A-phase branches off with a Eziemal R«8lataoae
eutral to a single-phase centre
f a distribution 2,500 ft. be-
ond, there must be added to
16 A-phase setting, 2X100X
5X0.098 = 49 volts = 2.2 per
snt.,making the new setting
5-f2.2 = 4.7 per cent. If the
Jier phases branch to similar
mtres of distribution, at differ-
it distances, the drops must
! computed similarly, and
Ided to the three-phase drop,
he connections of the compen-
tors for a three-phase, four-
re feeder are shown in Fig. 25. ^° Controlling
. ,
Mechaaiflm of
93. Automatic regulation
feeder voltage. In connec-
)n with automatic regulation
e General Electric Co. has de-
loped a device which serves as
line-drop compensator com-
led with a relay. This
vice,known as a "contact-
aking voltmeter," is shown To 8bunt(Potential)TnuiflfonD«r
or Preflaure Wiles
Fig. 26. It consists of a sole-
id
'ped at various points and
—
having windings which are Fig. 2C. Automatic regulators for con-
trolling feeder voltage.
;

' light out to adjustable

I tches, as in the line-drop compensator. One winding produces a mag-
1 ic flux proportional to the pressure; another carries current in proportion
1 the load and opposes the flux due to the feeder pressure. This counter-
1039
Sec. 12-94 DISTRIBUTION SYSTEMS

magnetomotive force may be adjusted roughly by setting the proper switcl

on tlie points A, B, or C, and the finer adjustments are made by the pointi
D to L. The pivoted bar carries the contacts which control the supply o
energy to the feeder regulator.
As the load increases, the plunger falls until the contact is made whicl
raises the pressure on the feeder. This increases the flux due to the pressun
and the plunger rises sufficiently to stop the movement of the regulatoi
until a further change in load or bus pressure occurs. This device givei
very satisfactory results at all power-factors from 75 per cent, to 100 per cent
94. BuB-bar Toltagre regulation. Where there is a variable moto;
load supplied by motor-generator converting equipment, it is desirable t<
maintain a constant bus pressure, in order to prevent the load variationi
from affecting the bus pressure and thus impairing the steadiness of voltagi
on the feeders supplying the lighting service. The automatic regulato;
devised by Tirrill has been successful in accomplishing this purpose.
Jlaln Contacts

Fig. 27. —Connections of Tirrill regulator.

98. Tirrill regulator. The general scheme of connections is shown i

Fig. 27. The secondary circuits of the shunt (potential) and series (current
transformers in the generator leads arc connected through a solenoid in
compounding relation. The series section is subdivided so that differen
rates of compounding may be secured. A movable plunger is actuated b'
this solenoid, which in turn actuates a counterweighted lever, the opposit
end of which is equipped to make electrical contact in a relay circuit. Th,
other contact terminal of this relay circuit is carried on a similar lever whic
is actuated by the plunger of a direct-current solenoid. This solenoid re
ceives current in proportion to the pressure at the_ exciter terminals. Th
relation of these contact-making levers is such that increased pressure at th
exciter brushes tends to open the relay circuit, while increased pressure at th
•

main generator terminals tends to close it.

This closing of the circuit demagnetizes the relay, which is differentiall
wound, and its armature is withdrawn by a spring. This shunts the fiel
rheostat of the exciter, increases its terminal pressure, and opens the rein
circuit,thus weakening its pull.
Where there are several units in parallel in a station, the regulator m;i
applied to the exciter for a portion of them and the bus regulated
constant pressure with the scries coil of the alternating solenoid cv
out. With this arrangement, the bus pressure may be maintaine
constant at any desired value by tho insertion of an adjustable resistanr
in the pressure circuit of the alternating solenoid.

SECONDARY DISTBIBUTION
96. The secondary mains of an alternating-current system serv
users in a local area, while the primary mains supply larger areas. Tl
standard system of secondary distribution in America is the single-phast;
1040
 DISTRIBUTION SYSTEMS Sec. 12-97

three-wire Edison system at approximately 110-220 volts for lighting

and small motor service, and 220-volt two-phase or three-phase for
general motor service; 440 volts and 550 volts are also used to some extent
for power systems in industrial plants. For the supply of mixed service
of lighting and motors from a secondary network, the fouT-wire, three-
phase system at 115-200 volts or 120-208 volts, approximately, is some-
times used.
97. The voltage of general distribution systems must be low enough
to be adapted to incandescent lamps, fans, heating devices and other small
paccessories, which are preferably made for the voltages around 110. Motor
voltages are higher in order to secure economy of conductor investment;
this is especially true with large installations.
98. Transformers are usually wound for a ratio of 2,200 to 110-220
rolts, though some of the systems where 115-230 volts are standard are
jsing a ratio of 2,080 to 115-230 volts. This secondary voltage permits a
ipacing between transformers of 600 ft. to 800 ft.
In laying out secondary systems for lighting service, it is usual
99.
.o limit the drop from transformer to consumer to about 2 per cent,
is required.
vhere first-class service In scattered districts where secondaries
.re too small and remote to warrant interconnection, the problem of design
onsists in striking a balance between the cost of conductors, and the cost of
ransformers and their losses.
By reaching out farther from the transformer with the secondary mains,
he number of transformers is reduced, and, their average size being larger,
bfeir total cost is smaller. This is true because the cost per kilowatt is less
)r the larger sizes, and because the kilowatt capacity required per kilowatt
jnnected is less for a large number of users than for a few.
100. Minimum annual cost. As the radius of distribution from the
ansformer becomes more than 500 to 600 ft., the cost of conductors increases
sry rapidly, and it becomes more economical to provide additional trana-
•rmers. On the other hand, if too many transformers are used, the iron
SB which goes on 24 hr. a day becomes excessive, and the investment per
lowatt in transformers is high. The minimum annual cost of a secondary
stem is that at which the fixed charges on conductors and transformers,
us the value of the iron loss, is a minimum. The iron and copper losses
standard American transformers appear in the table in Par. 101 (also see
0.6).
101. Losses and Efficiencies of Standard Transformers for
Alternating-current Distribution
2,200 to 110-220 volts, 60 cycles

BRating
Sec. 12-102 DISTRIBUTION SYSTEMS

102. All-day efficiency of transformers. In a distribution trans-

former, the iron loss may reach a considerable percentage of the daily con-
sumption of energy. A 5-kw. transformer which carries full-load 4 hr. a day
delivers 20 kw-hr. per day, and has a copper loss of about 102 watts at full-
load, while the iron loss would be about 45 watts. The copper loss per day
would be about 410 watt-hr., while the iron loss would be 24X45=1,080
watt-hr. The total loss being 1.5 kw-hr., the all-day efficiency is 20/21.5 =
93.0 per cent., and the full-load efficiency is 5,000/5,150 = 97.1 per cent. It
is apparent that the all-day efficiency varies with the load factor or hours'
use of the maximum load.
103. Calculation of secondary mains. The most economical size of
conductor and spacing between transformers for secondary mains may be
determined approximately as follows:* assuming a load density per 1,000 ft.
and an allowable psessure drop, determine the distance between transform-
ers which will result in that drop with several sizes of conductor.
The investment in wire and transformers may then be found. The fixed
charges on the investment plus the annual value of the iron losses in the
transformer constitute the annual cost of this secondary main (exclusive of
pole line or conduit). The minimum annual cost will be found to work out
approximately as in the curves shown in Fig. 28.
104. Curves of cost variation, overhead distribution. The varia-
tion of the elements of cost as the spacings between transformers and the
size of wire are changed, is illustrated by the curves in Fig. 28, which are
based upon a load density of 50 kw. per 1,000 ft., with overhead lines. It
is apparent from this curve that the minimum cost is found with No. 2
wire at a spacing of 600 ft. between transformers. The curves of total cost
at other load densities are shown in Fig. 29. These figures are based or
10,000 ft. of secondary main.
1800

800

700
S
5 600
O SCO
a
•^400
o
^ 300
 DISTRIBUTION SYSTEMS Sec. 12-106

ble with the larger sizes of conductor, so as to reduce the number of units
to a minimum. Furthermore, it is usually desirable to anticipate an
'

increase in load by installing a larger conductor than is required for

•immediate needs. The size of transformers is then gradually increased,
ifrom time to time, as the load increases.
\ 106. Uneven load density. The curves (Figs. 28 and 29) are based
[on an assumption that the load is uniformly evenly distributed along the
line throughout its length, but such is rarely the case in practice. At
occasional intervals, department stores, churches or other large customers
of energy throw heavy loads upon the line. It is necessary, therefore, to
locate transformers near such large consumers" premises and design the
lOaains between them to carry the scattered load.
107. Secondary networks. The gradual extension of mains on all streets
i-esults in a system of lines which is interconnected and becomes a network.
Transformers are preferably located at intersections where they feed in
ill directions with the best economy of copper. In the design of such net-
irorks the sizes of secondary cable are fixed by the local conditions. The
smaller consumers distributed along the routes are carried from mains of
Proper size, and the larger consumers such as theatres and department
tores are cared for by a separate installation of transformers in the immediate
.dcinity of the consumers' premises.
108. Underground construction is often required In networks
>nd this necessitates manholes of ample size for large transformers and
luch junction boxes as are necessary for operation. The space required
J somewhat difBcult to secure on account of pipes and other underground

ystems which limit the available space. In some cases it has been found
:esirable to install the transformers in a substation, supplying the network
arough low-tension feeders; this arrangement permits a saving in trans-
_)rmer investment and iron losses, as the diversity factor is better and the
nits are larger, but the cable investment is considerably greater.
109. Separate transformers for large motor loads. The design of
jcondary systems is subject to restrictions when inductive loads, such as
c lamps and motors, must be served along with incandescent lighting.
he heavy starting-current required by induction motors may momentarily
rerload the transformer and the secondary main. This causes a flickering
incandescent lamps served ,

the vicinity. It is neces- ~~

therefore, to install sep-
^-"^f
i \ f
'

llry, '

ww». ,w/w>^
l'|ate transformers for installa-
nns of motors if the best
Kulation is required for in-
Indescent lighting. Motors
liger than 10 h.p. can not
l^ally be supplied from a
lilting network without in-
liering with the service.
230 Volt,
110. Three-phase supply LigbUog Thrfe-phai«
|r mixed loads. In three- Motors
lase systems
Ithods carrying mixed
of
several
Fig. 30.—Three-phase secondary system,
with single-phase lighting service.
liting and motor loads are
use. The most common
thod consists of star-connected transformers supplying a four-wire
operated at about 115 volts from phase to neutral and 200 volts
Joss phase wires. The smaller lighting services are made three-wire
I connected to two phases and neutral, and large services are balanced on

lee phases. Four-wire service is required wherever both lighting and

Iter service are supplied.
In another method, illustrated in Fig. 30, all the lighting is carried
lie-phase from a three-wire Edison main. Motors are served by the
Illation of additional smaller transformers and a fourth secondary
le) wire. The lighting load is easier to keep balanced, and the higher
ssity factor requires somewhat less transformer capacity for lighting.
L Determination of transformer capacity. The selection of the
of transformers for various classes of consumers is important, since

L 1043
 .. ;

Sec. 12-112. DISTRIBUTION SYSTEMS

excess capacity involves idle investment and unnecessary core losses. Verj
few consumers use their entire connected loads at any one time. Where 8
number of consumers are served by one transformer, the various maximum
demands do not occur simultaneously and therefore the resultant maximum
demand is less than the sum of the individual demands. The demand
must be ascertained by measurements which may be made by means of ao
ammeter or by a Wright demand indicator (Sec. 3).
Certain ratios of xnazimum demand to connected load may be
established by a series of such measurements for the various classes of con-
sumers for which it is necessary to select transformers. These ratios oi
demand factors (Par. 1].2 to 118) may then be applied with reasonable
accuracy to the transformers for new consumers. The results of tests
made on various groups of consumers in Chicago appear in Par. 112.
112. Table ofDemand Factors in Lighting Service
(Based on Chicago Experience)

Kilo-
Number watts
Kilo- Demand
Description of load of cus- watts factor
con-
tomers
nected
demand (%) I

Residence. 137 84.7 18.9 22.3

Residence 68 126.6 15.75 12.4
Residence (119 kw.; stores 11 kw.). 196 129.5 28.85 22.3
Residence (1 customer, 7.5 kw.).. 5 10.3 9.45 92.0
Residence 70 kw.; stores 7 kw 77 77.0 21.0 27.3
Residence (59.7 kw.; hotel 48 kw.). 66 107.7 26.25 24.3
Residence (1 30-amp. rectifier).. . 121 183.5 30.5 16.6
Residence 34 47.5 10.5 22.2
Residence (2 30-amp. rectifiers).. . 19 79.2 15.7 19.8
Residence (1 30-amp. rectifier) 21 67.7 13.6 20.2
Residence (1 30-amp. rectifier) 21 54.1 13.1 24.3
Residence 47 68.7 8.4 12.2
Residence 144 129.95 22.6 17.4
Residence (4 30-amp. rectifiers) .. . 43 59.0 26.6 42.0
Residence 85 99.65 16.1 16.1
Residence 84 112.5 14.7 13.2
Residence, 20 kw.; Stores 15.7
(hotel 25 kw.) 38 60.7 27.3 45.0
Residence . •. . . . 59.0 8.4 14.2
Residence 100.45 13.7 13.6

113. In store lighting the maximum demand for window lighting

signs and other display lighting is from 90 per cent, to 100 per cent, of th
connected load. The demand on interior store lighting is from 50 per cent;
to 70 per cent. I

114. In residence lighting where the connected load is fifty lamps c«!
less, the average demand factor of a group of residences is from 15 per cem'
to 20 per cent, of the connected load; small residences and apartments havin
connected loads of forty lamps or less, average about 20 per cent, of the p"'
nected load.
116. In theatre lighting the border lamps and foot lamps, of sevi
colors, are not used simultaneously; and the stage and the auditorium m
not lighted simultaneously except for a very few minutes at a time. I
a small theatre the demand factor may be from 70 per cent, to 85 per centi
while in a large theatre it frequently runs as low as 50 per cent.
116. Influence of number of consumers on demand factor. I

feneral, a higher ratio must be used where but few consumers are
serv.
rom one transformer, than where there are more, as the occasional maximui
demands of individual consumers are proportionately much larger.
117. The selection of transformers for motor loads is more diffioul
as the maximum load may vary greatly from day to day or from moiit!
month. Elevator and crane motors require transformers having 1 00 per <

to 125 per cent, of the rated motor capacity, unless there are several mv-

1044
 DISTRIBUTION SYSTEMS Sec. 12-118

supplied by one unit. This is necessary in order to hold up the pressure in

starting. The average demand factors in motor service in Chicago are
given in Par. tl8. These figures were made up from several thousand
installations of continuous- current motors in Chicago, which were equipped
with maximum-demand meters.
118. Table ofDemand Factors in Motor Service
(Based on Chicago Experience)

Total installation
in h.p.
Sec. 12-122
 DISTRIBUTION SYSTEMS Sec. 12-122

'
Fig.35.—Effect of booster in one Fio. 30. —Effect of boosters in each
phase of three-phase circuit. phase of a three-phase circuit.

Fig. 37. — Connections

^22.5 w
of auto-transformers for 110-volt lighting.

S200 V, 8200 v.).

<- . J20 ^^ _ J<. - J20 Tt_ - >

S2D V.^

'?I0. 38. —Open-delta

two transformers supplied from
connection Fig. 39. — Transformation from
three-phase to two-phase, or vice
htee-phase four-wire system. versa,with tee-connection.

1047
Sec. 12-123 DISTRIBUTION SYSTEMS

^5.5 % Boosters

—2200 v.* -2310 Vi -2310 Yv

V^A^—»AA^ ^.^wv\^^^A^ SAAA^-xAAi^

lOtol

^220 Vr-
 DISTRIBUTION SYSTEMS Sec. 12-127

boost, in order to give 220-volt two-phase service from 2,200-volt primary

mains.
Two-phase 220-volt service from a three-phase four-wire
127.
system may be secured with three standard transformers, connected
shown in Fig. 40. The unit at the left has a ratio of 10 to 1, and is
as
connected from phase to neutral. The other two have ratios of 9 to 1, with
;their secondary coils in multiple, and are arranged as two limbs of a star-con-
tnection (Y), to give 220 volts across the outer wires. The three-phase
system is therefore unbalanced by this arrangement, since half the energy is
taken from one phase. The capacities of the transformers should be
selected accordingly.
It is possible to use transformers with ratios of 10 to 1, but if this is done
each of the phases supplying the right-hand transformer must be provided
with a boost of 15 per cent.
A »

B f f
c-
+ -

msmJ immj
110 V. I luOY. I

U ^22a-V.
I i

i
tG. 41. —Conversion from three-phase to single-phase, with balanced load.

128. Conversion from three-phase to single-phase. When single-

lase energy is required for a relatively large unit of load such as a welder or
"ass furnace, it is undesirable to supply it from one phase of a three-phase
'pply, as the unbalanced load interferes with pressure regulation and may.
ji'erload one phase before the line, as a whole, is fully loaded.
fiThe load can be distributed between the phases in the ratio of 50, 33 and
approximately, by connecting the single phase load to one phase of a
\

tlta-connected three-phase transformer installation. This is applicable

[a, 3-wire or in a 4-wire primary system. With a 4-wire system the method
(connection in Fig. 41 is sometimes used. This requires capacities in the
io 50, 50 and 50 and gives poor regulation of pressure. The current
tSuwn from the three phases is equal but the power factor on two of the
;)a8es is low and the energy is not balanced equally on the phases.
PROTECTIVE APPARATUS
1129. The insertion of fuses for protection in low-tension lighting
jitems has become universal, because of the low cost of fuses as compared
;h circuit breakers. In power systems where the circuits are opened fre-
j«3ntly, the circuit-breaker is found preferable.
|130. Plug-fuses. Thefire hazard from the flash which occurs at the
llting of a fuse led to the development of enclosed fuses, the earliest of
lich was the Edison plug-fuse, which is used very generally on circuits up
l20 amp.
|.S1. Cartridge fuses. Cartridge fuses, consisting of a tube of fibrous
[terial in which the fuse is mounted, with a filler of fire-resisting powders
used largely on circuit operating at 250 to 600 volts. Cartridge fuses
1049
Sec. 12-132 DISTRIBUTION SYSTEMS

have' been fully standardized by the National Electrical Code as to voltage

and current as follows: 250-volt: 0-30 amp., 31-60 amp., 61-100 amp.
101-200 amp., and 201-500 amp.; 600-volt: 0-30 amp., 31-60 amp.,
61-100 amp., and 101-200 amp.
132. The law of the operation of fuses was discovered by Preece ii
1888. It may be stated in the form,
Current =aVd' (6)
d being the diameter of the wire expressed in inches. The value of the con-
stant "a" varies with the kind of metal used. For copper it is 10,244; foi
aluminum 7,585, for lead 1,379, for tin 1,642 and for iron 3,148.
133. Fusing Currents of Copper and Aluminum Wires
 DISTRIBUTION SYSTEMS Sec. 12-140

140. Circuit-breakers are the preferable means of protection where

automatic cut-outs operate at frequent intervals, and also for circuits operat-
ling at high voltages, controlling loads of 100 kw. and upward. In general,
I
the circuit-breaker is expensive in first cost but inexpensive in operation,
while the use of fuses involves a considerable maintenance charge, but small
first cost.
On low-potential circuits the circuit-breaker consists of a switch of
suitable design, with which is combined a series coil so arranged that it
lifts a movable core and releases a spring-actuated mechanism which opens
the switch. Circuit-breakers are de.signed so that they may be adjusted
to operate at any point between 80 per cent, and 150 per cent, of their
rated capacity.
In high-potential systems a series transformer may be installed at a
convenient point to operate the tripping-coil of the circuit-breaker. On
circuits operating at pressures above 600 volts the switch is designed to
jreak in oil.
141. The operating mechanism of the circuit-breaker may be
lontrolled by hand, or electrically by means of solenoids. In hand-
'>perated breakers the energy required to open the circuit is stored in springs
lompressed during the act of closing. In electrically operated breakers
he power for both closing and opening the circuit is supplied through
Glenoids or motors.
The larger sizes of circuit-breakers and those operating at the higher
•oltages are usually controlled electrically, on account of the power re-
luired, and because of the greater facility of operation. Continuous
.urrent usually available in generating stations and substations, from the
is
ixciter system, and
is therefore used for the operation of solenoid-controlled
.reakers where possible. Motor-operated breakers are often equipped with
Iternating-current motors.
142. Relays. It is usual to design relays for operation with an inverse
Ime element; that is, with a relay set to operate at 100 amp. after 10
it will operate at about 300 amp. in 5 sec. and almost instan-
>neously at 1,000 amp. This characteristic gives prompt action in open-
»g the line under short-circuit, while reducing the likelihood of unneces-
«y interruption under brief overloads.
Oil Switch
Trip Coils
T.C.

Ground
^Series
Tranformers

J^ Generator iC^«v5

Two-phase. Two-phase; Three-phase, Three-phase;

Phases Grounded
Interconnected. Neutral.
ia. 42. — Relay arrangements for two-phase and three-phase circuits.

|li3. The arrangement of relays must be such that a short-circuit

Itween any two wires will operate the breaker. On single-phase circuits
IB relay is sufficient to accomplish this. On two-phase systems supply-
|j lighting and motor service it is desirable to provide separate relays and
Icuit-breakers for each phase. In the three-phase, three-wire system
Itbout grounded neutral, relays are required in two of the three wires; the
Iwe-pole type of circuit-breaker is used. In the three-phase, four-wire
Item having the neutral point grounded, it is essential that relays be in-
lUed in each phase wire, with single-pole breakers; in case of a ground on
l> phase the corresponding circuit-breaker opena without interrupting the
ptting service on the other phases (Fig. 42).

1061
 —
Sec. 12-144 DISTRIBUTION SYSTEMS

144. Relays on three-phase transmission lines. It la customary to

provide relays at the point of supply, commonly called overload relays
Where several lines are operated in parallel, further protection is necessary,
When the lines are connected to the same bus at each end, a short-circuil
will draw energy from both ends and circuit-breakers must be provided a(
both busses. The relays at tlie receiving end must, however, be of a type
which will operate only on reversal of the flow ol
liine energy. The converting equipment is provided
with reverse-power relays on the secondary side.
146. Speed-Iimitin? devices. It is important
that synchronous converters be protected by speed-
limiting devices designed to operate the direct-cur-
rent circuit-breaker when the speed exceeds a safe
value.
146. Lightning Protection. Overhead dis-
tributing lines are susceptible to the effects ol
lightning. A discharge among the clouds causes ar
abrupt discharge of potential on the wires, which
must be given an opportunity to escape to eartl:
without injuring the insulation of the apparatus.
147. The function of lightning-arresters i:
to protect apparatus by passing the discharge ol
lightning to ground, without permitting the arc thui
established, to be maintained. This may be accom-
plished on potentials up to 600 volts by a short gaf
of non-arcing_ metal. At 2,200 volts or higher
several gaps in series are necessary, with a resist
ance to limit the current. Since each wire of the
circuit is affected, discharge gaps must be provided
Fia. 43. — Solenoid type between each wire and ground.
of lightning-arrester. In systems having one side grounded, ever>
discharge is likely to be followed by the generatoi
current, as there is a fixed difference of potential between the circuit anc
earth. Arresters on grounded systems must, therefore, meet more seven
requirements than those on ungrounded systems.
The problem of protection of transmission To Line
lines becomes more complex as the voltage is
increased, and the study of protective methods
for lines operating at 20,000 volts and up-
ward is leading to new developments every -e
year. The discussion in this Section 'will be o
restricted to alternating-current distributing o
systems operating at less than 5,000 volts. o
148. Types of Arresters. The wide range
in severity of lightning flashes makes it well-
nigh impossible to design an arrester which o & «
will protect apparatus and yet withstand the
effects of a direct stroke at any point nearby. o-a
The arresters described in the succeeding para- o a
graphs (Par. 149 to 162) include the leading
commercial types which have been used in »
distribution work. -o
149. The Oarton-Daniels arrester, Fig. O
43, consists of air gaps and resistances, with a
solenoid so arranged that the plunger is raised
O—
by the passage of the generator current, thus o
placing additional gaps in series and rapidly o
diminishing or stopping the flow of energy.
The lightning discharge passes across the
shunted gaps to ground owing to the induc-
tance of the solenoid.
160. Multi-gap arrester. A modification
^ Ground ,

of the epark-gap and resistance type of ar-

rester has been employed quite extensively.
Fig. 44.— Multi-gap lighM
ning-arrester.
This is illustrated in Fig. 44, as made for 2,300
volts, and consists of three paths of discharge, one of which has a mg
1052
DISTRIBUTION SYSTEMS Sec. 12-151
Sec. 12-156 DISTRIBUTION SYSTEMS

In many cases the objection to overhead lines is minimized by locating

them in alleys.
166. Poles. Distribution lines are necessarily carried on wooden poles.
Iron poles are objectionable on account of the risk to linemen in handling
"live" primary circuits. Iron poles are used in some cases for street-
lighting circuits which are so operated^hat it is not necessary to do any work
on them while they are "alive." Tne cost of iron poles is about twice
that of wooden poles.
167. Concrete poles are being used increasingly in sections where the
ravages of insects and the nature of the soil make the life of wooden poles
very short. They are also being introduced for transmission work in places
where iron poles would otherwise be required.
168. The woods which are best suited for pole work are Michigan
cedar, Western cedar, chestnut, pine, and cypress.
169. The Michigan cedar grows with a natural taper of about 1 in. in
diameter to every 5 ft. or 6 ft. of length, making a very substantial and
rigid pole.
160. The Western cedar, which grows in Idaho and Oregon, has a
natural taper of about 1 in. in 8 ft. to 10 ft. of length. For the same size of
top the diameter of the butt is, therefore, smaller than that of the Michigan
cedar. The surface of Western cedar is smoother than that of the Michigan '

cedar and the poles are very straight and neat in appearance. It is neces- :

sary on important lines to use nothing smaller than 8-in. tops with these i

poles, in order to secure adequate diameter at the ground line.

161. The chestnut pole is quite different from the cedar poles. The.
specific gravity of the wood is high and the surface is irregular and knotted,
making the appearance of the chestnut pole not as good as that of cedar. i

162. Pine and cypress poles are more like cedar in their general char-
acteristics of weight and strength. Their use is limited to sections of the
country where the timber is native, as their life is comparatively short.
163. On the Pacific coast, California redwood and some other native
woods are used very generally.
164. Strength of wood poles. The strength of a wood pole must be,
sufficient to withstand the transversely acting forces, such as wind pressure,
on the pole and conductors, the unbalanced pull on the conductors when they
are broken and the side pull on curves and corners where guys cannot be'
provided. These forces place the fibre of the wood under tension and thd
load which a given pole will carry is determined by the inherent strength ol'
the wood fibre under tension and the moment of the forces acting on th«|
pole. The moment is
M=PL+PiLi+PtLi etc., (7,

in which P represents the force acting at one cross arm in pounds, L is th«
height at which the arm is attached in feet. Pi and Pi etc., are the foroei
acting on other arms and Li, Ln etc., are the respective heights. If s is tht
fibre stress in pounds per square inch, and c is the circumference at the groumi
in inches, the allowable moment of a pole of given size is -

3f = 0.0002638sc« (8;

Thus for a pole having a ground-line circumference of 40 inches and a)

allowable fibre stress in an emergency of 2500 lbs. per sq. in., the maximun
allowable moment is 71/ = 0.0002638 X 2,500 X (40) « = 42,200 Ib.-ft. If tb
average height of the attachments is 30 ft. the total force is 42,200/30"
1406 lbs. .

The breaking stress for western cedar or chestnut is from 5,000 to 6,00
lbs. per sq. in. and for Northern cedar 3, .500 to 4,000 lbs. per sq. in.
For the normal unbalanced forces such as those due to an unguyed coroe
the fibre stress should not exceed about 15 per cent, of that at the breakin
point, but for wind pressures and the unbalanced force due to broken winj
which are abnormal and do not persist long, the stress is usually taken^i
about 50 per cent, of that at the breaking point. Hence the working fibl
stresses for normal conditions may be taken at 800 lbs. per sq. in. for wester
cedar or chestnut and at 550 lbs. for northern cedar. For abnormal cm
ditions a stress of 2,500 lbs. for western cedar or chestnut and 1,800 lbs. If
northern cedar may be assumed.
 DISTRIBUTION SYSTEMS Sec. 12-165

for allowable moment is based on the assumption that

The above formula
I
lithe line is at or near the weakest point of the pole.
ground This is not always
Hbe case with northern cedar or other woods having a taper of 1 inch in 5
Ho 6 feet of length. The point of greatest fibre stress is that at which the
fdiameter is 1.5 times the diameter at the point where the load is attached.
That is with a pole having a diameter at the cross arm of 8 inches the greatest
jstress is at the point where the diameter is 12 inches. With a northern
(cedar pole this would be at a point 5 X (12 — 8) = 20 feet below the cross arms,
and with the usual sizes of poles about 10 feet above ground.
;

When the point of maximum stress is above the ground Une the allowable
moment is determined from the formula
!

; M
= 0.001781 sc«(ci-c) (9)
in the circumference at the point of attachment and c\ is that at
which c is
[the point of maximum stress.
I

It is usually found however that decay occurs

fat the ground line and as the age of the pole increases the ground line circum-
ference is reduced to such a value as to make the ground line the point of
greatest stress.
165. Example of calculation of pole size. Assume a Western cedar
p'ole carries two cross arms, one of which carries a normal transverse pull of
400 lbs. at a height of 33 feet and the other 200 lbs. at 31 feet. What should
be the ground-line circumference of the pole? =PLXPiL! =400 V33 M
X 200 X 31 = 19.400 Ib .-ft.. and 19,400 = 0.0002638 X 800c3 whence c> = 19,400/
0.211 and c = V
92,000 = 45.2 in. With a decrease of 3 inches in circum-
ference for each 8 ft. in length the circumference at a point 32 feet above
ground would be (32/8) X3=12 inches less than at the ground or 45.2 —
12 = 33.2 in. This would require a pole having a top diameter of about 11
i'inches.
i If the allowable fibre stress were increased to 2,500 lbs. instead of 800, as
under storm conditions, the moment could be increased to M
= 0.0002638
i
X2.500c3 = 60,700 Ib-ft.
[ If this were a Northern cedar pole the ground line circumference would be

'^'=°
=.-r.!f'onoo«QQ = ^33,600
5o0 X .0002638
c = -V^133,600 = 51.2in.
,
_
With a decrease of 3 inches in circumference for each 5 ft. in length, the
i circumference at a point 32 ft. above ground would be (32/5) X3 = 19.2 in.
i'less than at the ground.
c at top =51.2-19.2 = 32 inches.
166. Wind pressure. The design of pole lines to withstand wind pres-
sure must be considered when they are in exposed positions. The pressure
. on fiat surfaces normal to the direction of the wind may be calculated from
the formula
P = 0.004 F> (10)
.in which P is and V is the velocity in miles per hour. For
in lb. per sq. ft.
'

cylindrical surfaces such as wires and wood poles

P = 0.0025F2 (11)
In using the values of V taken from weather bureau reports it must be
noted that the observed values are taken at elevations considerably above
those at which wires are usually carried. The following correction should
therefore be made before using the bureau values in most cases.

Indicated velocity, miles per hour. 30 40

Sec. 12-167 DISTRIBUTION SYSTEMS
The wind pressure on a 40-ft. pole, of which 34 ft. is above ground, with
7-in.top and 14-in. butt, would be calculated as follows. Projected area =
i (7 + 14)/2 X 34X12 = 4,284
) sq. in. =29.75 sq. ft. Assuming a wind
velocity of 60 miles per hr., p = 0.002 X (60)^ = 7.2 lb. per eq. ft. Total
pressure on pole = 29.75X7.2 = 214 lb. This force acts at the centre of
gravity of the projected area, which is a long narrow trapezoid; or 15.1 ft.
from the ground-line. The moment of this force about the ground-Line is
therefore 214X15.1=3,230 Ib-ft. Taking the diameter of No. 6 A.W.G.
triple-braid weather-proof wire as 0.32 in., the total wind pressure at 60
miles per hr., on a 120-ft. span, would be 23 lb. and on twenty wires it would
be 460 lb.; this resultant force would act at a point about 3 ft. below the top
of the pole, or 31 ft. from the ground-line. The resulting moment would be
14,260 Ib-ft. The sum of the wind pressures on pole and wires would be
3,230 + 14,260 = 17,490 Ib-ft.
167. Selection of poles. It is usual to select poles with 7-in. tops for
important distributing lines.
The height of the poles selected for distribution purposes must be
governed by the clearance over local obstructions and also by the number of
cros.s-arms to be carried on the poles. Clearance over trees is especially
troublesome in residence sections where trimming will not be permitted.
In general it is desirable to use poles not less than 30 ft. long where
primary lines are carried, and in built-up sections a minimum size of 35 ft.
IS preferable.
168. Poles for joint-line construction. Where joint-line construction
with standard cross-arms is used, it is not usually possible to employ poles
shorter than 35 ft. In a few cases the lines have been placed in cable and
carried on 25-ft. poles on rear-lot lines. The use of poles over 40 ft. lona
is to be avoided wherever possible, on account of the cost, the increased
danger in storms and the diflSculty of handling transformers and service
connections.
169. Poles should be spaced in approximately equal span lengths of
about 100 ft. to 125 ft., to keep the sag within safe limits and to provide a
sufficient number of points at which service drops may be taken off. The
spans near self-supporting corner poles should be about 75 ft. long in order
to relieve the strain on the corner pole. The poles should be placed oppo-
site lot-lines to avoid interference with the rights of abutting-property
owners.
170. Shaving and painting. It is considered good policy to carefully
shave all poles, trim the knots, and give them two coats of paint. A
dark green color is very commonly used because of its harmony with
foliage in residence districts.

171. Stepping. Transformer poles and others which are climbed at

frequent intervals should be provided with pole steps. It is the practice
in many of the large city systems to provide steps on all poles.
172. Oaining. The gains should be cut for the cross-arms before the
poles are erected. The distance between cross-arm centres must be suffi-
cient to give clearance for service drops and allow a safe working space for
linemen. The space usually allowed is about 24 in.
173. Pole setting. Experience has proven that the following practice
is conservative, as regards the depth of setting.

Size pole (ft.)

 DISTRIBUTION SYSTEMS Sec. 12-174

one shoveler, in back-filling, in order to insure the stability of the pole.

Water may be used to advantage, where available, in settling the back-
fill. In swampy soil, the digging of holes is greatly facilitated by the use
of a sand-barrel. This consists of a sheet-iron cylinder about 30 in. in
diameter and 3 ft. long, which is separable into two parts lengthwise, and
is readily removed
after the pole is in
place. Various
methods of setting are
shown in Fig. 47.
174. Ouying: and
bracing. Where the
of a line
direction
changes, the tension of
the wire should be
supported by guying or
bracing. The bracing
method requires con-
T siderable space, and is
X
more unsightly than a
guy. G uys are secured
in various ways, de-
'

FiQ. 47. Methods of —

setting self-sustained poles, pending upon the
space and the clear-
,ance required. Where nothing prevents, the guy cable may be secured to
!an anchor of timber or some form of patent anchor (Fig. 48). On public
thoroughfares guys cannot be run directly to anchors without interfering
with traffic, and the guys must be run to Stubs at such height as to
'
permit free passage of
traffic beneath. Guys
over roadways should clear
about 25 ft., and those
over pathways about 12
ft. (Fig. 48).
W here side-arm con-
struction is used it is
necessary at corners to guy
the cross-arms as well as
tlie poles. At heavy cor-
ners a "head" guy is run
from the base of the corner
pole to the upper part of
' next pole in the line,
tension in the corner Fig Anchor and stub guy.
:is may thus be re-
i Lrelieving the strain on the corner pole.
t'd, In straight-away lines the
h( ad guy is used to limit the extent of damage in case several poles go
down; this is sometimes called "storm guying."
175. Galvanized steel cable is generally employed for guying pur-
poses because of its high tensile strength. Such cable is made in sizes vary-
inz indiameter by steps of t's-in., from J-in. up. The ultimate break-
ing strength of i-in. cable is about 3,000 lb.; iVin., 4,500 lb.; f-in., 6,000
lb and J-in., 12,000 lb. Having calculated the tension, the size of guy
:

cables should be such that the strain will be from one-fourth to one-fifth the
ultimate breaking strength of the cable, or the factor of safety of the
steel cable, from 4 to 5. Anchors should be placed at a distance from
tiie pole not less than one-quarter the height of the guy attachment. In
general, J-in. cable is used for the smaller loads, while the |-in. size is
standard for corner poles where the load of the ordinary two-arm to three-
arm distribution line is to be supported.
176. Strain insulators. It is important that guy cables attached to
iEtubs be equipped with strain insulators not less than 8 ft. from the ground.
This precaution is advisable for the protection of the public and of linemen.
177. Cross-arms. Southern pine and Oregon fir are the best woods
:for cross-arms because of their straight grain, high tensile strength, and

67 1057
Sec. 12-178 DISTRIBUTION SYSTEMS

durability. The cross-section should be such that the arm will safely bear
the weight of a lineman in addition to that of the wires. Experience indi-

i il2

4 Pin Arm
Fig. 49. —Dimensions of standard cross-arms.
cates that a cross-section 3.5 in. wide by 4.5 in. high is ample for the average
requirements of distributing lines. For transformers of 20 kw. and larger it
is usual to provide arms
Quj ^OroMArm Guy ^ of jj larger cross-section.
Main lines are commonly
built of six-pin arms, with
four-pin arms on the
Haid Guj smaller distributing lines.
Nl Where secondaries for both
lighting and motor service
must be carried on the
same arm, it is usually
rw
necessary to employ six-
pin arms.
Bpftn not to £xo«cd »^—>J The spacing of pins
should provide safe work-
ing room for linemen and should take into ac-'
count the average sag of the wires. Under thei
usual working conditions of distributing lines,!
it is not safe to attempt to use spacings lesaj
than 12 in. The spacing of the pole pins mustj
give sufficient room for the men to climb to the'
upper arms, at least 30 in. being required for
safety. The dimensions and spacings of
standard cross-arms are shown in Fig. 49.
178. Double cross-arnis. At corncr.s
terminals, and other points where any unu.Hu.i
load is to be supported, the poles should 1"
fitted with double arms. In turning corners .i
a single pole, the double-arming of both s( i

of arms makes the pole difficult of aoces.s tc

linemen. It is preferable, in case there M'
more than two cross-arms, to double-arm tli
FiQ. 50.—Reinforcement first pole away from the corner in each dircc
of corner poles by double tion, as shown in Fig. 50.
cross-arms on adjacent m
poles.
179. Cross-arm fittings. Cros.s-armfl
fastened to the pole by through-bolts wliir

1058
 DISTRIBUTION SYSTEMS Sec. 12-180

should be i in. in diameter and from 12 in. to 16 in. long. The side on
which the arm is attached is known as the face of the pole. CrosB-arm
braces are usually made of strap iron about J in. by 1 in. and 26 in. to 30
in. long, and are attached to the pole by means of lag screws and to the
cross-arms by stove bolts. For side-arms it is usual to use a brace of
angle iron. This is rigid enough to bear the weight of a lineman on the
step.

180. Cross-arm pins. Wooden pins are preferred for distribution

work on account of their low cost and insulating qualities. Locust, elm,
oak and some other woods are common, but locust is superior to all in
strength and durability. Iron pins are commonly used for transmission
lines where the size of the insulator necessitates a pin so long that wooden
pins are not strong enough unless made undesirably large.
181. Insulators. The common type of insulator for distributing lines is
that known as the deep-groove double -petticoat insulator, shown in Fig.
51. The dimensions are sufficient to carry 4,000-volt circuits safely. The
point of support is low and the side strain on the pin is a minimum These
insulators are made in glass and porcelain. The glass insulator is slightly
less expensive than the porcelain in the deep-groove double-petticoat type,
as is most commonly used. Some companies are using porcelain for pri-
mary wires and glass for secondaries, as a means of assisting linemen in
the identification of circuits. Other porcelain types for higher voltages are
also shown in Fig. 51.

182. Wire stringing. In erecting wire, the tension should be made suffi-
cient to prevent too much sag in the spans, and yet not so great as to unduly

6600 Volts 11,000 Volts

Fig. 51. —Standard types of insulators.

stress the wire. For practical purposes the approximate formula for sag and
tension given by llankine may be used:

(lb.) (12)
"
8S
in which T is the tension in pounds, h
the span length in feet, w is the
is
weight per foot of conductor and S is the sag in feet at the centre of a
horizontal span. If the span length is doubled, the tension myst be
quadrupled in order to keep the sag the same. If the tension is the
same on several spans of different lengths, the sag_ is different in each
span. The sag of any span when the tension is known is found by changing
Eq. 11 to the form, s=L^w/8T.
183. Sag tables. The maximum tension in a span is limited by the
strength of the wire and supports. The ultimate breaking strength of an-
nealed copper wire is about 34,000 lb. per sq. in., but the working stress
should not be over one-fourth of this. The ultimate tensile strength of hard-
drawn wire is about 60,000 lb. per sq. in. See Sec. 11 for a detailed treat-
ment of sag and tension problems. The following table of sags for copper
wire is taken from the National Electrical Safety Code, third (1920) edition.

1059
Sec. 12-184 DISTRIBUTION SYSTEMS

184. Sags for Hard and Medium-drawn Bare Copper Wire for Dif-
ferent Span Lengths
Heavy Loading Districts

(Sags are given in inches)

Size
A.W.G.
No.
 DISTRIBUTION SYSTEMS SeC. 12-186

The values in the table are not the tneoretical values derived by formula,
but include some allowance for flexibility of supports which experience has
indicated is permissible.
In service the sag tends to increase causing "slack," which may become
a hazard to the service if not taken up. This is caused by the permanent
elongation of wire and by the movement of poles supported by guys which are
not strictly rigid. Such a condition is common in the spring when the earth
is softened by tnawing. Elongation of the conductor is likely to be found in
soft copper conductors after a few years of service.
186. Expansion andrcontraction of spans with temperature changes.*
The changes in sag due to expansion and contraction under varying tempera-
tures are of much importance in the erection of the conductors. Lines erected
during the winter months are likely to be too slack during the summer, and
allowance should be made accordingly. The length of wire in a span, dis-
regarding the elastic stretching due to the load, varies in proportion to the
coefficient of expansion and the range of temperature:
Lt=Lo(l + aot) (13)
in which a
is the coefficient of expansion, t is the temperature in deg. fahr.
and Lo isthe length of wire at zero temperature. The linear coefficient of
expansion of copper is 0.000017 per deg. cent, or 0.0000094 per deg. fahr.
In practice the pole supports have a certain degree of flexibility which tends
to take up part of the slack caused by expansion and to prevent excessive
strains being placed on the wires by contraction during cold weather.
187. Transformer installations. Transformers are usually supported
on cross-arms by means of iron hangers. This class of construction is
suitable for transformers of capacities up to 20 kw. For larger units the
cross-arms should be double, and heavier than the standard arm. Large
transformers which cannot be placed inside the building are often installed
on a platform between two poles.
188. Overhead service connections. The connections to buildings
by which consumers are served, called "services," are very numerous and
represent a large fraction of the total cost of the overhead line system.
The most common support consists of a "buck" arm on the pole and a malle-
able iron or steel bracket at the building. The buck arm provides ample
pin space from which to support several services to different buildings.
Where the secondary main is carried on vertical racks the service arm is
not required as the connection may be made directly at the rack. An
extra rack is provided for the back side of the pole, if services are taken
off on both sides of the line.
In sonie localities where buildings stand close together and are of uniform
depth it is feasible to connect a row of buildings by one or two services, from
the pole Une, through distributing main attached to the rear walls of the
group at a suitable height. The ser\-ice is attached to the building at a
height of 12 to 25 feet, the minimum height being governed by the desirable
clearance from the ground and the maximum height by the accessibility
to line construction men working from ladders.
The service is often extended in conduit directly from the point of attach-
ment to the basement, in order to give greater accessibility to the service
switch and meter.
189. Grounded secondaries. To protect life and property in case
a primary circuit becomes crossed with a secondary, it is very important
that the secondary be grounded. This is preferably done by connecting
the secondary circuit to water pipes where these are accessible. Where
the ground must be made outdoors, the most practicable method is to drive
a galvanized iron pipe into the ground to a depth of about 8 ft. The
points to be grounded in various kinds of secondary mains are indicated
in Fig. 52.
190. The grounding of secondaries up to 160 volts has beenre-
auired by the National Electrical Code since 1913. There is some
i doubt as to the advisability of grounding secondaries when the difference of
potential between any wire and ground is higher than 250 volts, owing to
the possibility that shocks from such a system may prove fatal.

* Thomas, P. H. "'Sag Calculations for Suspended Wires;" Trans. Amer.

Inst, of Elec. Eng.; Vol. XXX, 1911; p. 2229.

1061
Sec. 12-191 DISTRIBUTION SYSTEMS

191. When the ground connection is made to a pipe at the pole,

the ground-wire is preferably brought down the pole in half-round wooden
moulding. The ground
/-'^nI
I wire may be soldered to
'i ? the pipe about a foot
'•'• '
' Single Phase above the ground, or
may be attached by
means of a pipe cap as
shown in Fig. 53.
192. Arrangement of
wires. The position of
wires on the cross-arms
should be assigned ac-
Open.Dclta
cording to a systematic
plan. Circuits should be
kept on the same pins
throughout their course,
to facilitate maintenance
work. In general,
through lines should be
carried on the upper
arms and local distribut-
ing lines at the bottom.
All the wires of a circuit
should be carried on ad-
Gxojmd jiicentpins. Connections
carried across the pole
for transformers or ser-
vice drops should leave
one side of the pole free
for climbing.
193. Joint occupancy
of pole lines. The use
of a joint line of poles is
preferable to separate
Ground
lines, on thoroughfares
Star where there are many
Connection service drops, as it

Fio. 52.—Connections for grounded secondary. avoids much confusion.

Where poles are occupied
jointly by both electric-light and telephone companies, the lighting xinrm
should always occupy the upper pogition. A clearance of about 4 ft. should
be maintained between the lower lighting wires
and the telephone wires. Joint-line construc-
tion is the rule in most of the larger cities.
For details of recommended forms of joint-
line construction, the " Report of Com-
see
mittee on Overhead Line Construction," Trans.
N. E. L. A., 1911.
UNDSaaROUND CONSTRUCTION
194. Edison tube system. The under-
ground system devised by Edison consisted of
20-ft. lengths of iron pipe inside of which were
copper rods imbedded in compound to exclude
moisture. These lengths were made with vari-
ous sizes of conductor from No. 4 A.W.G. up to
500,000 cir. mils for mains and up to 1,000,000
cir. mils for feeders. Feeder tubes were pro-
vided with three pressure wires to indicate at
the station the pressure at the end of the feeder.
19B. Arrangement of Kdlson tube system.
Edison tube is joined by stranded connectors
enclosed in east-iron couplings which are filled Fia..£3. — Ground-pipe cap.|
with hot compound. At intersections the tubes
1062
 DISTRIBUTION SYSTEMS Sec. 12-196

are interconnected through fused junction boxes. Such tube lines are carried
along each side of the street near the curb except where consumers are
scattered or where an alley is used. The Edison tube system was the
standard method of distributing low-tension energy underground until about
the year 1897. The change to cable was made on account of the inability
of the tube feeders to carry overloads without causing burn-outs. The
necessity of opening street pavements in each case where repairs were made,
also involved considerable expense.
196. Conduit systems. The early alternating-current and series-arc
systems which were installed underground were unable to use a system similar
to the Edison tubes because of the higher voltages employed. They were
compelled to devise a drawn-in conduit system with manholes for hand-
ling the cables. Creosoted wooden pump log was tried and was satisfactory
for some classes of work, but was too short-lived and inflammable.
Other systems were devised in which the ducts were intended to provide
insulation, but 'experience proved that it was not practicable to maintain
such a system. This led to the development of methods in which the insu-
lation was applied to the conductor and the conduit was of some durable
fire-proof material.
197. Modern standard conduit systems. Various forms of duct
were tried out, but the most suitable were found to be those of fire-proof
material such as terra cotta and clay tile.
A conduit made entirely of concrete and known as Stone pipe has been
used to soma extent instead of clay tile. This is
made in 5-ft. lengths and jointed with metal ferrules
to preserve the alignment, single duct only being
used. The conduit is laid in concrete, making a
solid and durable duct system. The concrete pipe
is fragile, however, and the breakage is likely to be
greater than with the tile duct, if not carefully
handled.
Various forms of fibre conduit have also been
used to some extent. These are laid with concrete
around and between them, so that if the fibre disin-
tegrates in after years there will remain a concrete
duct system. The principal advantage is in the
ease of handling and lack of breakage.
198. Laying out a conduit line. In the de-
sign of a draw-in duct system, the number of ducts. Fig. 54. — Arrangement
the size of manholes and their location are the im- of ducts for a large line,
portant considerations. The number of ducts
must be sufficient to care for the local distribution, for feeders, for trans-
mission lines and for future requirements. It is desirable to lay sufficient
reserve ducts to care for probable requirements for about 5 years ahead.
The maximum number of ducts which it is advisable to put into a line
is governed chiefly by the safety of the cable equipment. The space available
for training the cables is limited, and if more than twenty to twenty-five
cables are carried through a manhole, a large part of the load is endangered
by a failure of any of the cables. Where conditions are such that a very
large line must be used, protection may be had by separating one-half of
the duct line from the other by a 6-in. concrete barrier and by building
double manholes. A line having more than four ducts in each layer is to
be avoided where possible on account of the difficulty of properly training
the cables. The arrangement shown in Fig. 54 is a desirable one where
twelve or more ducts are laid.
199. Location of manholes. Manholes must be provided iri sufficient
number to permit the drawing in of cable without overstraining the insulation.
Thus the manhole spacing should be not over 500 ft., with large cables,
400 ft. is a safer limit. Where distribution by overhead lines in alleys with
under-ground lines on the street is used, manholes should be put opposite alley
intersections as far as possible. The number of manholes required where
numerous underground service connections are needed must usually be
sufficient to enable services to be brought in at intervals of 25 ft. to lOO ft.
In distribution by means of subway-type transformers and a second-
ary network, it is usually necessary to build extra large manholes for the
transformers in order to get sufficient room and proper ventilation.
1063
 — ^

Sec. 12-200 DISTRIBUTION SYSTEMS

Manholes should be so designed that the cables may be trained with a

minimum of waste and with sufficient space to enable a jointer to work
efficiently, as in the oval-shapod man-
'^o'^ shown in Fig. 55. At intersections
gy r "
— — i

—
—>| K--2 *K 3 4 >+< 2 ^leTK a square design is preferable, as shown
\ I

_^
^

1 ~ l' )BS5^^^^Si
I
l"+j^in Fig. 56. In practice it is usual to
1 1
__ I
L o> provide manholes 5 ft. by 5 ft. at junc-
I

~^'^ &<*ns where there are eight ducts, that

•^ W^^ ^^-^j^^ '
^. va/timiiX'. « 9ft-^ Xi^: <CTr::r.rn ^ oo^ j^^ where two four-duct lines cross; 6 ft.
'\/X^//&'/ .d i
''

if by 6 ft. where there are twelve to eigh-

teen ducts; 7 ft. by 7 ft. where there are
twenty or more, and larger as the needs
of the case may require.
The size and the shape of man-
holes are often governed by local ob-
structions such as gas or water pipes,
or conduit lines of other companies.
The depth must be sufficient to give
head room, and yet should not be so
great as to carry the floor of the man-
hole below the sewer level. Service
-r^j o • '/, manholes may be 5 ft. high inside,
'&". ,Jl
f lij'|fi| but junction manholes should be 6 or
«" < 6-- 7 ft. from roof to floor. In some cases
> |
> l
|
*t^|"
a shallow form of manhole known as a
hand hole is used for distribution
laterals. These are made about 3 ft.
by 4 ft., and 4 ft. deep. They are
placed above the conduit line so that
only the top row of ducts enters the
handhole. The distributing mains are
thus accessible for service taps, and the
through lines in the lower ducts are not
in the way.
of duct. Tile conduit 200. Forms
in single- and multiple-duct is made
Fia. 55. —Oval manhole.
single-duct pieces being about
18 in. in length, and multiple-duct 36
pieces,

in. long. The dimensions of ducts in general use are shown in Fig.
57. Miiltiple-duct is somewhat cheaper than an equal number of single

FiQ. 56. — Square manhole.

1064
 DISTRIBUTION SYSTEMS Sec. 12-201

'
ducW and requires less labor. In a large system it is considered preferable to
use single-duct to secure the advantage of having two thicknesses of tile
between adjacent ducts. The single-duct also has the further advantage
that the joints may be staggered, thus making it less likely that the heat
of a burn-out may damage the cables in adjoining ducts.
201. Installation of conduit system. In laying a line of ducts the
grades must be carefully established so that no pockets are formed
where standing water may freeze and injure the insulation of the cables
and break the tile. It is important that manholes where work must be
done frequently, or where transformers or junction boxes are installed, be
provided with sewer connections. The conduit line is protected from
future excavators, and made secure against the possibility of getting out of
alignment, by surrounding it with 3 in. of concrete on all sides. The con-

3 Ft. Long art. Long

Standard Multiple Tile Ducts
Fig. 57. — Forms of tile duct.

Crete further acts as a water shed and minimizes the leakage of gas into the
conduit system.
202. Manhole construction. The
vaults or manholes provided to
facilitate cable drawing and splicing are constructed of brick or concrete.
In city streets where other underground structures interfere the walls are
Freferably built with sewer brick, only the floor and roof being of concrete,
n building lines in open country, as for inter-urban telephone lines, forms
are used and the entire vault may be advantageously constructed of concrete.
Brick walls should be 8 inches thick and laid up with a good quality of
cement mortar. The floor should be connected to a sewer for drainage where
it is available, except that in sandy soil the natural drainage is sometimes
BufBcient to prevent an accumulation of water in the vault. The roof of the
vault must have sufficient strength to support the heaviest street traffic
passing over it, which necessitates the use of steel reinforcement in most
cases.
The manhole or entrance to the vault is covered by a cast iron cover
having a roughened surface and of such strength as to bear the weight of
trucks passing over it. Both circular and square covers are used, the
circular cover having the advantage that it cannot fall into the vault in

1065
Sec. 12-203 DISTRIBUTION SYSTEMS

handling. Square or rectangular covers are preferred where low tension

junction boxes and transformers are to be placed in the manholes.
Manhole covers are made single or double according to the service and
local conditions. Single covers with openings for ventilation are preferred
for conduit systems having power conductors, as this minimizes the danger
from gas explosions. Double covers make it possible to have a lock on the
manholes to prevent unauthorized entrance to the manhole. The inner
cover is made lighter and if ventilation is not essential it may be provided
with a gasket to keep the manhole free from surface water and dirt.
203. Cable supports should be provided for cables on the walls of the
vault to prevent undue strain on the sheath and permit an orderly arrange-
ment. This is sometimes done by arranging shelves of brick, or other suit-
able material but the shelf is usually only wide enough for one cable of the
larger sizes, and this docs not give sufficient room with the larger duct lines.
It is, therefore, usual practice to provide racks of such a design as to permit
two cables to be carried on each. In some forms the bracket on which the
cable rests is detachable, and is not placed on the rack until a cable is to be
installed.
204. Cost of Duct-lines per Duct-foot
Cost of paving per square yard

No. of ducts None 1.50 3.00 4.50

1914 1920 1914 1920 1914 1920 1914 1920 1914 1920

2 0.40 1.25 0.56 1.40 0.70 1.55 0.85 1.70 1.00 2.15
4 0.23 0.70 0.31 0.78 0.38 0.85 0.46 0.93 0.53 1.00
6 0.21 0.64 0.27 0.70 0.32 0.75 0.37 0.80 0.45 0.86
9 0.19 0.59 0.24 0.64 0.28 0.68 0.32 0.68 0.37 0.77
12 0.18 0.55 0.22 0.59 0.26 0.63 0.30 0.67 0.34 0.71
16 0.17 0.52 0.20 0.55 0.24 0.59 0.28 0.63 0.31 0.66
20 0.17 0.50 0.19 0.52 0.22 0.55 0.24 0.57 0.27 0.60

206. Cost of manholes. The costs of certain sizes of manholes as built

under conditions existing in the City of Chicago are given in the following
table, in Par. 206. The cost of paving is not included. The dimensions are
those inside the manhole, the last being depth.
206. Cost of Manholes
 DISTRIBUTION SYSTEMS Sec. 12-208

Duplex cable has been used quite extensively in series-arc systems.

lines.
It is difficult to train, and susceptible to injury from bending at too small
a radius. Duplex and triplex cables are somewhat less expensive than their
equivalent in single-conductor cables with the same insulation.
The concentric arrangement is employed for large low-tension feeders in
some cases. This arrangement is advantageous as it permits the use of a
leingle duct for the feeder.
Low-tension distributing mains having three conductors of the same
size are preferable of single-conductor cable, to facilitate making service taps.
I

'This work must be done while the lines are alive, and is much more easily
:accomplished when one polarity may be dealt with at a time. The same is
I
true of service cables.
Transmission cables are almost universally of the three-conductor type.
Insulation is placed on each conductor sufficient for the voltage between
phases, and then a layer is placed over all three conductors in addition, as
shown in Fig. 58, to provide insulation to ground.
-Lead

Flo. 58. —Cross-section of high-tension cable. Fig. 59. —Lay-out of

through cable lines to
avoid the same routes.
208. Cable insulation. Cables are insulated with rubber, varnished
eambric, or oiled paper. Rubber insulation is used where frequent taps are
made, as on distributing mains, but not generally for feeders and transmission
lines. Varnished cambric has been used to some extent in recent years as a
substitute for rubber. Oiled paper is used almost exclusively for feeders and
transmission lines, and can be used for primary distribution if the joints are
well made and the ends are protected by suitable potheads.
209. Thickness of cable insulation. The smaller low-tension cables
4 . .

are provided with about 57^-in. insulation between conductors and lead;

this is the least which it is advisable to use for mechanical reasons and is
sufficient for 600 volts.

it is customary to provide
5.6
In cables of 350,000 cir. mils to 1,500,000 cir. mils,
— in. to -— in. of insulation, to insure sufficient
mechanical strength to stand handling during installation. A thickness of
in. is found sufficient for 2,000-volt to 6,000-volt single-conductor cables
32
10.
up to No. 4/0 A.W.G., while ^-in. is required for potentials from 9,000 volts
to 13,000 volts.
210. The insulation provided in transmission cables in large trans-
mission systems varies from 66 mils per 1,000 volts between conductors, at
8,600 volts, to 22 mils at 25,000 volts; and from 52 mils per 1,000 volts
between conductor and ground, at 6,600 volts, to 16 mils at 25,000 volts,

1067
Sec. 12-211 DISTRIBUTION SYSTEMS
211. Selection of duct position for cables. In placing cables in the
duct-system a uniform method of selecting ducts should be followed as
far as possible. Cables used in local distribution should be given a place,
preferably in the top row, so that manholes can be built for service laterals
without sinking them below the top row of ducts. Ducts should be selected
for through lines so that they may be trained with the least interlacing
with other cables. Lack of attention to this detail may result in a tangled
condition of cables which greatly impedes any repair or reconstruction work.
212. Routing of cable lines. Through lines should be so routed as to
utilize different duct lines to the best advantage. The service is better assured
if transmission lines are separated as much as possible. This can be done by
routing lines running to the same substation through different conduits, as
indicated in- Fig. 59.
213. Installation of cable. Cables are drawn into ducts by a line at-
tached to a source of power. This line is put through the duct by the use of
detachable rods of wood, which are pushed into the duct as they are joined
together. They are then drawn through with the pulling-line attached, and
disjointed as they come out. The cables are secured to the pulling-line by
exposing the copper and making a secure mechanical connection, or by means
of patent cable-grips, which are more quickly attached and removed.
The cable-pulling line is run over pulley-wheels leading out of the manhole
to the source of power. Small-sized cable is wound on reels and cut to the
required length as it is drawn in; but a length of about 400 ft. of three-
conductor high-voltage cable, or of 1,000,000-cir. mil feeder cable, fills a
reel, and it is usual, therefore, to order such cable in lengths to fit.
214. List of Operating Three-conductor, High-tension, Cable In-
stallations
(From High-tension Underground Electric Cables, by H. Floy)
 DISTRIBUTION SYSTEMS Sec. 12-215

215. Training. The training of cable through manholes must avoid

sharp bends, tangled relations with other cables and the possibility of
injury by employes while working in the manhole. It is customary to
support cables on iron racks hung on the walls. In some cases brickwork
shelves are built around the walls, on which the cable is laid. It is usual
to protect cables in manholes to prevent the communication of trouble to
other cables. This is done by wrapping them with some fire-proofing
material, or by the use of split tile. With large cables, the radius of
bends should not be less than ten times the diameter of the cable. The shape
of the manhole walls should be designed with this in view.
216. Jointing or splicing. In jointing single-conductor cables, the
lead sheath is removed about 6 in. back from the end and enough insulation
is cut away to permit a soldered connection to be
made. When the connection is complete, the bare
parts are wrapped with tape until the equivalent of
the cable insulation has been applied. A lead sleeve
which has previously been slipped back over one
of the cables is now wiped on the two cable sheaths
so as to enclose the joint. The air space around
the joint is then filled with hot insulating com-
pound poured into a small hole in one end of the
sleeve; a similar hole is left open in the other end of

)£

Fig. 60.
No.6

—Cable splicing. Fig. 61.

Liiy
— Porcelain pothead;
single conductor type.

ike sleeve to allow air to escape. These holes are then closed by soldering.
The joint should be allowed to cool before it is moved, so that the compound
will hold the parts rigidly in placed
In jointing three-conductor cables, the lead must be removed about
10 in. to facilitate the taping of the conductors (Fig. 60). In making joints
for voltages of 6,600 volts and higher, it is important that as little air remain
ito the taping as possible. If paper tape is used, each layer should have
compound poured over it before the next is applied.
1069
Sec. 12-217 DISTRIBUTION SYSTEMS

The jointer requires the services of a helper in preparing the lead sleeves,
heating solder and compound, and guarding the entrance to the manhole.
A three-conductor high-tension joint in a paper cable usually requires
about 4 hr. to complete, two joints a day being a fair rate of progress in such
work.
217. Pole terminals. In many primary distributing systems, it is usual
to run feeders and important mains underground for some distance from the
station, and connect with overhead lines in the more scattered areas. This
class of distribution requires that the cable ends which are brought up the
pole to the overhead lines be properly protected by cable terminals or
potheads. Various types of terminal are in use, some of which include
means for connecting and disconnecting the overhead line. Many such
distributing systems have been equipped with porcelain potheads which
have been very successful in protecting cables. The first such device was
designed for a single-conductor cable, as illustrated in Fig. 61. The insu-
lation is hermetically sealed by filling the porcelain sleeve with compound.
The cap sheds all water and may be safely handled by a lineman when the
line is alive. The connectors provide means for readily opening and clos-
ing the circuit when necessary for repair or alteration work. Other forms
have been devised for multiple-conductor cables, in which there is a pot
of cast iron- with porcelain tubes set into the cover (Fig. 62).
818. Subway junction boxes. The arrangement of junction boxes and
similar accessories in manholes should be worked out so as not to obstruct
the space needed for the cables. Low-
tension junction boxes are of two
types, one of which is mounted on the
wall in a vertical position, while the
other is placed in the roof of the man-
hole so that it is accessible for replac-
ing fuses or cleaning contacts from above
ground. The surface type has its ad-
vantages in districts where the drainage
of manholes is not perfect.
219. Branch-line junction boxes.
In a primary distributing system in
which mains are underground, it is
necessary to have means by which
branches may be disconnected, with-
out shutting down the circuit, when a
transformer is to be connected or a cable
repaired. Subway junction boxes with
copper connections have commonly been
applied to this work. The parts of the
cable from which the lead has been re-
moved are sealed in from moisture by
wiped sleeves, or by filling the lower
part of the box with hot compound.
The porcelain pothead (Par. 220)
has also been found convenient
manholes, as the cap
for this purpose, in
Fig. 62. —Cabletype.
pothead; triplex may be submerged without permitting
water to reach the live parts.

DISTRIBUTION ECONOMICS
220. Oeneral criterion for most economical size of conductor.
The loss of energy in a conductor diminishes as the size of the conductor ia
increased, and vice versa. The generating capacity required to supply the
energy loss follows the same law. The size of conductor with which tlie sum
of the fixed charges on conductor and generating capacity, plus the value
of energy loss, is a minimum, is the one which it is the most economical
to employ.
221. Fixed chargres con.sist of interest, depreciation, taxes and insur-
ance. Those are computed at different rates, depending upon the character
of the equipment. Interest should be figured at not less than the rate paid
on the bonded debt, which is about 5 per cent. (Sec. 25).
1070
 DISTRIBUTION SYSTEMS SeC. 12-222

S22. Depreciation is based upon the working life of the equipment,

allowing for changes in the state of the art, and the scrap value of the equip-
ment when taken out of service.
Weather-proof wire consists of about 80 per cent, copper and 20 per cent,
insulation. It is conservative to figure 7 per cent, on the insulation, or 1§
per cent, of the whole wire, with 1 per cent, added for the labor of replac-
ing, making a total of 2J per cent, of the original cost of the wire. Poles
have a life of about 15 years, with little salvage value. Other overhead
line material must be replaced at intervals of 5 to 10 years. The aver-
age rate for overhead lines may thus be taken at about 5 per cent.
The life of lead-sheathed paper or rubber cables is indeterminate, but
this may be conservatively taken at 15 years. The junk value is compara-
tively high, as the copper and the lead sheath constitute a considerable
percentage of the cross-section of the cable. It is, therefore, safe to estimate
depreciation at 3 per cent, for cables of No. 4/0 A.W.G. and larger, and at
5 per cent, for the smaller sizes.
223. Taxes and insurance must be considered as fixed charges of the
same class as interest and depreciation. They vary somewhat with the
locality, but are usually from 1.5 per cent, to 2 per cent., total.
224. The total fixed charges on underground cable and conduit may
be taken at 5 per cent, interest, 4 per cent, depreciation, and 1 per cent, taxes,
a total of 10 per cent. The total rate on the average overhead system
may be taken at 5 per cent, interest, 5 per cent, depreciation, and 1 per
cent, taxes, a total of 11 per cent.
225. Oeneral formula for annual conductor costs. The cost of a
conductor varies inversely as its resistance per unit length, and the value of
energy and generating capacity to supply it vary directly as the resistance
per unit length. The total annual cost is
Y = -^+bR+cR (dollars) (14)
in which a, 6 and c are constants depending on the cost of the conductor and
the cost of energy. These are determined as follows: Par. 226 to 236.
226. Formula for annual fixed charges on wire. The cost of insu-
lation varies approximately with the size of the conductor. For bare wire
the product of weight per 1,000 ft., W, by resistance per 1,000 ft., for all
sizes, is. WR= S2; with weather-proof insulation WR
= S8 for the sizes No. 4
to No. A. W.G., or 36 for sizes from No. 2/0 to 350,000 cir. mils. The value
of 1,000 ft. of conductor at 15 cents per pound is 0.15TF dollars. Hence,
when W = 38/R, the cost per conductor of a circuit L thousand feet long ia
Ci = 0.15TrL = -^^^^|^^ (dollars) (15)
it
Taking the fixed charges at 9 per cent., the annual cost is
_ 0.09X0.15X38L = 0.513L
~
Ci = ^ — ,. „ ,
(dollars) (16)
Thus a = 0.513L, in this case (Eq. 14).

227. Formula for annual fixed charges on single-conductor cable.

With underground conductors a change in the size of the conductor does
L not make a proportionate change hx cost. The table in Par. 229 gives the
' coat per 1,000 cir. mils of various sizes of single-conductor and three-con-
ductor lead-sheathed cables. The resistance per 1,000 cir. mils per 1,000 ft.
of copper at ordinary temperatures is about 10.4 ohms. If M
is the number
of 1,000 cir. mils and P is the price per 1,000 cir. mils, the cost of a single-
conductor cable is MP. M=10A/R and the cost of the cable is 10.4PZ,/jR,
where L is the number of thousands of feet.
For single-conductor low-tension cable the value of P averages $1 .20
for cables from No. 2/0 A.W.G. to 500,000 cir. mils, and the value of each
conductor ia
_ 10.4X1.2L 12.481,
Ci = ^ = —^— ,, „ , ,,_,
(dollars) (17)
Taking the fixed charges at 9 per cent., the annuat conductor cost is
y^ „,
C'2=
0.09X 12.48L 1.12L ,, ,,
(dollars),
,,.,
(18)
^~R~~
Id in this case a= 1.12L (Eq. 14).

1071
Sec. 12-228 DISTRIBUTION SYSTEMS

228. Formula for annual fixed charges on three-conductor cable.

In the case of three-conductor cables the cost per 1,000 cir. mils in Par. 229
isbased on the total cross-section of the three conductors. The cost of three-
conductor cable is
C3 = 3X10^1; (dollars) (19)

and the annual charges are

,„ 0.09X3X10.4PL 2.8PL
C 3 (dollars) (20)
R R
and a = 2.8/'L. Thus the value of a may be derived for different kinds of
cable and at various values of copper, lead and insulation. Where a circuit
is composed of more than one cable, this must be taken into account in
figuring the total annual cost for the circuit; that Is, for a two- wire circuit
the value of "a" is doubled and for three cables it is trebled.
229. Cost of Lead-sheathed Cables

Size conductor
A.W.G. or cir.

mils
 DISTRIBUTION SYSTEMS Sec. 12-233

put for the year, to the possible output at the rate of the maximum load,
iscalled the load factor of a circuit. If the loss factor of the feeder is 20
per cent., the annual loss is
Z!«X0^|i><2i^l.752/^« (kw-hr.) (22)

The loss factor for a load having the characteristics illustrated in Fig. 63
is about 16 per cent.
233. Calculation of loss. Given the character of the load curve, the
loss factor may be determined in the manner described (Par. 231 a,nd 232)
and the annual loss of energy calculated from the maximum load /, in terms
of R, the resistance per 1,000 ft. of conductor. The loss at the time of the
annual maximum load being DRL, the annual loss is
^^^'-^'-^ ^^^^
i;ooo
where F is the loss factor. loss equals lAOI^RL kw-hr. when the loss
The
factor is 16 per cent. The value of this energy may be taken at about 1 cent
per kw-hr. in the smaller plants, 0.7 cent in the larger engine-driven plants
and 0.5 to 0.3 cent in the turbine-driven plants. At 1 cent, per kw-hr.
the value of the annual energy loss per conductor, at 16 per cent, loss factor,

Ci = O.OUOI^RL (dollars) (24)

and the constant c is equal to 0.0140/^2/.

1000

900

800

700

« 600

i 500
a
400

300

200

100
Sec. 12-235 DISTRIBUTION SYSTEMS
load. The only variable in the equation being R, the value of F will be a
minimum, according to the rule of the calculus, when dY/dR = 0.
-, ^
If F = —
0.513L
= „„„^^,„. ^,
0.026/ 2iSL, then
it
h
,
dY 0.026/2ft2I/-0.513Z, = . ^,
ru=
an sr 0. There-
W
fore, 0.026/2/J2I,= 0.5131,, and I^"^ = 0.513/0 026 =19.7; whence IR = VlQ^ .

= 4.44. For instance, if / = 100 amp., i2 = 0.0444 ohm, which is about the
resistance per 1,000 ft. of a No. 4/0 conductor.
235. Examples of calculation of most economical size of conductor.
Assume generating capacity costing $80 per kw., energy at 0.4 cent per
kw-hr. and the loss factor at 25 per cent. With single-conductor low-tension
cable of 500,000 cir. mils to 1,000,000 cir. mils, the cost per 1,000 cir. mils
averages 90 cents per 1,000 ft., Par. 229.
0.09X10^X0.91, 0.84Z,.
Hence
R R R
80X0.121 mL
bR = O.OOQGimL,
1,000
0.004 X 8,760X 0.25/2i?i.
cR = 0.0087 I^RL.
1,000
F = ^-|-0.018372fiZ,.

and IR = = V'46 =6.7 per 1,000 ft. of conductor. With 600

0.0183

amperes iJ = 6.7
)ffc;r = 0.011, which is about the resistance of 1,000 ft. of
oOO
1,000,000-cir. mil cable.
In the case of three-conductor, 10,000-volt cables, with generating capacity
costing $80 per kw., energy at 0.4 cent per kw-hr., loss factor at 25 per
cent, and the cost of No. cable $1.75 per 1,000 cir. mils,
o = $2X0.09X10.41,
aR ^ =—1.87 ,
per conductor. ,

K H=^
0.0\&Z C^RL per conductor. Therefore
87
= 1.01 and for 100 amp. ij = - — =0.101 which is nearest the
0183 100
resistance of No. cable, per 1,000 ft.

236. The curves in Fig. 64 show the

line charges, station capacity charges
40
and line losses for various sizes of con-
ductor, assuming a current of 100
- 36 amp., with overhead lines, energy at 1
cent, per kw- hr., cost of generating
Iso capacity at $125 per kw. of capacity,
Q and loss factor 12 per cent.

I20 BIBLIOORAPHT
237. Selected list of reference

a 10
literature.
Abbott, A.V.— Electric Transmis- "

< Crocker, F.B.

— "Electric Lighting."
sion of Energy."

R. — "Distribution by
Vol. II. ., . ,

Emmett.W. L.
the Three-phase System." Trans. A..

I. E. Vol. XVII,
Ferguson,
E.,
A.
— 805, 1901.
Underground L.
p.
"
Electrical Construction." International
Electrical Congress, St. Louis, 1904.
DuRciN,W. A.— "Location of Faults in High-tension Cable." Proc. Nation.il
Electric Light Assn., 1910, Vol. I, p. 498.
Del Mar, W. A.—" Electric Power Conductors „ i^, .„„, .

Floy Henrt.— " High Tension Underground Electric Cables, I<.lectncal

Publishing Co., N. Y., 1909.
1074
 DISTRIBUTION SYSTEMS See. 12-237

—
Melsom, S. W. and Booth, H. C. " Heating of Cables with Current."
Journ. Inst. Elect. Eng., Vol. XLVIII, pp. 711-751.
—
Jdnkerspeld, p. Chairman Sub-Comm. on Distribution, Distribution of
Electrical Energy.
—
Trans. A. I. E. E., 1914, pp. 236-293.
Geab, H. B. and Williams, P. F. " Electric Central Station Distribut-
ing Systems." D. Van Nostrand Co., New York, 1911.
—
Hatden, J. L. R. " Notes on the Resistance of Iron-pipe Grounds." Trans.
A. I. E. E., Vol. XXVI, p. 1209, 1907.
—
Lincoln, P. M. " Synchronous Converters vs. Motor Generators."
Trans. A. I. E. E., Vol. XXVI, p. 303, 1907.
—
Lukes, G. H. " Distribution in Suburban Districts." Proc. National
Electric Light Assn., 1908, p. 67.
—
JuNKEHSFEiD, P. .\ND ScHWEiTZEH, E. O. " High-potential Underground
Transmission." Trans. A. I. E. E.. Vol. XXVII, p. 1499. 1908.
—
Perrine, F. a. C. "Electrical Conductors." D. Van Nostrand Co.,
New York, 1903.
Osgood, F. —
" Report of Overhead Line Committee." Proc. National
—
Electric Light Assn., Vol. II, 1911, p. 374.
ToRCHio, P. " Operation of High-tension Underground Systems." Trans.
—
A. I. E. E., Vol. XXII, p. 421, 1903.
Wagner, H. A. " Single-phase Distribution." Proc. National Electric
Light Association, 1909.
—
Teichmuller, R. S. " Theory of Heating of Cables." Elek. Zeitschrift,
Nov. 3, 1904.
Fisher, H. W. —
" Electric Cables for High-voltage Service." Trar^s.
A. I. E. E., Vol.
Whitehead, B.
XXII,
J.
—
p. 417, 1903.
" Re.sistance and Reactance of Armored Cables."
Trans. A. I. E. E., Vol. XXVIII, p. 737, 1909.
—
Elden, L. L. "Analysis of Distribution Losses in a Large System."
Trans. A. I. E. E., Vol. XXVI, p. 665, 1907.
—
Stone, E. C. and Atkinson, R. W. " Cost of Transformer Losses."
Tran.s. A. I. E. E., Vol. XXX, p. 2181, 1911.
—
Elden, L. L. " Relay Protective Systems." Trans. A. I. E. E., Vol.
XXXI, p. 1413, 1912.
Dushman, S.—" Heating of Cables." Trans. A. I. E. E., Vol. XXXII.
165, 1913.
Berg, E. — "Constants Cables and Magnetic Conductors."
J. of Trans.
XXVI,
Atkinson and Fisher. — "Current Rating Cables." Trans. A.
\. I. E. E., Vol. 555, 1907. p.
of I. E. E.,
^o\. XXXII, p. 327, 1913.
"National Electrical Safety Code," 3rd. Edition, 1920. Gov. Printing
Office, Washington, D. C.

1075
I
 SECTION 13

INTERIOR WIRING
BY TERRELL CROFT
Directing Engineer, Terrell Croft Engineering Company. Member American
Institxtte of Electrical Engineers. Member American Society of Mechanical
Engineers. Member American Society for Testing Materials. Member,
Illuminating Engineering Society. Author of: The American Electricians'
Handbook, Practical Electricity, Wiring of Finished Buildings, Wiring for
Light and Power, Electrical Machinery, Practical Electric Illumination and
Central Stations Steam Boilers, etc.

CONTENTS
(Numbers refer to Paragraphs)
Relation of Wiring to Fire Risk 1 Wiring Calculations and Lay-Outs 63
Methods of Wiring 7 Installations 107
Wires and Cables 22 Protection 125
Fittings and Accessories 41 Miscellaneous 130
Interior Wiring Circuit Nomen- Bibliography 135
clature 54

1077
)

SECTION 13

INTERIOR WIRING
RELATION or WIBINQ TO FIKE BISK
1. The National Electrical Code was drawn originally in 1807. It
was the product of the efforts of the National Conference on Standard
Electrical Rules. This comprised delegates from the various insurance,
i

electrical, architectural and allied interests of the United States. The

object of the conference was to formulate a set of rules for the installation and
construction of electrical apparatus in a manner free from fire hazard. The
National Electrical Code resulted. The "Code" was immediately adopted
by the National Board of Fire Underwriters, 135 William St., New York
City. It at once placed electric wiring on a safe basis. At present prac-
tically all wiring is in accordance with Code rules. The fire insurance
policies in some states and communities expressly provide that the Code
shall be followed in detail. The National Conference on Standard Electrical
Rules has disbanded but the work of the Underwriters' National Electrical
Association and the National Conference has been taken over by the National
Fire Protection Association, in which are represented the following organiza-
tions: American Electric Railway Association; American Institute of
Electrical Engineers; Associated Factory Mutual Fire Insurance Cos.;
National Board of Fire Underwriters; National Electric Light Association;
National Electrical Contractors Association; National Electrical Inspectors

Periodically the National Fire Protection Association convenes

and authorizes such revisions or additions to the Code as are dictated by
advances in the art. The National Electrical Code is revised every 2 years.
A supplement and a "List of Approved Fittings," are issued semi-annually.
Either can be obtained gratis on application to any Underwriters'-Asso-
ciation office, to any local inspection bureau, or to The National Board
of Fire Underwriters, 135 William St., New York City.
2. Legal status of the Code. The Code has no statutory force. It
merely comprises the rules of the National Board of Fire Underwriters.
However, certain cities have passed ordinances providing that all work
installed in such cities shall be in accordance with the Code. This gives it a
legal status in these cities. Moreover, other cities .have legalized require-
ments of their own, which are, usually, essentially Code requirements.
Where local requirements are authorized by ordinance or statute they, of
course, take precedence over the Code rules.
5. Electric Service Company Rules are often enforced by local electric-
power companies. These may relate to location and details of service
entrances, provisions for meters, minimum voltage drop allowable in circuits
and similar matters. The electric service company supplies free copies of
such rules.
4. The National Code rules of are srreat economic importance in
relation to hazard and fire insurance. Without question, fire lass
fire
amounting to many thousands of dollars has been averted by their apnli-
cation. When installing any electrical equipment, first ascertain whether
there are local installation rules (ordinances) in force in the community.
If there are such they should be followed. If there are none follow the
National Electrical Code rules.
6. Inspection. —
Every electrical installation should be inspected, when-
ever an experienced inspector is available, to insure that it complies with
either local or Code rules. In cities where rules have been adopted by
ordinance, such inspection is usually mandatory. Where inspection is
not mandatory, it is always advisable to retain an inspector from the most
convenient Underwriters' Bureau to examine the work while it is beir" eui«
installed. Nominal fees are charged for such inspection.
1078
 INTERIOR WIRING Sec. 13-6

6. All fittings and materials used in wiring installations should be

approved by the Underwriters Laboratories. Practically all standard
equipment now being marketed is so approved and, usually, is so marked.
When in doubt one should refer to the "List of Approved Fittings" referred
to above, or consult The Underwriters' Laboratories, 207 East Ohio St.,
Chicago, 111.

METHODS OF WIRING
7. There are eight methods of wiring. (1) open or surface wiring;
(2) concealed knob and tube wiring; (3) wooden-raceway wiring; (4) metal-
iwiring; (.5) flexible-tubing or circular-loom wiring; (6) rigid iron-conduit
wiring; (7) flexible metallic conduit wiring; (8) flexible steel-armored cable
rwiring.
8. Open wiring on knobs and cleats (Fig. 1) is a cheap and satisfactory
[method if installed in compliance with Code requirements. It is largely
used in industrial plants and in mercantile establishments where appearance
is unimportant. Single-braid, rubber-covered or slow-burning weather-
proof wire may be used. Wires having slow-burning insulation must not
•

be used in damp places. The wires must be supported at least every 4.5
ft. (137 cm.) except in buildings of "mill" construction where, if "not liable
to be disturbed," they may be supported at every beam, provided that the
wires are No. 8 or larger and are carried at least 6 in. (15.2 cm.) apart.
In dry places for voltages up to 300, the wires must be separated at least

Wires on Cleate on
Knnning Board
Wires on Cleats

Ko.Sor Larger
Wire on. Knobs

^To Drop Light

Fig. 1. — Methods of supporting open wiring.

3j| in.(6.35 cm.), and they must be at least 0.5 in. (1.27 cm.) from the surface
wired over. For voltages between 301 and 600, wires must be at least 1 in.
(2.54 cm.) from the surface and must be separated 4 in. (10.2 cm.). In
damp places, for voltages up to 300, wires must be held 1 in. (2.54 cm.)
from the surface; above 300 they should be 4 in. (10.2 cm.) from the surface.
Where wires are exposed to niechanical injury, protection must be afforded
as specified by the Code. Wires must also be protected by porcelain tubes
where they pass through walls, timbers or partitions. See the National
^EUclrical Code for other minor requirements.
In structural-steel mill-type buildings, open wiring is carried
on porcelain knobs or cleats which may be secured with stove bolts at
points where there are spaces between the members or where holes are
already punched. Sometimes it is desirable to screw the cleats to blocks
which are clamped to the members with hook bolts.
Open work is especially suited to locations which are damp or hot
surh as dye works, breweries, dry kilns, metal refineries and the like. In
sucli installations special precautions must be observed; these precautions
arc fully described in treatises on wiring.
9. Knob-and-tube wiring (Fig. 2) is used in frame buildings, and is
the cheapest method of concealed wiring. Although it has given satis-
faction, in progressive communities being superseded by rigid conduit.
it is
In some cities only rigid iron or flexible conduit or flexible steel-armored
•cable is approved for concealed work.
The single-braid, rubber-insulated conductors are carried within the
floors, walls and partitions of the building. Where passing through timbers
they must be insulated with porcelain tubes. On a vertical run the wires

1079
 1

\ Sec. 13-10 INTERIOR WIRING

must be protected from plaster droppings by tubes which extend at least
4 in. (10.2 cm.) above the horizontal timbers which have been pierced.
Within partitions and floors, where the wires are carried on knobs, the knobs
must be spaced not more than 4.5 ft. (1.37 m.) the wires should be spaced;

at least 5 in. (12.7 cm.) and should be carried on separate timbers. They

Steel Switch
Box

Vertical Runs

Surface Switch
Fig. 2.- -Typical details of knob and tube method of wiring.

may be closer together if encased in flexible tubing. Only split knobs

should be used for conductors smaller than No. 8; either split or tie knobs
may be used for larger conductors. The wires must have the same insulation
as the wires they support, and must not be smaller than No. 14. Flexible
tubing must be used to protect conductors at each outlet, and must extend
from the last point of support into the
outlet box in one continuous length.
Sheet-steel boxes must be used for
shown in Fig. 2.
flush-switch outlets as

itLL___j »r^ -o/ T

^oo^*i^ raceway is, as a rule,
^^'
used only for making additions to
T wi~~T 1 'i^~^
r*
y ^
Wi ^^
^^s_,^^^s_,<!^P
^ jr
'
existing installations where good ap-
pearance is a consideration but where
running the conductors concealed is
1
-'^
'a! ^^^^^^^^^^P
-^ — ^'"^''''•'''(''"'WmiW'^ iL-
either impossible or economically pro-
hibitive. Wooden raceway wiring is

-b\ ^
iCjudfiiwjitEXS Eequitc/
now prohibited by ordinance in many
communities. Wooden raceway wiring
is not approved for damp plaoos or
at Least
where the difference of potential be-
FiQ. 3. —Standard, two-wire, wooden
raceway.
tween any two wires of the same
system exceeds 300 volts. Single-
braid rubber-covered wire is required.
No joints or splices are permitted except at outlets and at fittings. There
are many styles of approved moulding fittings. With them almost any
conceivable combination of connections can be realized.

1080
 INTERIOR WIRING Sec. 13-11

11. DimenBions and capacities of wooden raceways. Below are

given the dimensions of standard two-wire wooden raceways; the products
of various manufacturers vary somewhat. All dimensions are given in
inches (Fig. 3). (Kirkpatrick Mfg. Co.)

A
Size of
groove
Sec. 13-14 INTERIOR WIRING
1
14. Typical Dimensions of Flexible Tubing (Circular Loom)
Below are given the dimensions of one standard line of flexible tubing, or
circular loom, which has been approved by the Underwriters' Laboratories.
 INTERIOR WIRING Sec 13-19
metallic conduit is furnished in coils of from 25 to 250 ft., depending
upon the conduit size. The wire and the general installation requirements
are practically the same as for rigid conduit. Many fittings for flexible
metallic conduit are manufactured, although no elbows are required.
19. Electrical Trade Size of Conduits for the Installation of Wires
and Cables
(1920 National Electrical Code)
Table 1. Two- wire and Three- wire Systems

Size of
conductor,
B. & S. gage
 .

) Sec. 13-20 INTERIOR WIRING

20. Flexible steel-armored conductor (Fig. 6) has found considerable
application during tiie last few years, due to its adaptability for electrical
construction in finished buildings. It can be run with practically no regard
for pipes or other grounded obstructions and can be fished for relatively-
long distances. It is more expensive than conductors in circular loom but it
provides a thoroughly dependable job. Flexible steel-armored conductor
consists of rubber-insulated wire or cable, i)rotected from injury and to some
extent from dampness by two layers of spirally wound flexible steel armor.
It is manufactured "leaded" and "unleaded." The leaded conductor has
a lead sheath (between the armor and the cloth covering which is wound
over the rubber) to exclude dampness. Both types are made in any reason-
able gage of wire or cable. The leaded type is approved for use in all classes
of buildings and can be installed during or after their construction. TBe
unleaded tvpe is approved only for use in locations that will not be per-
manently damp.
' Flexible Steel Armour

Unleaded
-Flexible steel-armored conductor.

21. Relative Costa of Various Methods of Wiring:

(Based on Values in "Electric Light Wiring," C. E. Knox)
Relative cost
Method of wiring
in per cent.

Conduit (rigid iron) 100

Raceway or Moulding (metal) 80
Flexible metallic conduit 80
Flexible steel-armored cable 70
Raceway or Moulding (soft wood) , 50
Open wiring (knob and cleat) 40
Flexible tubing or Circular Loom (.now obsolete) 40
Concealed knob and tube 35
The values given are approximate for average conditions. They include
all labor and material for "roughing in" but do not include lamps, fixtures,
switches or accessories.
WIKES AND CABLES
22. Electric wire and cable terminology. (U. S. Bureau of Standards
Circular No. 37.)
Wire. A slender rod or filament of drawn metal. The definition restricts
the term to what would ordinarily be understood by the term "solid wire."
If a wire is covered with insulation, it is properly called an insulated wire;
in general the term "wire" will be understood to include the insulation.
Conductor. A wire or combination of wires not insulated from one
another, .suitable for carrying a single electric current.
Stranded Conductor. A conductor composed of a group of wires or any
combination of groups of wires. The wires in a stranded conductor are
usually twisted or braided together.
Cable. (1) A stranded conductor (single-conductor cable); or (2) a
combination of conductors insulated from one another (multiple-conductor
cable). The component conductors of the second kind of cable may be
either solid or stranded, and this kind of cable may or may not have a
common insulating covering. A small cable is called a "stranded wire"
or a "cord," both of which are defined below. Cables may be bare or
insulated, and the latter may be armored with lead or with steel wires o^
bands.
Strand. One of the wires or groups of wires of any stranded conductor.
Stranded wire. A group of small wires, used as a siuKle wire. A wire
has been defined as a slender rod or filament of drawn metal. If such a
filament is subdivided into several smaller filaments or strands, and is used
1084
 INTERIOR WIRING See. 13-23

as a single wire, it is called "stranded wire." There is no sharp dividing

line of size between a "stranded wire" and a "cable." If substantially
insulated, it called a "cord," defined below.
is
Cord. A small cable, very flexible and substantially insulated to with-
stand wear. Usually the insulation of a cord contains rubber.
Concentric strand. A strand composed of a central core surrounded
by one or more layers of helically laid wires or groups of wires.
Concentric-lay cable. A single-conductor cable composed of a central
core surrounded by one or more layers of helically laid wires.
Rope-lay cable. A single-conductor cable composed of a central core
surrounded by one or more layers of helically laid groups of wires. This
kind of cable differs from the preceding in that the main strands are them-
selves stranded.
N-conductor cable. A combination of N conductors insulated from
one another. (It is not intended that the name as here given be actually
used. One would instead speak of a "3-conductor cable," a " 12-conductor
cable," etc. In referring to the general case, one may speak of a "multiple-
conductor cable," as in definition for "Cable" above.)
N-conductor concentric cable. A cable composed of an insulated
central conducting core with tubular stranded conductors laid over it con-
centrically and separated by layers of insulation. Usually only 2-con-
ductor or 3-conductor. Such conductors are used in carrying alternating
currents. The remark on the expression "N-conductor" given for the
preceding definition applies here also.
Duplex cable. Two insulated single-conductor cables twisted together.
They may or may not have a common insulating covering.
Twin cable. Two insulated single-conductor cables laid parallel, having
a common covering.
Triplex cable. Three insulated single-conductor cables twisted together.
They may or may not have a common insulating covering.
Twisted pair. Two small insulated conductors twisted together, without
a common covering. The two conductors of a "twisted pair" are usually
substantially insulated, so that the combination is a special case of a "cord."
Twin wire. Two small insulated conductors laid parallel, having a
common covering.
23. Specifications for insulated conductors are given in detail in
the Standard for Rubber-covered Wires and Cables which is issued and revised
periodically by the Underwriters' Laboratories. Since these specifications
are subject to revision, it is inadvisable to repeat them here. Practically
all rubber-insulated wire on the market is manufactured in accordance with
Code requirements. To each coil is fastened a tag indicating the approval
of the Underwriters' Laboratories. Unapproved wire should not be installed.
24. Current-carrying capacity of copper wires. If the current
carried by a given conductor is too great, the conductor will become so hot
that it will be unsafe, or may, if insulated, damage its insulation. Certain
Bafe current values have been determined for different sizes of conductor,
and are listed in Par. 27. Less current is permissible in rubber-insulated
wires than in wires insulated with other materials because relatively low
temperatures may injure rubber insulation. For interior wiring, the ca-
pacities recommended by the National Electrical Code in Par. 27 should
not be exceeded unless contrary local municipal ratings are mandatory.
25. Allowable current-carrying capacities of aluminum wire are
84 per cent, of the values given in the table for copper wire (Par. 27), assuming
the same kind of insulation.
26. Rubber-covered or rubber-insulated wires and cables (Par. 30,
81, and 32) when protected with one braid over the insulation, are known as
aingle-braid wires. When two braids are used to afford additional pro-
against injury by abrasion, they are known as double-braid wires.
Rubber-insulated conductors must be used for all concealed inside wiring
Itection
and for all wiring in damp places. They must be used throughout where
the voltage exceeds 600. Conductors insulated with less expensive materials
(see following paragraphs) can be used out-of-doors on pole lines and inside
in dry places where the wires are exposed. The National Electrical Code
'WTvmXa single-braid, rubber-covered wires for exposed interior wiring in
':lamp places and in raceways. See Par. 17 for requirements for conduit
irfre.

1085
) Sec. 13-27 INTERIOR WIRING

27. Allowable or Safe Current-carrying Capacities of

Insulated Copper Wires
(1920 National Electrical Code)

B. & S.
 INTERIOR WIRING Sec. 13-30

5S

a^

a ?

5 s

•3S
Sec. 13-31 INTERIOR WIRING
31. Dimensions and Weigrhts of Rubber-covered Wires and Cables
for Voltaeres from 600 to 1,600

A.W.G.

Solid

14

00
000
0000
 3 I

INTERIOR WIRING Sec. 13-33

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69 1089
Sec. 13-34 INTERIOR WIRING

34. Slow-biirning weather-proof conductors (Par. 33) are some-

times used for interior exposed wiring in damp places, where there are cor-
rosive vapors, provided that the voltage does not exceed 600. They are
cheaper than rubber-insulated conductors. The insulation consists of an
inner weather-proof coating and an outer fire-resisting coating. The Code
requires that the fire-resisting coating be -^^ the thickness of the entire
coating. To meet this condition the manufacturers use one weather-proof
braid and two fire-resisting braids. The fire-resisting compound consists of a
mixture containing white lead, oxide of zinc, chalk, or some similar substance.
The outer braid is rubbed smooth on the outside. The manufacture of slow-
burning weather-proof conductors has been discontinued by some nianufao-
turers and they are now seldom used. Slow-burning weather-proof wire is
cheaper than slow-burning wire. It is not suitable for out-of-door service.
Wires with a fire-resisting outer coating have the advantage that dust
and lint do not adhere readily to their outer surfaces, as is often the case
with weather-proofed braids. If dust does collect, it can be easily swept off.

35. Weather-proof, slow-burning conductors have a fire-resisting

coating next to the conductor and a weather-proof coating on the outside.
They are not approved by the Code.

36. Twin wires or cables (Par. 37) (sometimes called "conduit wires")
are used where they are to be drawn into conduit and should never be used
except in conduit or in metal raceways. Each wire is rubber insulated to the
thickness indicated in Par. 30, and then is served with a braid or with a tape.
The two conductors are finally bound together parallel one with another,
with a tenacious braid at least 0.0312 in. thick for wires larger than No. 10
B. & S. gage and 0.0125 in. for No. 10 B. & S. gage or less in size. This con-
struction is considered by the Underwriters' Laboratories as equivalent to
that of double-braid, rubber-covered wire. Twin conductors larger than
No. 0000 should not be used because of their tendency to kink.

37. Dimensions and Weights of National Electrical Code-

Stranded, Twin (Flat) Wire and Cable, 0-600 Volts
(General Electric Co.)

Solid Stranded

Siie of each Dimensions Dimensions

conductor Weight in in in. Weight in in in.
A.W.G. lb. per 1,000 lb. per 1,000
ft. Thick- ft. Thick-
Width Width
ness

214 0.33X0.57 214 0.35X0.61

162 0.26X0.48 162 0.32X0.51
126 0.28X0.44 126 0.29X0.48
100 0.22X0.40 100 0.23X0.42

38. Fibre-cored cables (Par. 39). Alternating current flowing in large

cables has greater density on the surface of the conductor than in the center
(so-called skin effect) Therefore an ordinary cable will not carry as great an
.

alternating current as a direct current, with the same temperature rise.

To compensate for this it is advisable, for single-conductor cables 700,000
cm. ancl larger for 60-cycle circuits, and 1,250,000 cm. and larger for 25-
cycle circuits, to strand the copper around a non-conducting fibre core.
The weight of copper in a cable of this type is the same per ft. as in a copper
cable without a core, but owing to its annular cross-section the cored cable
is much more efficient in alternating-current circuits and also has a some-
what greater current-carrying capacity due to the larger radiating surface.
The copper strands can be covered with any desired type of insulation.
1090
 INTERIOR WIRING Sec. 13-39

S9. Dimensions and Current-carrying Capacities of Fibre-cored

Cables. (General Electric Co.)

Size
cir. mils
 ^

Sec. 13-42 INTERIOR WIRING

)
partitions, so that only the plate and operating buttons are visible. Types
can be obtained which will furnish practically the same service as surface
snap switches. Those of the flush type are more expensive but present a
neater appearance than surface switches.
42. Electrolier switches (Fig. 9) control lamps in independent groups
such as would be used in an illuminated dome or electrolier. Switches
are made for this service in the "flush," "surface" and "pull" types.
Operation of the two-circuit switch is as follows: Position A, all lamps off;
B, only those of group 1 are on; C, both groups on; D, only those of group 2
are on. With the next movement all lamps are extinguished. The sequence
outlined is typical, but all electrolier switches do not provide just this
sequence. A three-circuit switch is neces.sary for controlling three groups.
With one type, the sequence for the different positions is as follows: A,
connects group 1; B, connects groups 1 and 2; C, connects groups 1, 2, and
3; D, disconnects all lamps.
Metal Ferrules Fiber Tube ^ ., „, ..
^FiberTube / Knife Blade
—\ ' ' 1 Contact
 INTERIOR WIRING Sec. 13-47

eluding 60 amp. at 600 volts, and the knife-blade contact type for currents
of from 61 to 600 amp. at 250 volts and of from 61 to 400 amp. at 600
volts. See National Electrical Code for detail dimensions of fuses of
different capacities. A
cartridge fuse
usually consists of a tube of fiber or
some similar material which enshrouds Copper Ferrti le Ter;i
the fuse link. The link terminals are Powdered/Filling
connected to contact pieces at the
ends of the tube. An insulating
powder surrounds the link and fills
the tube. In some forms the fuse link
is encased in a small air chamber, as
illustrated in Fig. 12. The formation
_ FD8<yWire Fibre Tube
of destructive arcs is prevented in
fuses of the cartridge type and the Fio. 12.
fuses themselves are capable of being
—
Typical enclosed-fuse con-
struction.
very accurately rated.
47. The ratings of enclosed fuses are specified by the Underwriters'

thus:
—
laboratories, in its publication "Standard For Cartridge Enclosed Fuses,"
"Fuses must be so constructed that with the surrounding atmos-
phere at a temperature of 24 deg. cent., they will carry indefinitely 110
per cent, current without causing the tubes to char or externally- visible
soldered connections to melt. With a room temperature between 18 and
32 deg. cent., fuses starting cold must blow on 150 per cent, current without
causing the tubes to char or externally-visible soldered connections to melt
within the times specified in Par. 48.
48. Time Intervals Within Which National-Electrical Code-Stantlard
Enclosed Fuses Must Blow On 150 Per Cent. Bated Current

Rating of fuse, amperes Maximum allowable time interval,

minutes

0-30 1
31-60 2
61-100 4
101-200 6
201-400 12
401600 15

_
49. Renewable fuses (Fig. 13) are those in which the fusible element,
in.stead of the entire fuse, can be replaced by the user. They were not,
until recently, approved by the Underwriters' laboratories. In spite of this
they, because of their decided economic advantages, were widely used. The
Underwriters' laboratories defines a standard cartridge-type renewable
—
fuse thus:r "A fuse expressly in-
Ren '"" bi El t
Inculating ShelK ^\V '
"^•^l,,!^^
^ciampinsr ci
Sleeve
tended by the manufacturer to be
renewed by the user with Suitable
elements supplied by the manu-
facturer. Under this definition
are included renewable fuses with
separately enclosed renewable
Contact Blades
renewable fuses with renewal
links,
links not separately enclosed, and
Fig. — Partial sectional view
13. cartridge enclosed fuses with two
of
or more links intended to be
Economy knife-blade-contact-type re-
newable fuse. used successively." Renewable
fuses are made in both the Ferrule-
Contact and the Knife-Blade-Contact types and are approximately of the
same over all dimensions as Code standard enclosed fuses. They fit the
same cut-out as do standard enclosed fuses, are made in essentially the same
capacities, and have about the same operating characteristics.
50. Fusing currents of commercial fuse wire. The following
values are approximate, as the fusing current is determined by the propor-
tions and kinds of alloys used, kind and form of terminal, length of fuse and
on other factors. (From Knox's "Electric Light Wiring;" table by Mr.
Bathurst.J
1093
Sec. 13-51 INTERIOR WIRING

Nearest size
A.W.G.
 —

INTERIOR WIRING Sec. 13-54

approved currents and voltages are given by the Code. combination of A

the Edison plug cut-out, and the ferrule fuse and fuse-plug casing that can
be used in connection witn it, constitutes a most satisfactory fuse arrange-
ment. However, this arrangement is hmited to a capacity of 30 amp. at
125 volts. The Edison plug cut-out, which^ has a right-hand thread, is
approved only for 125 volts; the Bryant Electric Co. makes a similar
cut-out having a left-hand thread, which is approved, under certain con-
ditions, for 250 volts. The right-hand thr ad cut-out is approved for only
125 volts because the Edison fuse-plug, which ia not safe at a greater voltage,
can be used in it. Cut-outs for open-Unk fuses consist merely of slate blocks,
having mounted on them the necessary terminals.
INTEBIOE-WIEING-CIRCUIT CALCULATIONS
54. Interior-wiring-circuit terminology. To render definite the
Bucceeding discussions, the following definitions are included. These specify
the generally accepted meanings of the terms involved. See Fig. 14 for
graphic definitions.
•.',W//J>>^.- >fjf»/l
Sub Main Main Distribution Centers -

Branch
Incandescent Lamp

Electric Service Company's Main

Fig. 14. —Illustrating interior-wiring-circuit nomenclature.
65. A
feeder or feeder circuit (F, Fig. 14) is a set of conductors, in an
interior-wiring system, extending from the original source of energy in the
installation to a distributing center and having no other circuits connected
to it between the source and the center.
66. A
sub-feeder (F», Fig. 14) is an extension of a feeder, or of another
sub-feeder, from one distribution center to another and having no other
circuit connected to it between the two distribution centers.
57. A main (M Fig. 14) is any supply circuit to which other consuming
circuits — —
sub-mains and branches are connected through automatic cut-
outs (fuses or circuit breakers) at different locations along its length. Where
a main is supplied by a feeder, the main is frequently of smaller wire than
the feeder which serves it. An energy-utilizing device is never connected
directly to a main, a cut-out always being interposed between the device
and the main.
68. A
sub-main {M,, Fig. 14) is a subsidiary main fed, through a cut-
out, from a main, or from another sub-main, and to which branch circuits
are connected through cut outs.
.59. A
service, or service connection (S, Fig. 14) is a set of conductors
constituting an underground or overhead connection between a supply
circuit (usually belonging to a public-service corporation) in a thoroughfare
street —
and the interior or isolated wiring system. A "service" provides a
path over which electrical energy is delivered to the consumers.
A branch or branch circuit (B, Fig. 14) is a set of conductors, feeding
60.
through an automatic cut-out (from a distribution center, main or sub-main)
to which one or more energy-utilizing devices are connected directly, that is,
without the interposition of additional cut-outs. The only cut-out asso-

1095
 :

Sec. 13-61 INTERIOR WIRING

ciated with a branch is the one through which the branch is fed at the main
sub-main or distribution center.
61. A tap or tap circuit (T, Fig. 14) is a circuit, serving a single energy-
utilizing device, which is connected directly to a branch without the inter-
position of a cut out.
62. A distributing or distribution center {D, Fig. 14) in an interior-
wiring system, is the location at which a feeder or sub-feeder main or sub-
main connects to the subordinate circuits which it serves. The switches
and automatic cut-outs for the control and protection of the sub-circuits
are, usually, grouped at the distribution center. In interior-wiring parlance,
a distribution center may be merely an arrangement or group of fittings
whereby two or more minor circuits are connected at a common point to
another larger circuit. A panel box is one form of distribution center.
WIEINQ CALCULATIONS AND LAYOUTS
63. The resistance of a circular-mil-foot of commercial copper wire
(a wire 1 ft. long and having cross-sectional area of 1 cir. mil) is usually
quoted as frorn 10.6 to 10.8 ohms, at 75 deg. fahr. (24 deg. cent.). For
wiring calculations 11 ohms per mil foot is a sufficiently accurate assump-
tion. (See Sec. 4 for the Annealed Copper Standard.) On this basis the
resistance of any commercial copper conductor is:

R —M^
cir. mils
(ohms) (1)

Wherein, iZ = resistance of conductor in ohms, Z = lengthof conductor in

feet and cir. mils = the area of the conductor in circular mils. Also:
y^nxixi (^^,^^^ ^2)'
cir. mils
where V represents the drops in volts and 7 the current in amps.
64. Procedure in determining the size of conductor for a given
circuit. Practically all interior wiring problems involve the deter-
mination of the size of wire that will carry a certain current a given dis-
tance with a permissible drop in volts. The successive operations are
^ in (a) Determine the current,
amperes, that will flow in
^ the circuit.
Load Centerx (b) Determine the distance
from the point of assumed con-
stant voltage to the load cen-
T« ter of
the circuit (Par. 66).
Main This distance will be the ac-
^ tual circuit length if the load
" is concentrated at one end.
(c) Decide what voltage drop
or loss is allowable (Par. 66,
67 and 68).
Fia. 15. —An example of load center.
(d) Determine from the
mulae the size of wire that will
for-

give the desired voltage drop.

(e) Check the derived wire size for current-carrying capacity, using the
table in Par. 27.
(f) Where economy of operation must be considered, check the cost of
the energy dissipated in resistance; this should be maintained within reason-
able limits. See Par. 87 to and including 91.
66. The load center of a circuit is that point at which it can be
assumed that the total load is concentrated. The load center of a group of
receivers, each of the same input and symmetrically arranged, will be at
the middle of the group. (Fig. 15.)
To determine the load center of a group of receivers of unequal capacities
or unsymmetrically located, first multiply the normal current taken by each
receiver by its distance from the starting point of the circuit; add all the
products thus found, and divide this sum by the total current of the circuit.
See Fig. 16. After some experience, one can by inspection usually determine
the location of the load center with sufficient accuracy. Calculations for
this factor are seldom made by experienced circuit designers.

1096
 INTERIOR WIRING Sec. 13-66

66. Allowable voltage drop in incandescent lighting circuita,

should not exceed 3 volts in 110-volt circuits and 6 volts in 220- volt circuits.
Sometimes 4 or 5 volts drop is allowed in 110-volt circuits, but these are
decidedly the upper limits and do not represent good practice. In per-
centages of the receiver voltage, a drop of from 1 to 3 per cent, is satis-
factory and a 4.5 per cent, drop is the maximum. (See Par. 69.) The
above values represent the voltage drops from the source of assumed
constant voltage to the lamp. Because of the extreme sensitiveness of
the incandescent lamp to variations in voltage, the lamps may be subjected

(-Load Center

80'x 100 A -8000

lOO'x 40 A = 4000
130' it 20 A = 2800
lao / 14600 \ 91.25 ft. Distftuceto Load Center

Fia. 16. —^Determination of the load center of a circuit having receivers of

unequal capacities, unsymmetricaUy located.

to excessive overvoltages if the drops suggested above are exceeded

will materially decrease their life.
which
They may also be subjected to under-
—
voltages when the circuit is loaded —
which will decrease their brilliancy
(Sec. 14). Some central-station companies specify that the total drop in
110-volt, interior-wiring circuits shall not exceed 1 volt.
67. Allowable voltage drop in motor circuits. 5 per cent, dropA
is in accordance with excellent practice and a 10 per cent, drop or even a
slightly greater one is often considered satisfactory. These drops are
reckoned on the receiver voltage. The drop should be calculated on the
basis of full-load motor current. Where incandescent lamps are on the same
circuits with motors the drops suggested in Par. 66 should not be exceeded.
In designing motor circuits the question of conductor economy (Par. 88)
should be considered.
68. Typical Apportionment of Drop in 110-Volt Lighting Circuits
 . , 1

Sec. 13-70 INTERIOR WIRING

it should be consulted regarding its practice in this respect. Some com-
panies require that the voltage drop in interior wiring installations which
they are to serve, shall not exceed a certain maximum. In any case, it is
frequently the practice to allow one volt drop for the branches and to appor-
tion the rest of the available drop to the main circuits and feeders.
70. Apportionment of drop on 2,400-7olt distribution systems
is often made under the assumption that the secondary voltage at the trans-
formers remains practically constant. This will be found true in a well
laid-out system, particularly if automatic feeder regulators are used.
71. Apportionment of drop in motor circuits is frequently made on
the basis that 1 volt will be allowed in the branches, two-thirds of the remain-
ing drop in the mains and one-third in the feeders. Most of the drop should
be confined to the mains in order that a variation in the load on one motor
of a group will affect the others as little as possible. Where motor circuits
are fed by transformers, it is usually assumed that the voltage at the second-
ary side of the transformers remains practically constant, and therefore all
of the allowable drop is apportioned to the secondary circuit. Where a group
of motors is fed by a main and branches, the drop in the branches, if they
are not too long, is frequently 1 volt or less, under normal working conditions,
because the Nat. Elec. Code requires that a branch conductor serving a
motor be capable of safely carrying a current at least 10 per cent, greater
than the normal full-load current of the motor.
72. Currents Causing a Drop of 1 Volt in Circuits of Different Lengths
and of Different Sizes of Wire
Totallength (single distance) of circuitinfeet
(The total length of wire is twice the single distance)
Sire A.W.G.
20 30 40 60 100
ft. ft. ft. .50 ft. ft. 70 ft. 80 ft. 90 ft.
ft.

14 9.3 6. 4.6 3 3 2 2.3 1.8

12 14.8 9. 7.4 5 4 4 3.7 2.9
10 23.6 15. 11.8 9 7 6 5.9 4.7
33.0 25. 18.7 15 12 10 3 7.5
46.0 39. 29.7 23 20 16 14 8 11.8
5 54.0 50. 37.6 30 25 21 18 7 15.0
4 65.0 63. 47.4 37 31 27 23 18.8
3 76.0 76. 59.8 47 39 34 29 23.8
2 90.0 90. 75.0 60 50 42 37 5 30.0
1 107.0 107. 93.5 75, 68 53 46 7 37.4
127.0 127. 119.8 95, 79 68 69 5 47.6
00 150.0 150. 150.0 120, 100 86 75 60.0
000 177.0 177. 177,0 152, 127 108 95 76,0
,000 210.0 210. 210.0 192. 160, 136 120 96.0
200 ,000 cm. 200.0 200. 200.0 181 151, 129 113 6 90.9
300 ,000 cm. 270.0 270. 270.0 270, 227, 194 170 4 136.2
400,,000 cm. 330.0 .330. .330.0 330. 303, 259 227 2 181.8
500,,000 cm. 390.0 .390. .390.0 .390. 378. 324 284 1 227.2
600,,000 cm. 450.0 450. 1450.0 4.50. 4.50, 389 340 8 272.7
700 ,000 cm. 500 . 500. 500 .500, 500 . 461 ,397 7 318.1
800,,000 cm. 550.0 5.50 5.50.0 5.50. .5.50. 519 4.54 4 0'363.6
900,,000 cm. 600.0 600 .0 600,0 000
1 600 584 4 51 3 ,5,400.0
1,000,,000 cm. 650. Oj 650 .0!650.0:650 0,650, 0,650 0;508 7:,50; ,0,454.5

Values below the heavy type exceed the maximum safe currents allowed
by The National Electrical Code (Table 22) for rubber-covered wire.
73. Per cent, voltage drop in practical wiring calculations is usually
taken as a percentage of the receiver voltage. The voltage drop may be ex-
pressed in percentage of impressed voltage by the expression 71= F/(£-t-K),
where p is the per cent, drop, V is the drop in volts and E is the voltage at
the receiver.
74. Calculation of two-wire, direct-current circuits is effected by
means of the following formula,
., 22X/XZ. ,„,
cir. nuls- (3)
y
1098
 INTERIOR WIRING Sec. 13-75

wherein F=drop in volts in the circuit, J = current in amperes, L = length

one way or the single distance of the circuit, in feet and cir. mils = the crosa-
sectional area of the conductor in circular mils.

76. Calculations of three-wire, direct- current circuits are made with

Eq. 3,Par. 74. In a balanced three-wire circuit no current flows in the neu-
tral wire. In making wiring calculations in practice for three-wire circuits,
it is assumed that the circuit is balanced. Ascertain the current that will
flow in the outside wires of the three-wire circuit and then use Eq. 3, Par. 74.
The drop in voltage V in the formula is the drop in both of the outside wires
and is twice the drop to each receiver connected between the neutral and an
outside wire. Obviously V can be twice as great for a three-wire circuit as
for the equivalent two-wire circuit. The neutral wire if unfused should be the
same size as each of the outside wires in order to conform with Code require-
ments, but when ungrounded and properly fused it may be smaller.
76. The method to be used in calculating an alternating-current
circuit is determined by the characteristics of the circuit under consideration.
Where the circuit is short and the conductors will He reasonably close together,
the approximate methods suggested in following paragraphs can be used;
these artially disregard the effects of p )wer-factor and line reactance.
The results obtained from these approximate formulas are usually subject
to less error than other factors entering into the ordinary wiring calculation.
Where circuits are long and the conductors lie far apart, the results given
by the approximate formul&s should be checked by the Mershon-Diagram
(Spc. 12) which considers the effects of power-factor and reactance.
Although the Mershon method is a trifle tedious, it will usually be found the
quickest and the best when all things are considered. The use of the tables,
that are frequently given for the determination of alternating-current
conductors, may lead to inaccurate results, unless the user is famihar with
their derivation. The effects of capacitance (electrostatic capacity) are
inconsequental and need not be considered in ordinary interior wiring
calculations.

77. Line-reactance voltage drop may be decreased either by diminish-

ing the distance between the wires, or by dividing the copper into a greater
number of circuits. Reactance is Uttle affected by changing the size of
the conductor. In interior wiring installations the conductors can be no
nearer together than certain minimum distances specified by the National
Electrical Code. Where installed in conduit the conductors are so close
together that their reactance is practically negligible. All the wires of any
alternating-current circuit (two wires for a single-phase circuit, three wires
for a three-phase circuit or four wires for a two-phase circuit) should be carried
as close together as feasible or, in a conduit installation, they must all be in
the same conduit, in accordance with the Code.
78. Skin effect in interior wiring calculations is ordinarily of little
consequence, and need not be considered unless conductors are larger than
600,000 cir. mils in area. (Sec. 2 and Sec. 12.) As a general proposition
conductors larger than 600, OCX) cir. mils are very difficult to handle, and,
hence, are uneconomical to install: therefore, when greater area is required
it is usual to arrange several conductors in parallel. Some engineers will
use no conductor larger than 300,000 cir. mils in interior wiring. Fiber-
cored cables (Par. 38 and 39) should be used where conductors larger than
600,000 cir. mils are required.
79. Calculation of alternating-current circuits of high power-
factor, such as those which supply incandescent lamps: in this case treat
the circuits as if they were direct-current circuits, using Eq. 3, Par. 74.
This method is not strictly accurate but is sufficiently so for ordinary con-
ditions. If the circuits are long and the wires are widely separated, the
conductor sizes obtained as above should be checked by the Mershon-dia-
gram (Sec. 12).
80. To calculate single-phase, alternating-current circuits where
line reactance may be neglected. The following formulas can be safely
used for the calculation of branch circuits and also of feeders and mains
where the conductors are carried in conduit or are not very long. Where
the circuits are of considerable length the result given by the formula should

1099
 —

) Sec. 13-81 INTERIOR WIRING

be checked with the Mershon diagram (Sec. 12). The current may be found
from the expression:
a:i*.x 1.000
^ ^ ,^^

wherein, 7i = current in amperes, Kw. = kilowatts input of the load, E"

voltage of circuit and p.f. = power-factor of load.

^—
cir. mils =
., 22X/iXL
(5)

Wherein, cir. »nt7s = area of conductor; /i = current in amperes; L = length

(one way) of the circuit in feet and V = volts drop allowable.
81. Calculations of single-phase branches from three-phase
clrctlits are made in the same way as those for any other single-phase
circuit (Par. 80). However it must be remembered that if the branch is
connected between one of the three phase wires and the neutral, the voltage
impressed on the branch circuit will be 0.58 times the voltage across any two
phase wires of the three-phase circuit.
82. To calculate two-phase, four-wire, circuits where line react-
ance can be neglected the following formulas can be used. The limitations
for this method are the same as those for single-phase circuits as outlined,
Par. 80. As with the single-phase equations (Eq. 4 and 5, Par. 80), the
Mershon diagram (Sec. 12) should be used ^r checking the conductors
for circuits of considerable length. Where the current is not known it can
be found thus:
^ ii:t«.X 1,000 KW.X50Q
^^'"P^-^ (^>
^'^EX^Txi^ E~Xl^
Wherein, It = current in amperes in each of the four wires of a balanced
two-phase circuit, and the other symbols have the same meanings as in
Par. 80. The current being known:
cir. mils = (7)
^
Wherein the symbols have the same significance as outlined in this and
all of
preceding paragraphs. Use four wires of the same size.
83. To calculate three-phase, three-wire, alternating-current
circuits where line reactance can be neglected the following formulas
can be used. The limitations for this methoof are the same as those outlined
for single-phase circuits in Par. 80. As with the single-phase equations the
Mershon diagram (Sec. 12), should be used for checking the results obtained
for circuits of considerable length. Where the current is not kilown, it may
be obtained from the expression:
Kw.X 1,000 Kw. X5S0
^• = ^^""^'-^ ^«^
l;xpT/.xl.73= .Bx^T/:"
Wherein It is the current in each of the three wires of a balanced three-
phase, three-wire circuit, and where the other symbols] have the same sig-
nificance as in Par. 80. When the current is known, then
IIX/3XLXI.73 = 19X/»XL
cu. mils = ,„,
.,
(9)
y y
Wherein the notation is the same as outlined in this and preceding para-
graphs.
84. Calculation of single-phase circuits where line reactance must
be considered. The Mershon diagram (Sec. 12), is recommended for
making such calculations. Other and apparently simpler methods are
available, but all simple methods are inaccurate under certain conditions
and are likely to get their user into trouble unless he is familiar with their
derivation and limitations. The Mershon diagram does not offer a direct
method of ascertaining drop; it is a "cut-and-try" method. Trials arc made
until a conductor size is found that will bring the drop within the specified
limit. It is .seldom that more than two trials are necessary. The method i»
a little tedious but not difficult, and will be found accurate under all ordinary
conditions.

1100
 ;

INTERIOR WIRING SeC. 13-85

86. To calculatea two-phase, four- wire, alternating-current

circuit where line reactance must be considered, use the Mershon
diagram (Sec. calculating
12), a single-phase circuit (Par. 80) which will
transmit one-half the power at the same voltage. The two-phase trans-
mission will require two such circuits.
86. To calculate a three-phase, three-wire, alternating-current
circuit where line reactance must be considered, use the Mershon
diagram (Sec. 12), calculating the conductor size for a single-phase circuit
(Par. 80), which will carry one-half of the load at the same voltage. The
three-phase transmission will require three such conductors.
87. Power loss in any circuit. Assuming that 11 ohms is the resist-
ance of a circular-mil-foot of copper conductor, the power loss in any con-
ductor may be found thus:
p^ nxi^Xl
cir. mils
.
(jQj

Wherein, P = power lost in the conductor in watts, I = the current in amperes

in the conductor, Z = length of the conductor in feet and cir. mils = urea, of
the conductor in circular mils.
For a two-wire circuit (direct-current or single-phase).
Pp = 2X11XJ^XL
;
22XJ'XL
=^ 77—
Tj
,
(watts),
., .,,.
(11)
cir. mils cir. mils
For a four-wire, two-phase circuit (assuming balanced currents)
P= -.

cir.
77
mils
— —7
cir.
7-.

mils
— (watts) (12)

For a three-wire, three-phase (assuming balanced currents)

circuit
„ = 3X11X/'XL 33 X J' XL
P 77— =— , „ , (watts)
",,,,
n;
(13)
cir. mils cir. mils
Wherein, P = the power, in watts, lost in the circuit; / = the current in am-
peres which flows in each of the wire.? of the circuit; L = the length (one
way) of the circuit; and cir. miis = cross-sectional area in circular mils of each
of the wires. The above formulas can be used only when all of the wires of
the line are of the same size.
88. Conductor economy in interior wiring installations always should
be considered as a matter which is subordinate to the Code requirements.
Obviously any conductor selected for a specific installation must fulfil the
requirements of mechanical strength, ample carrying capacity (Par. 24 and
27), and permissible voltage drop (Par. 66 and 67). Frequently one of these
three considerations will definitely determine the size of the conductor;
however, a calculation of the resistance or I^R (power) loss (Par. 87) may indi-
cate that it will be desirable to use a larger size th^n is otherwise necessary.
89. Annual charges may be considered, in connection with the
economical selection of a conductor size, to be made up of two items: (o)
resistance-loss charges; (6) investment charges. Resistance-loss charges
depend upon the resistance, the current and the unit cost of energy, and
may be decreased by an increase of conductor size. This, however, calls
for a greater investment with consequently larger investment charges.
A conductor should be selected of such a size that the total annual charge
(Sec. 25) will be a minimum.
In Fig. 17 the effect of a variation of conductor size on resistance-loss
charge, investment charge, and total annual charge is shown graphically.
The interest charges on the conductor increase directly with its cross-
sectional area (graph A, Fig. 17). The resistance-loss charges decrease
inversely as the cross-sectional area of the conductor (graph B, Fig. 17).
The total annual charge (graph C, Fig. 17), the sum of graph A and B, is
at its minimum value directly over the point where graphs A and B intersect.
That is, the conductor size that will have the least total annual cost is that
one for which the annual interest charge equals the annual resistance-
loss charge. This proposition (Par. 90) has been demonstrated mathe-
matically by Lord Kelvin.
90. Kelvin's law was deduced in 1881 by Sir William Thompson (Lord
Kelvin). The original law was modified into the following more exact form
by Gisbert Kapp: "The most economical area of conductor is that for which
the annual cost of energy toasted is equal to the interest on that portion of tht

1101
Sec. 13-91 INTERIOR WIRING

capital outlay which can he considered proportional to the weight of copper used."
On the basis of the above law it can be shown that:

Wherein: cir. mi7s

*cir. mils
= area
= 55,807 X/ ^Vc^ (14)

in circular mils of the most economical conductor;

/ = the mean annual current (Par. 94). Ct = cost of energy per kilowatt-
hour, in dollars; Ce" cost of copper in dollars pier pound, installed; A =
/
 INTERIOR WIRING Sec 13-92
The cost of unit length of conductors (preferably 1,000 ft. or 305 rn.) may
be obtained from the manufacturers' wire lists. Power loss may be cal-
culated from Eq. 10 to 13, Par. 87.
By use of this table the situation may be made readily apparent, and
a decision may be speedily reached. This method may be uaed as a check
upon Eq. 14, Par. 90.
92. In alternating-current systems of distribution there are the
two-wire and three-wire single-phase systems; the three- wire and the four-
wire, two-phase systems, and the three-wire and four-wire, three-phase
systems. All of these are usually fed from the secondaries of transformers
located outside the building, either on poles or in subways.
93. Single-phase, two-wire and three-wire systems of distribution
are similar to the direct-current systems, and the same precautions should be
taken in the three-wire system to balance the loads on each side of the
neutral.
94. Factors for determining the mean annual current. To
ascertain the mean annual current for substitution in Eq. 14, Par. 90,
multiply the maximum current by the ratio applying to the conditions under
consideration, given in the column headed "Factor" in the following table.
The table is calculated on a basis of 24 hr. X36o days = 8,760 hr. per year.
Example. If a maximum current of 1,000 amp. (7) flows J of the time or
6,570 hr. per year and a current of 750 amp. (J7) flows i of the time or
2,190 hr. per year the factor "0.944" would be used; that is, the value
0.944X1,000 amp. =944 amp. would be the mean annual current
for substitution in the equation of Par. 90 (Eq. 14).

Proportion of maximum current "I

carried

U H

95. Two-phase distribution may be effected with four or with three

wires. In the former case there is a pair of wires for each phase, while
in the latter there is one wire for each phase and a common wire for both
phases. The circuits must bebalanced on either .side, just as in the case of
a three-wire, direct-current system, the only difference being that where
three wires are used, the common wire is 1.4 times as large as either of

1103
Sec. 13-96 INTERIOR WIRING

the other two, since it must carry 1.4 times as much current. Motors are
connected to both phases and employ all three or all four wires as the case
may be. With four lamps are connected to each phase as though
wires, the
the supply were single-phase and care should be exercised to balance each
phase as nearly as possible.
96. The three-phase system is usually employed where motors form
a greater part of the load. Three conductors are necessary. Where
lamps are required they are either balanced on the three-phases or connected
between each main conductor and a common conductor of smaller size
usually connected to the middle point of the star-connected secondary.
The e.m.f. between any one of the three wires and the neutral is 0.577 (or
0.38) times the e.m.f. between the mains.

Ground on Neutral

Three-WIro
|;;^Feeder

Two-Wire
(Branches

^M^
-The two-wire system. Fia. 19. —Three- wire system.
97. Two-wire and three- wire systems. The two-wire system (Fig.
18) is used for most interior power and branch-circuit incandescent lamp
wiring. The three-wire system (Fig. 19) used for feeders and mains. In
three-wire systems the neutral wire is grounded and unfused "except vhere
the circuit is entirely unexposed to leakage or induction through overhead
construction from aerial circuits operating at pressures exceeding 600 volts."
Hence the neutral is, except where there is no exposure to aerial circuits
operating at pressures exceeding 600 volts, made the same size as each of the
two outer wires.' Hence the marked economy of copper which is theoreti-
cally possible with the three-wire system is not always realizable in interior
installations. When the neutral is grounded the neutral wire must be the
same size as the outer wires. See Code rules 13a, 136, 23b and 15A6.
When the neutral is grounded the three wires of the system are of the same
size because if one of the outer fuses should blow, one side of the system
would be loaded while the other side would carry no current. In such a case
the neutral would have to carry the same current as the outer wire, and were
it smaller than the outer wire it would be overloaded. Where a grounded
neutral has the same cross-section as either of the outer wires, the neutral
fuse is to be omitted; but not otherwise. By making the neutral of cross-
section equal to the combined cross-sections of the outer wires, the system
may be easily changed to a two-wire system. The latter plan is usually
followed in large buildings, where a two-wire isolated plant is used and where
the emergency connection with the utility company's mains is three-wire.
98. The load on a three-wire system must be balanced, that is,
the watts load should be approximately the same on either leg of the three-
wire circuit. A variation of 10 or 15 per cent, may be permissible. Good
balance is particularly important at maximum load. Unbalance causes
unequal voltages, which is noticeable as producing a non-uniformity of
illumination, and it may bring an overload on the conductors.
99. Planning residence wiring. Secure the floor plans or insf)cct the
building. Decide where the meter is to be located; the point of entrance
should be as close to the meter as possible. A good arrangement is to locate
the service entrance (Par. 107) and the meter in the cellar. If the wires

1104
 INTERIOR WIRING Sec. 13-100

enter between the first and second floors, the meter may be installed in the
rear hall. Ascertain how many lamp outlets there will be, their location,
and the current required by each. Locate the distribution center at some
central point convenient of access. Divide the incandescent-lamp outlets
into groups which absorb less than 660 watts, each group being fed by one
branch circuit from the distributing center. Not more than 16 standard-
size sockets are permitted on branch circuit
which serves incandescent lamps, except in
special cases. See Par. 104. It is best to
subdivide the outlets so that no branch
circuit will have an initial load greater than
440 watts, which allows 220 watts for
growth, so that the maximum of 660 watts,
specified by the Code, shall not be exceeded.
Locate the switches and calculate the
feeders required. Incandescent lamp branch
circuits are usually of No. 14 wire unless
they are longer than 100 ft. (30.5 m), in
which case wire at least as large as No. 12
should be used; No. 14 is the smallest size
permitted by the Code. Fig. 19A shows a
typical lay-out for a small residence. Usu-
ally one panel or a group of cut-outs is
sufficient for a residence. It is always
preferable to group all cut-outs instead of
locating them at random.
Fig. 19A.— Example of a con-
In a small build- duit-wiring lay-out in a resi-
ing, branch cut-outs or the panel box can dence.
often be set near the meter at the entrance
or in the hall. In a two-story house they can be installed in the cellar
stairway or in the rear hall, and in a three-story building they can be in-
stalled in the second floor hall. Where there are more than three stories,
distributing centers can be located every second or third floor.
100. Important features of large lay-outs. There are five important
factors that should be considered in designing the wiring lay-out for a large
building (Knox, " Electric Light Wiring"). They are: (o) control of groups
of receivers (other than hall or night lights) from the main switchboard;
(6)
control of hall lights from the main switchboard; (c) maximum load that
"^
served by one feeder; (d) the best maximum Umit for the size of
!u J
the feeder conductors; (e) the proportion of the total voltage drop that can be
allowed in feeders and mains.
101. Wiring lay-out for a large building. Make a sectional-elevation
drawing of the structure and a floor plan of each floor. Indicate the receivers
(lamps and motors) on the plans and then so locate the panel boxes that no
lighting branch circuit shall be much over 100 ft. (30..5 m) in length,
or have
a load much greater than 440 watts. Panel boxes should be so located that
tbey are accessible and that the circuits can be readily run to them. Com-
pute the load on each panel box and indicate it, at the box, on the drawing.
J^ay out the mains and feeders (see Fig. 20) . First decide whether the hall
or public lights will be controlled separately or with the private
lights from
the main switchboard, because this feature affects the arrangement
of the
leeders and possibly that of the mains. Next decide whether there should
separate feeder to each floor or whether several floors or portions thereof
if
^
on », i-«'^'''^ "X
the ditterent
°"*' feeder. Where it is unnecessary to control the loads
floors separately, and where the resulting conductor size will
not be prohibitively large, the cheapest and probably the
best arrangement
is to serve several or possibly all
floors with one feeder. Usually, the only
Umit to the number of floors that may be served with one feeder is the
re-
nnentent of control that is desired from the main switchboard.
It is fre-
quently necessary to make several tentative lay-outs and
computations
Delore the most desirable arrangement is found.
Segregated motors and
groups of motors, unless very small, should be served by independent
feeders.
102. Arrangement of feeders. Solely on
a basis of initial cost, it is usually
Cheaper to run a few large conductors than a number of small
ones. It does
not pay, however, to endeavor to install conductors
larger than 1,000,000
S^- ™"^- When large capacity is necessary, use several conductors having

rg 1105
Sec. 13-103 INTERIOR WIRING

larger than 700,000 cir. mils are not desirable because of skin effect. Often
the space available for conductor runs necessitates small conductors (Par.
38 and 78).

Blower Mutci SinJtfih tioorcU

Individual Feeder to Each Floor
One Feeder Serving All Floors

h
•ii'
Fia. 20. —Wiring lay-outs in large buildings.

103. Motor circuits are subject to many special Code requirements.

One unfamiliar with its rulings should consult the Code before he attempts
to install motor wiring. The principal requirements follow: (a) Motor
circuits must be designed to carry a current at least 10 per cent, in excess of
that for which the motor is rated, (b) Where wires installed in accordance
with this ruling would be overfused in order to provide for the starting
current, the wires must be of such size as to be properly protected by these
larger fuses, (c) Where alternating-current motor leads arc rubber insulate<L
the wire may be protected in accordance with Table C, Par. 27. (rf) The
rated capacity of the running fuses must not exceed 125 per cent, of the
name-plate current rating of the motor, except whore no standard size fu.^r
exists, then the next higher standard fuse-size may be used, (e) To proyid.
for the peak loads encountered in variable-speed motor service see ratings
indicated in the Code, (f) Every motor installation (except for cranes)
must be protected by a cut-out and must be controlled by a switch which
plainly indicates whether it is on or off. (g) Small motors may be grouped
under the protection of a single set of fuses, provided their aggregate capac-
itj; does not exceed 660 watts, ih) For motors of 0.25 h.p. or less on cir-
cuits at voltages of .300 or under, single-pole switches may be used, (i)
Switch and starting box should be so located that they are visible from the
motor.
Motor manufacturers always furnish with each machine a diagram of
connections and instructions for installation. These data should always
be consulted.
104. Electric heating-device circuits (see National Electrical Code)-
A heater of a capacity greater than 6 amp., or 060 watts should be protected
by an individual cut-out and should be controlled by a switch or plug
1100
 INTERIOR WIRING Sec. 13-105

connector which indicates whether the device is "on" or "off;" this should
be^visible from the heater. Heaters of a capacity smaller than that indicated
above can be grouped under the jjrotection of a single set of fuses, provided
the capacity of the fuse does not exceed 10 amp. Such heaters can also be
connected individually to hghting circuits.
106. Heating device outlet plates will be found convenient; each is
provided with a receptacle, a switch and an indicating lamp socket. They
are regularly manufactured for current capacities as high as 20 amp. Key-
less brass sockets have a maximum rating of 6 amp. Ordinary pull-chain
and key sockets have a maximum rating of 2.5 amp. Standard separable
attachment plugs are approved for 660 watts at 250 volts or 10 amp. at
110 volts. Where ordinary key sockets are used for switching heating
devices, they soon break down under the action of the arcs due to the
relatively heavy currents. Snap or knife switches should always be used
for heating devices. Specially constructed asbestos-covered, flexible
cords are required for devices absorbing more than 250 watts.
all In a
first-class installation, is always desirable to install separate circuits for
it
•the heating devices, extending from the entrance switch to the receivers.
This permits individual metering and insures that the heavy currents
drawn by the heating appliances will not interfere materially with the voltage
regulation of the interior lighting circuits.
Sec. 13-108 INTERIOR WIRING
slant outwardly and downwardly to prevent the entrance of moisture. A
drip loop should be formed in the service wires. The entrance switch should
usually be so arranged that it will discoiyiect all of the equipment in the
building. For permissible exceptions, see Code Rule 24. Where conduit is
used, the two or the three rubber-insulated wires should be carried in one
conduit.

In Attic In Basement
Fio. 22. — Service entrances.
108. Distribution center panels may consist merely of porcelain cut-
outs held to the back of the box with wood screws, or may be more elaborate.
The panel provides a convenient means of connecting the branch circuits
to a main through fuses. Switches may be used in both main and branch
circuits or they may be omitted entirely. Many satisfactory installations
are in operation without switches at the distribution center but switches
are a great convenience for opening circuits when replacing fuses or for
testing. In general, knife switches should not be used for the control of
the lamps, as they arc frequently of improper design to withstand perma-
nently such service. Individual lamp-group circuits should be controlled
by either flush or surface snap switches mounted outside the panel box.
109. Standard wiring: symbols adopted by the National Electrical
Contractors' Association and the American Institute of Architects
(Copyrighted by the National Contractors' Association.)
Ceiling outlet elcctrifc only.
; Numeral in center indicates num-
ber of standard 16 c-p. incandescent lamps.

^•f(_ Ceiling outlet; combination. J indicates 4-16 c-p. stand- jfl^

)m<^ ard incandescent lamps and 2 gas burners. If gas only, ^^
Bracket outlet; electric only. Numeral in center indi-
cates number of standard 10 c-p. incandescent lamps.
Bracket outlet; combination. J indicates 4-16 c-p. stand-
ard incandescent lamps and 2 gas burners. If gas only.
Wall or baseboard receptacle outlet. Numeral in center indi-
cates number of standard 16 c-p. incandescent lamps.
Floor outlet. Numeral in center indicates number of Standard
16 c-p. incandescent lamps.
Outlet for outdoor standard or pedestal, electric only. Numeral
indicates number of standard 16 c-p. incandescent lamps.
Outlet for outdoor standard or pedestal; combination, g indi-
cates &-16 c-p. standard incandescent lamps; G gas burners.
Fig. 23A.

1108
 :

INTERIOR WIRING Sec. 13-109

Drop cord outlet. One-lamp outlet, for lamp receptacle.

Arc lamp outlet.

C^--C3~--~^ Ceiling
fan outlet.

Special outlet for lighting, heating and power-current, as de-

scribed in specifications.
S. P. switch outlet. Show as many symbols as
there are switches. Or in
D. P. switch outlets. case of a very large group of
switches, indicate number of
switches by a roman num-
3-way switch outlet. eral, thus; S' XII; meaning
12 single pole switches.
4-way switch outlet.
Describe type of switch in
Automatic door switch outlet. specifications, that is, flush
or surface, push button or
Electrolier switch outlet. snap.

Meter Distribution Junction or pull

outlet. panel. box.

Motor outlet. Numeral in center indicates horse power.

Motor control outlet. =5^ Transformer.

Main or feeder run Main or feeder run
' concealed under concealed under
floor. floor above.
Main or feeder run
Branch circuit run
exposed.
concealed under
floor.
Branchcircuit run
concealed under ,
Branch circuit run
floor above.
exposed.
-— Pole line. Riser.
Telephone outlet;
private service. W Telephone outlet;
public service. Q Bell outlet.

Push button out A n n u n ci a tor.

n Buzzer outlet. E2
let. Numeral
indicates num-
Numeral indi-
cates number of
ber of pushes points.

" ^ Speaking tube. -© Watchman

outlet.
clock Watchman
tion outlet.
s t a"-

fTS Master timeclock TS Secondary time

outlet.
[
LL' clock outlet.
I 1 I Door opener
Special outlet for signal systems,
j5^1
'—' as described in specifications. I
Battery outlet.
I
Circuit for clock, telephone, bell "or other service, run
,

under floor, concealed. Kind of service wanted ascer-

__^____^__^^ tained by symbol to which line connects.
Circuit for clock, telephone, bell or other service, run
under floor above, concealed. Kind of service wanted
ascertained by symbol to which line connects.
Heights of Center op Wall Outlets (unless otherwise specified)
Living rooms 5 ft. 6 in.
Chambers 5 ft. in.
Offices 6 ft. in.
Corridors 3 ft. 6 in.
Height of switches (unless otherwise specified) 4 ft. in.
Fia. 23B.

1109
Sec 13-110 INTERIOR WIRING
110. Installation of watt-hour meters and maximum-demand
meters. (^Rules and Regulations of the Cormnonwealth Edison Co., Chicago):
Meter loops should be provided in the mains at an accessible location, and so
arranged that the meter may be mounted with ordinary wood screws on the
wall. A meter board must be provided ol suthcient size to allow the installa-
tion of a watt-hour meter and maximum-demand meters. Two maximum-
demand meters are installed on three-wire mains. Maximum-demand
meters will not bo installed on installations under 1 kw. Sufficient space
must be provided about the meters to allow the removal of the case.
Meter boards should not be erected on a wall which is subject to any
considerable vibration, or in places subject to excessive moisture or heat.
A pressure- wire tap must be provided in all cases where all wires of the circuit
are not looped out. On three-wire mains the pressure-wire tap must be
made on the neutral wire. The general arrangements of meter loops should
be such that a meter can be installed without crossing any wires, if possible.
If this is impracticable, sufficient flexible tubing should be left on the wires
to make possible an installation which will be in accordance with the wiring
rules.
Meter loops should not be placed above 7 ft. from the floor, and should
be as near the point of entrance of the service as possible. In office buildings
meter loops should bo located at a central point in meter closets or public
corridors, and in apartment buildings in the basement of the building, so
that meters may be installed and maintained without annoyance to tenants.
Meter loops must be located relative to fuses so that meters are protected
by the fuses. They must never be placed between the service and the service
switch. Generally speaking, not more than one meter installation will be
provided for the same class of service in any one building.
Meter loops for service supplying temporary lighting or power to new
buildings during construction must be located on adjoining premises. No
three-wire meters larger than 200 amp. are used. Installations requiring
meters of larger capacity will be provided with two meters, one on each side
of the three- wire main; space should be allowed accordingly in arranging
meter boards.

111. Protection of watt-hour meters against unauthorized or mali-

cious interference is effected by means of seals and enclosing cabinets.
See manufacturers' catalogues for further information, and " Aleternien's
Handbook," published by the National Electric Light Association.

112. Panel boxes arc cabinets arranged to contai" distribution-center

panels or cut-outs and switches for protecting and controlling branch circuits
where they are tapped from a main. It is desirable, in so far as possible, to
group cut-outs in a wiring system; to this is due the popularity of panel
boxes. Originally boxes were made without gutters; their disadvantage
was that it was necessary to carry the entering wires for each branch circuit
to a point opposite their proper cut-out. When the boxes are provided
with suitably-proportioned gutters (Code Rule 26, o) (now the usual fornOi
conductors can enter the gutter at the most convenient point and can be
carried in the gutter to a point opposite the cut-out. This arrangement
results in material savings, particularly in conduit work.
Panel boxes may be either of the surface type, which extends wholly
beyond the wall, or of the flush type, which does not extend beyond the wall.
Surface-type boxes are used principally for factory wiring and for conduit
installations in old buildings.
Panel boxes pf sheet steel are suitable for factory work. The barriers in
boxes with wooden gutters, are usually of slate or marble. The inside of a
wooden box must bo completely lined with a non-combustible insulating
material. Slate or marble 0.25 in. (0.04 cm.), thick, or asbestos board 0.125
in. (0..32 cm.) thick may be used. Where iron conduit enters a box, the lining
may be of either 0.25 in. (().()4 cm.) slate or marble, of 0.125 in. (0.32 cm.) as-
bestos board or of 0.0()2 in. (0. 1(3 cm.) galvanized or painted sheet steel. Hoxeg
should be painted inside and out. An asbestos or steel lining is preforabla
because slate or marble breaks easily. The door should close against a rabbet
in order to be dust tight. Glass panels, 0.125 in. (0..'}2 cm.) thick, may be used
5n the doors. A 2-in. (5.08 cm.) space should be provided between the fuses
and the door.
1110
 INTERIOR WIRING Sec. 13-113

113. Cost of interior wirinj^. Prices of labor and material differ in

various localities and at different times. It is, therefore, difficult to state
even approximately what the cost of interior-wiring systems should be.
In large cities, these variations are not extreme and it is possible to state the
limits within which the cost, expressed in terms of the usual contractor's
price per outlet, should lie. The approximate figures given below apply to
interior wiring of all classes, from the small residence to the large hotel or
office building. They cover the portion of the work from the main source
of supply, assumed to be at the building line. In case the building is lighted
from its own plant, these figures will apply to the portion of the installation
lying between the lamp and the plant switchboard. No lamps, fixtures or
reflectors are included in these prices:
Exposed wiring, $3.00 to $5.00 per outlet. The data are based on large-
city material and labor conditions for the year 1919, the pay rate of a
journeyman wireman being $8.00 per 8-hour day. For other conditions
the costs should be modified accordingly.
Wire in metal raceway, $5.00 to $$7.00 per outlet.
Concealed knob and tube wiring, $3.50 to $4.00 per outlet, with $1.00
added per switch outlet.
Wiring in iron conduit and in nejv buildings, $8.00 to $11.00 per outlet.
Wiring in iron conduits in concrete buildings, $9.00 to $12.00 per outlet.
In the above, switches and base-board plugs are considered as outlets
when the iron box is included. If the switch and plate are also to be fur-
nished, approximately $1.00 per outlet of this nature should be added. For
the larger installations in modern buildings the price of $9.00 per outlet,
including all wiring and feeders up to the lighting fixture, has been found to
be a fairly close figure.
114. Estimating costs of conduit installations. The Treasury
Department of the United States uses the following method for computing
the material required for conduit wiring in federal buildings. (Nelson
S. Thompson, Electrical World, Sept. 9, 1911.) The material is taken off
accurately from the drawings. The total amounts of conduit and wire are
the lengths scaled from the plan plus the following: Number of ceiling outlets
X2 ft.; number of bracket outlets X 10 ft.; number of switch outletsy. 10 ft.;
number of baseboard outlets X 4 ft.; number of two-gang sivitches X 15
ft.; and number of three-gang switchesX20 ft.

116. Cost per foot for installing flexible steel-armored conductor

(Bx) (Fig. 6) is, for the No. 14-wire size: 10 cents per foot for lalaor and
10 cents per foot for material making a total cost of 20 cents per foot installed
complete.
116. Cost of pulling wire into conduit. The figures are based on the
same labor and material conditions as those outlined in Par. 122.

A. W. G.
Sec. 13-117 INTERIOR WIRING

117. Labor cost for roughing in outlets. The figures are based on
same labor and material conditions as those outlined in Par. 122.

Fitting
 INTERIOR WIRING Sec. 13-122

35
§5

a o

"_3
.5*
73 —

Ol

O S
CO 9
Sec. 13-123 INTERIOR WIRING
123. Percentage increases of certain wiring materials since 1914-
1916. This table was compiled in January 1920, (see Electrical Review,
Jan. 3, 1920).

Material Per cent,

increase

Batteries, dry 75
Cabinets and cut out boxes. 80
Conduit, interior 100 to 150
Fiber 50
Fittings, conduit 80 to 200
Fuses 25
Panelboards 80
Receptacles, flush. 50 to 70
Sockets 50 to 75
Switches, knife 50
Switches, snap 50 to 100
fLamp cord 100
Wire \ Rubber-covered 55 to 85
i
Weatherproof 100

124. A typical estimating sheet which illustrates the method used in

practical interior-wiring estimating is reproduced in Fig. 24. Labor and
material costs are computed on a unit basis. Sheets much more elaborjite
than that illustrated are in use but for the average condition it will satisfy
every requirement.
PEOTECTION
128. General principles regarding the use of fuses. Fuses or some
other form of overload protection should be used where the protection of
conductors or appliances against overload is desirable. The National
Electrical Code specifies (Rule 23) in detail as to their application. Constant-
potential generators should be protected against overload by fuses or their
equivalent. Single-pole protection is acceptable under certain conditions
for direct-current generators. Fuses shoula be placed at every point where
a change is made in the size of wire, unless the fuse on the larger wire is of
such capacity that it will protect the smaller one.
Fuses must be inserted in all ungrounded service wires, and must be
located in an accessible place as near the entrance to the building as possible.
In grounded-neutral three-wire systems, the neutral wire is not fused.
No group of small receivers, whether motors, incaiidescent lamps or heating
appliances, requiring more than 060 watts should in general depend on one
cut-out. For theatre wiring, outline lighting, signs and large fixtures
1320 watts may be dependent on one cut-out; Code Rule 23d. The rated
capacity of a fuse protectins any wire should not exceed the safe carrying
capacity of that wire as specified in Par. 27. Each wire for a motor circuit,
except at a switchboard, should be protected by a fuse whether or not cir-
cuit-breakers are uaed, except where the motor is of such large capacity that
fuse protection cannot be obtained, in which case it is only possible to use
circuit-breakers.
126. Fuses vs. circuit-breaker. Fusoa possess a time element of opera-
tion (.=ee Fig. 2,'>) which circuit-breakers do not have unless specially
designed therefor. Due to this property, fuses delay the opening of an
over-loaded circuit, where the operation would be practically instantaneous
with circuit-breakers; fuses, then, may bo preferable for motor circuits and
for circuits that are subject to very brief overloads, especially where expert
supervision of electrical apparatus is maintained, as in large mills and fac-
tories. Where there are many fuse replacements, the cost of fuse renewals
is considerable.
Circuit-breakers can bo reset in less time and with less trouble than is
required to replace blown fuses, and no spare parts are required. Circuit-
breakers may, therefore, be preferable where the time saved by their use
is an important consideration. The first cost of the circuit-breaker equip
ment is much more than the cost of fuse equipment, but under severe servi.
the circuit-breakers will prove less expensive in the end.
nil
INTERIOR WIRING Sec. 13-127
Sec. 13-128 INTERIOR WIRING

since the voltage thus imposed will be twice that for which the equipment
was designed.
128. Alternating-current, low-voltage, secondary circuits must be
grounded. This is the recommendation of the Code rule 156 and is the
practice of progressive central-station companies. Grounding minimizes
accidents to persons and damage, by fire, to property. If some point of a
low-voltage secondary circuit is grounded, no point of the circuit can
rise above its normal potential (except under unusual conditions) in
case of a breakdown between primary and secondary windings of the trans-
former, or of other accidental connection between the primary and secondary
circuits. See the Code for further information regarding grounding.
The ground connection should be made at a neutral point or wire if one is

TransformerB^ Secondaiy Windings

.»iiO-j<L_iiu„
^ Vol titT^ Volt
' ^620 Vo

Single-Phase Three-Wire
110 Volts 110-220 Volts-

Transformera-.

Three-Phase Delta Connection Ihrcc-Phnse Star or Y- Connection

Fio. 26. —Ground connections to secondaries of commercial transformers.

accessible. Where no neutral point is accessible, one side of the secondary
circuit may be grounded {Code rule 156). Fig. 2C illustrates how some of
these connections are arranged with commercial transformers. The neutral
point of each transformer feeding a two-phase, four-wire secondary, should
be grounded, unless the motors taking energy from the secondary have

frtts or Water
Pipe

Ground on a Conduit System Ground on a Metal Raceway System

Fig. 27. —
Methods of grounding.
center or
interconnected windings. Where they are interconnected, the
neutral point of only one transformer is grounded. No primary windings
of each transformer
are shown in the illustration and the secondary winding
is shown divided into two sections, aa in
commercial transformers.
129. All metal conduit and metal raceway systems must be
grounded by attaching an approved clamp (there are many
(see Fig. 27),
connecting u
on the market) to a conduit or raceway of the system and
on the sirtci
with a ground wire to another clamp attached to a water pipe
1110
 INTERIOR WIRING Sec. 13-130

side of the meter. The wire must be soldered in the clamps. All parts
of the conduit or raceway system must be in good electrical contact. In
an ungrounded system of conduit, "sneak" currents are possible. These
leak from one wire to the conduit through an abrasion of insulation and reach
the other side of the Une through another ground. The resistance of the path
may be sufficient to hold the "sneak" currents below the line fuse capacity,
and yet these currents may be sufficient to start a fire. Grounding the
conduit also eliminates the possibility of electrical shock to persons coming
in contact with the conduit. In combination fixtures the gas pipe should
be in thorough electrical contact with the conduit or raceway system at
each outlet box.
Wire for grounding ordinary conduit or raceway runs must be of copper
or of other metal which will not corrode excessively {Code Rule \5A}) at
least No. 10 A. W. G. gage, where the largest wire contained in system is
not greater than No. A. W. G. gage; it need not be greater than No. 4
A. W. G. gage where the largest wire contained in conduit is greater than No.
A. W. G. gage. Service-conduit ground wires shall be not less than No. 8
gage copper. AH ground wires must be protected from mechanical injury.

MISCELLANEOUS
130. bell signal work in dry places is usually No. 18 copper,
Wire for
double-cotton-covered and paraffined. Where more than two or three
bells or similar devices are connected to the circuit, or where the circuits are
long. No. 16 wire should be used. No. 14 is frequently used for battery
wires. Rubber-covered, twisted-pair wires, Uke those employed for interior
telephone wiring, can often be used to advantage in damp places or where
the circuits are exposed. No. 20 wire, although sometimes used, is too small
for reliable work. Annunciator and twisted-pair wire is made with insulating
coverings of different colors, so one can be selected that will match the
surroundings, and be inconspicuous. Cables of annunciator wire, which
can be obtained with practically any number of conductors from 2 up to
200, are very convenient and economical for large installations. In perfectly
dry locations, a cable having a paraffined, braided-cotton covering can be
used, but if it is to be exposed to dampness a lead-covered cable should be
installed. By having the cable conductors covered with braids of different
colors, the conductors can be readily identified. A kind of weather-proof
wire called "damp-proof," is quite satisfactory for exposed wiring in damp
places. It is more expensive than annunciator wire, but it has a better appear-
ance when installed. Seethe National Electrical Code, the "Telephone" section
in this book and the Western Electric Co. catalogue for further information.

Vibrating flefl Closed

Circuit Closing Springs
Continuous Circuit Springs
_Kinging Open Circuit
Bell
Battery
nf
Circuit \\
Switches ,
M
Closed Circuit System
Open Circuit System with Two Alarm Circuits
Fia. 28. — Burglar-alarm system.

131. Telephone wiring may follow the practice of the central-exchange or

he intercommunicating system. In the former, single pairs of wires radiate
rom a switchboard to
all stations. In an intercommunicating system, a
-able of twisted pairs of insulated wires extends continuously through all
he stations.
I
This cable must contain at least one more wire than there are
tations (Sec. 21). Conductors of No. 25 A.W.G. have been used; also
>o. 22 and No. 19, according to transmission requirements (Sec. 21).
i 138. Kre alarm wiring should be very carefully and substantially in-
tailed. As a general proposition, the wires should be heavier than would be
sed in ordinary signal practice; nothing smaller than No. 14 should be used
i^)ors and nothing smaller than No. 8 out of doors. For interior lines, rubber-

1117

It
Sec. 13-132 INTERIOR WIRING

insulated copper should be used, while for outside construction, weather-

proof copper wire is satisfactory. The simplest possible arrangement con-
sists of an alarm gong connected to a battery and a group of single-polo
switches that are normally open. In case of fire one of the switches is closed,
and the alarm rings until it is stopped.
Burglar-alarzn systems (see Fig. 28) may be divided into two general
Automatic
TwoButtonV, Burner
^
Key
Spark Gap BumeTl

Condenser

Series System
Conuectiou Strip
Ground on
Gas Pipe Multiple System
Fig. 29. —Electric gas-lighting circuits.

classes: (l)The open-circuit system, in which the circuits for the protected
doors and window.? are normally open, and when a circuit is closed by the
opening of a door or window, an alarm is sounded. (2) The closed-circuit system
in which the alarm is sounded by the opening of a circuit normally closed.
Open-circuit systems are simpler, but closed-circuit systems are more

ibrating Bells

[Hall, Dining : Point Buttons

I
Room or Rear
-Door Push
Button i—Batteries^-i-
-^i:

2-Line Ketum Call

Special 3 Point
2TlJattc>r!cs,
01 Xletum Call-Uuttons

Front Doojc
IFusL Buttons

Ldooi Opener

Hi|i^
A Common Battery Drops
Bell wiring in an Simple Aauunciatoj; Circuit
Aputtmont Ilouso C
Using a Single Battery
FlQ. 30. — Typical electric bell and annunciator circuits.

sensitive and provide better protection; in the latter if the circuit is openet
at any point, the alarm is sounded. Annunciators and burglar alarm htting:
protectioi
to be used in connection with either system are obtainable for the
of doors, windows, shades, transoms and locks. See the "American l^lectn
dans' Handbook."
1118
 INTERIOR WIRING SeC 13-133

133. Electric gas-lighting wiring (Fig. 29) may follow the multiple
system or the series system. In the multiple system a spark is made by the
breaking of an electrical circuit containing a reactance coil. One aide of the
circuit is usually grounded on the gas pipe. Electrically equipped burners of
many types are obtainable. Certain spark coils are equipped with relays
which sound an alarm if the system becomes short-circuited. Open circuit
cells are used, a battery of 6 Leclanche cells in combination with a spark
coil being usually sufficient.
In the series system, a spark gap is installed at each burner. The spark
may be fed from induction coils or from frictional or static machines. The
series system may be best adapted to large auditoriums, where many
lamps are used in groups. It is now seldom used because such places are
almost invariably Eghted with electricity. See the " American Electricians'
Handbook."
134. Electric bell and annunciator wiring. The possibilities for differ-
ent circuit combinations are almost numberless. Those shown in Fig. 30
are typical. Two ordinary vibrating bells will not work well together in
series; so when it is necessary to connect two bells in series, one should be a
single-stroke bell. A multiple arrangement is preferable. The best arrange-
ment of battery cells may be determined by trial. An ordinary bell requires
about 0. 1 amp. for its operation. Return call-bell circuits {B, Fig. 30) are so
arranged that, when a station is signalled, the party called can respond by
pressing his button. Ground return circuits may be used but are undesirable.
Continuous- ringing bells are so arranged that, when the button is pressed, the
bell continues to ring until reset. For elevator annunciators a cable is used,
having as many conductors as there are buttons and one additional battery
wire. If two annunciators are to operate simultaneously, their drops should
be connected in series. See the "American Electricians' Handbook" for
further information.

BIBLIOORAPHT
136.Selected literature on electric wiring.
AuERB.^CHER, Louis J.
McGraw-Hill Book Co., Inc.
—
"Elcctrical Contracting." New York, 1910.
Cook, A. L. —
"Interior Wiring." John Wiley & Sons.
Croft, Terrell. — New York, 1917.
"American Electricians' Handbook." New York,
1920. McGraw-Hill Book Co., Inc.
Croft, Terrell. —
"Wiring For Light & Power." McGraw-Hill Book
Co., Inc., New York, 1920.
Croft, Terrell. —
"Wiring of Finished Buildings." McGraw-Hill
Book Co., Inc., New York, 1920.
CusHiNG, H. C. Jr.,
—
"Standard Wiring For Electric Light & Power."
New York, 1918.
—
Horstman, Henby C. and Tousley, Victor H. "Modern Electrical
construction," 1913. "Modern Wiring Diagrams and Descriptions for
Electrical Workers," 1914. Fred J. Drake & Co., Chicago.
—
Montgomery, J. H. "Electric Wiring Specifications." D. Van Nostrand,
New York, 1915.
—
MoxEY, L. W., Jr. "The Electrical Contractor." McGraw-Hill Book
Co., Inc., New York, 1915.
—
McGraw-Hill Book Co. "Wiring Diagrams of Electrical Apparatus
and Installations." New York, 1914.
—
National Fire Protection Association. "National Electrical Code."
New York 1920
Poole, Cecil P.
New York, 1906.
—
"The Wiring Handbook." McGraw-Hill Book Co.,
Sharp, J. M. — "Practical Electrical Wiring." D. Appleton & Co., New
York, 1916.

1119
>
 SECTION 14

ILLUMINATION
BY PRESTON S. MILLAR
General Manager, Electrical Testing Laboratories; Past'-President, Illuminating
Engineering Society; Member, American Institute of Electrical
Engineers, etc.

CONTENTS
(Numbers refer to Paragraphs)

PEODUCTION or LIGHT
General Theory of Light Production 1

CHARACTERISTICS OF ELECTRIC LAMPS

Incandescent Lamps 19 General Characteristics of Arc
Carbon Filament 33 Lamps 84
Tantalum Filament 46 Carbon Electrode Arc Lamps 88
Tungsten Filament The Flame Arc Lamp 97
Vacuum Type 47 Long- Burning Flame Arc Lamp 102
Type
Gas-Filled 73 Metallic Electrode Arc Lamp 108
Tube Lamps 116

ACCESSORIES FOR ILLUMINANTS

General Principles 130 Indirect Lighting 154
Reflectors for Industrial Lighting 140 Semi-Indirect Lighting Units 158
Reflectors for Commercial Light- Accessories for Special Purposes 165
ing 148

ILLUMINATION CALCULATIONS
General Considerations 171 Calculation of Illumination In-
Computation of Total Flux or tensity 185
Mean Spherical Candle-Power 173 Coefficients of Utilization 188
Computation of Zonal Flux 180 Brightness 205.

APPLIED ILLUMINATION
Fundamentals of Vision 207 Methods of Illumination
Characteristics of Illumination
Physiological and Psychological
Effects of Illumination 223

PHOTOMETRY
Fundamental Principles 252 Portable Photometers 281
Standards of Luminous Intensity 260 Spectrophotometers and Color-
Photometers and Photometric imeters 286
Apparatus 265 Photometric Adjuncts 288
Integrating Photometers 279 Photometric Testing 297
BIBLIOGRAPHY, 303

1121
) SECTION 14

Illumination
, ,n...uw>i. PRODUCTION OF LIGHT
^^6kneral theory of light production
1. Light may be defined as radiant energy of those wave lengths to
which the human eye is sensitive. Energy, of a nature with which the
problem of light production is concerned, is radiated through a number of
octaves forming the spectrum. The human eye is stimulated to vision only
by that radiation which is between wave lengths 0.76yu and 0.38/*, or one
octave. Oi =0.001 mm.) The limits of visibility are not definitely
fixed, but those given are reasonably typical.
2. Incandescence is that process of light production, classed as tempera-
ture radiation, in which a body, usually a solid or a liquid, produces light
without altering its nature in
the process. The spectrum
of such radiation usually is
continuous.
3. Pure temperature
radiation is not completely
realized in ordinary light
sources, but it characterizes
the theoretical "black
body" which radiates the
maximum possible energy at
all wave lengths (Fig. 1).
According to the Stefan-
Boltzmann law, the total
radiation of such a body is
proportional to the fourth
power of its absolute tem-
perature
(1)
 ILLUMINATION Sec. 14-6

where
J = radiation intensity; C «= constants;
e = temperature in deg. abs. and e = logarithmic base
Curves of radiation from a black body, computed according to this law,
appear in Fig. 2.
6. Perfect black-body or
temperature radiation is not
found in artificial illuminants.
Among incandescent electric
lamps it is approached —
most
closely by "untreated" carbon-
filament lamps (10-watt, 110-volt
and 50-watt, 220-voIt types) in —
lesser degrees by " treated "-car-
bon, " metallized "-carbon and
tungsten-filament lamps. The
carbon filaments depart from a
black body less than does plati-
num, for which a displacement-
law constant (Par. 4) of 2630 has
been found.
6. Gray-body radiation is
distributed throughout the spec-
trum in the same proportions
as black-body radiation, but is
everywhere less intense. It dif-
fersfrom black-body radiation in
quantity, not in quality.
7. Selective radiation is dis-
tributed differently throughout
the spectrum and does not obey
the laws of black-body radiation
Sec. 14-9 ILLUMINATION

metallic-flame) arc-lamps are examples pf this method of light production.

Radiation by luminescence may be strongly localized in a few lines of the
spectrum, as in the mercury-vapor lamp (Fig. 4), or may be distributed so
generally as to approximate, for many illuminating purposes, a continuous
spectrum. It usually manifests more pronounced selectivity than is found
among incandescent solids. Unlike temperature radiation, luminescence
is characterized by fixed spectral distribution of radiation, this being \tl-
dependent of the intensity of the excitation.*
Green
Violet Blue Yellow

.40/1 Aif. .55/4 .58/1

Fig. 4. —Visible spectrum of mercury arc.

 ILLUMINATION Sec. 14-13

the variation of eye sensibility with wave length. If, however, a narro-w
band of spectral radiation be separated and studied, a definite and repro-
ducible ratio between energy and light value may be obtained. And if this
band be selected from the part of the spectrum where the light value is highest
(say 0.55/1), the minimum possible mechanical equivalent of light will
result. Ives,* having compared with his own the experimental data and
calculations of other investigators, has assigned the value of 0.02 watt per
mean spherical candle, or 0.0016 watt per lumen, as the most probable
mechanical equivalent of yellow-green light, to which the eye is most sensitive.
With this criterion of light producing efficiency available for the highest
point of the ocular-luminosity curve (Fig. 5), a scale of ordinates for that
curve is established, and the curve yields the sensibility coefficient for
each wave length. This applied to the radiation curve (Fig. 2), gives a
curve of visibility, from which the total illuminating power may be inte-
grated. The value so obtained should equal the candle-power or the lumens
as measured by a photometer. The value of mean spherical candle-power
per watt or of total lumens per watt, when stated in terms of the most
efficient light per watt, yields the "reduced luminous efficiency." (Drys-
dale's terminology.) The table of Par. 13 shows data of this kind baaed
upon Ives' compilation.
13. EfElciency of light production
(Electrical Worid— Vol. LVII, p. 1566)

Per watt Reduced lumi-

Watts per nous efficiencies
mean sph. (based on
c-p. Mean Lumens radiated
sph. o-p. energy)

Per cent.
Yellow-green 0.55/i 0.02 65 800 100
Firefly
Black-body, about 5,000 10 125 15
deg. abs.
Ditto, excluding energy 22 274 34
outside limits 0.76m to
0.38/1.
Ditto, excluding energy 26 330 41
outside limits 0.70/t to
0.40/1.

14. In "reduced luminous eflaciency" (see Par. 12) we have a very

practical measure of efficiency of light production, because for any illuminant
the ordinary commercial rating is directly comparable with the standards
of highest possible efficiency. With this system of rating, everything de-
pends upon the correctness of the standard of light production. But it
may be noted that all artificial illuminants are so low in efficiency that a
considerable error in fixing the standard would not alter materially the
conclusions as to the inefficiency of illuminants. Standards for this pur-
pose appear in Par. 16.
'
16. White-light efficiency. "Reduced luminous efficiency" (Par. 14)
is the light flux per watt in per cent, of the yellow-green flux obtained from
' 1 watt radiated at 0.55/». Such yellow-green light would be undesirable
' for most illuminating purposes. The generally accepted ideal is white light.
- ivest has proposed the radiation between 0.70/i and 0.40^ from a black body
It 5,000 deg. abs. as a standard of white light, and has assigned 330
. umens per watt as the most probable value of the most efficient white light
)btainable. This is a satisfactory criterion for illuminating purposes. IvesJ
•:
ilso has studied the spectrophotometric curves of some of the common in-

f -iandescent sources to ascertain what proportion of their light is available to

' •Luminous Efficiency, Trans. I. E. S., Vol. V, p. 113: Hyde, Forsythe and
.3l«iy, Phys. Rev., Vol. XIII, p. 45.
fl :
\ Electrical World, Vol. LVII, 1909, p. 1566.
I Bulletin, Bureau of Standards, Vol. VI, p. 238.

1125

m.
 Sec. 14-16 ILLUMINATION
form white light. Assuming colored absorbing screens of exactly the desired
values to transmit with minimum loss that part of the radiation of each,
wave length necessary to produce white light, he has shown the "white-light"
or "daylight efficiency" of each source. These values appear in Par. 17.
16. Light-producing efficiencies of certain electric illuxninants
Mean Lumens Reduced
spherical
Light source per luminous
c-p. per
watt efficiency
watt

Per cent.
Radiation at 0.55>i 65 800 100
Radiation from black body at 5,000 20 330 41
deg. abs.
and
—
excluding that outside
0.4/i.
0.7m
—
Mazda vacuum lamp 1.0 w.p.c. 0.78 9.8 1.2

— ——
. .

Mazda gas-filled lamp1000 watts. 1.53 19.3 2.4

Magnetite-arc 4.0 amp. ....... 0.85 10.7 1.3

——
.
-xi
Flame-arc 10-arap. white-light 1.4 17.6 2.2
carbon approximate.

17. White-light efficiencies of incandescent lamps

Per cent, of
Watts per White- ;

White- most efficient

Lamp mean Lumens li^ht
light
white-light
spherical per watt lumens
efficiency (330 lumens
c-p. per watt
per watt)

Per cent. Per cent.

Carbon. . . . 4.85 2.59 7.6 0.195 0.06
Carbon. . . . 3.75 3.35 8.6
• 0.29 0.09 il
Gem 3.10 4.05 10.0 0.405 0.12
Tantalum. 2.60 4.83 10.0 0.485 0.15
Tungsten... 1.56 8.05 13.7 1.10 0.33

'
18. Physical and physiological aspects of white light. Both ill
standard of white-light efficiency and the values shown for common ilium
nants are values for continuous-spectrum light from incandescent sourcM
That is to say, this method provides only for true white light, which!
satisfactory physically as well as physiologically. Light produced b
luminescence, which has a line spectrum, may be accepted as white in
physiological sense, but may fail to serve for certain illuminating purpose
where true white light is required. It is doubtful if such light should I:

compared with true white light upon the same terms. At any rate notatio
should always be made of the peculiarities of spectral distribution of sue
light.

CHARACTERISTICS OF ELECTRIC LAMPS

INCANDESCENT LAMPS
19. Incandescent electric or glow lamps produce light by process <

incandescent or temperature radiation. Hyde* has estimated that

operated at the same true temperature, the several filaments, due to favoi
aole selectivity, would be more efficient than untreated carbon, which
least selective. Relatively these efficiencies are as follows: untreatc
carbon, 100 per cent.; tantalum, 110 to 112 per cent.; tungsten, 125 to 1.
per cent.
20. The resistance characteristics of the more common types are shov
in Fig. 6,t where 100 per cent, corresponds with the standard rated efficient

• Lectures on Illuminating Engineering, I. E. S.—Johns Hopkins Universit

t Lewinson. Modern Incandescent Lamps
" —School
" of Mines Quarterl
Vol. XXXIII, April, 1912.

1126

I
ILLUMINATION Sec. 14-21
Sec. 14-23
ILLUMINATION Sec. 14-25
 Sec. 14-26 ILLUMINATION
26. Commercial ratings
(February, 1920)

Initial rated values

)
 ILLUMINATION Sec.l4r-29

range of flicker as the frequency is increased; and the morie marked flicker
when the finer-filament lamps are operated at a given frequency. They
indicate that the tungsten lamp is less adaptable for use upon low-frequency
currents than the carbon lamp.
Experience indicates that while lighting from 25-cycle circuits is satis-
factory for many purposes, yet is not entirely satisfactory for all classes of
service with all sizes of lamps. This frequency appears to be just a little
too low to be generally acceptable. j

60

50
Sec. 14-31 ILLUMINATION
31. BritrhtnesB of light sources*

Candle-
Source power per Lamberts
sq. in.

Crater, carbon arc 84,000 40,900

Magnetite arc 4,000 1,950
Nernst glower (115-vblt, 6-amp. d.c.) 3,010 1.460
Incandescent lamps:
Tungsten, 1.25 watts per candle 1,060 516
Grapnitized carbon filament, 2.5 watts
per candle 750 365
Tantalum, 2.0 watts per candle 580 283
Carbon, 3.1 watts per candle 485 236
Carbon, 3.5 watts per candle 400 195
Carbon, 4.0 watts per candle 325 158
Acetylene flame (1-ft. burner) 53 26
Acetylene flame (j^-ft. burner) 33 16
Welsbach mantle 31 15
Welsbach (.mesh) 66 27
Cooper-Hewitt mercury vapor lamp 14.9 7.3
Kerosene flame 9.0 4.4
Gas flame (fisntail) 2.7 1.3
25-watt frosted tungsten lamp:
Tip 1.67 0.8
Side 6.0 2.9
Additional data:t
—
Flaming arc clear globe
Tungsten filament of gas-filled lamp
2,435
1,400

Candle flame
—
Mercury vapor quartz tube 487-292
1.5-1.9
Sky—daylight hours:
With light clouds 2.0
Clouds predominating, generally cum-
ulus 1.9
Blue predominating, clouds cirus 1.5
Cloudless, blue or hazy I
1.0
Cloudy, storm near or present i
. 7 or less

32. Life performance for the various lamp types is treated in Pars. 33
to 83. In general, however, the life is variable to a marked degree, and it
is necessary to consider averages of large groups of lamps rather than the
performance of a few samples before drawing conclusions concerning values.
Also it is to be borne in mind that the only generally applicable statistics
of performance are those obtained in a laboratory under reproducible an^
ideal conditions of operation. In service the performance may vary largelsj.
All performance data given herein must be qualified to the extent that they
may not be strictly appHcable to a given set of operating conditions.
CABBON-FILAMENT LAMPS
S3. Classification. Carbon-filament lamps may be classified according
to filament characteristics under "untreated" (Par. 34), "treated" (Par. 36)
and "metallized" (Par. 44) lamps.
34. Untreated carbon filaments are now employed principally in sign
lamps of tne 10- and 20-watt .sizes of the 110-volt range, and in lamps of
the 220-volt range. As the filament has a higher resistance, it is shorter
and may be disposed in a small bulb, where the longer treated filament can-
not be utilized. As they are capable of only 30 to 10 per cent, of the useful
life of treated-filament lamps, they are operated at a lower eflficiency and
are used only where necessary.

• Ives and Luckiesh. Electrical World, February 16, 1911.

t "Illuminating Engineering Practice," I. E. S., Univ. Penn. Lectures,
1916.

1132
 ILLUMINATION Sec. 14-35

35. TTntreated carbon-filament lamps

Specific con-
Commercial Specific
Rated i Mean rating, watts
sumption,
output,
Average
and hori- Total watts per total
per mean lumens
average
I

zontal lumens horizontal

mean per
life,
watts c-p. spherical hr.
c-p. watt
c-p.

105 to 125 volts

10 2.0 21.2 5.0 2.12 2,000
20 4.8 51.2 4.15 2.56 1,000

200 to 260 volts

35 7.95 84.0 4.40 5.24 2.40 1,000
60 16.26 170.4 3.69 4.40 2.84 750
120 32.52 340.8 3.69 4.40 2.84 750

36. The treated carbon filament (having a coating of graphitic carbon

deposited by flashing in an atmosphere of hydro-carbon vapor) is the stand-
ard carbon filament employed in most lamps manufactured from 1893 to
about 1908. The principal sizes and corresponding statistics appear in
Par. 37.
37. Treated carbon-filament lamps
Specific con-
Rated Mean Commercial Specific
rating, watts
sumption,
output,
Average
and hori- Total watts per total
per mean lumens
average zontal lumens
horizontal
mean per
life,
watts c-p. spherical hr.
c-p.
c-p.
watt

20 4.82 50.4 4.15 5.05 2.52 1,500

30 9.29 96.0 3.23 3.91 3.20 1,050
50 16,83 174.5 2.97 3.61 3.49 700
60 20.20 209.4 2,97 3.61 3.49 700

38. Treated carbon-filament lamps. This form of lamp beginning

with 1894 was the principal illuminant for electric lighting service until dis-
100 aOO 300 400
120

110
Sec. 14-39 ILLUMINATION
and blackened bulb and the consequent increase throughout life in the watts
per candle.
39. Candle-power performance curves of typical high-grade treated
carbon filament lamps are given in Fig. 10, being a combination of curves
published by several lamp manufacturers from independent tests of their
products.
i Hoars
300 400

Fia. 10. —Candle-power

group
performance throughout useful
of treated carbon-filament lamps.
life of a typical

iO. Candle-power deterioration throughout life is due in approximately

equal parts to decrease in watts occasioned by increase in filament resistance,
and to increase in absorption of light due to bulb blackening.

r
p;100
 ILLUMINATION Sec. 14-42

42. Performance on direct current compared with alternating

current. So far as is known there is no material difference between the
performance of carbon lamps on direct current and on 60-cycle sine-wave
current.
43. Status of carbon-filament lamps. By reason of their ruggedness
and low cost, treated carbon-filament lamps continue to command a con-
siderable sale. Where theft or breakage is apprehended, or when cost of
power is very low, carbon-filanfent lamps may often be used to advantage.
In 1919 all forms of carbon-filament lamps aggregated about 7 per cent, of
the total incandescent lamps sold in this country.
44. Metallized cswbon filament (Gem) lamps are so called because the
temperature coefficient throughout the ordinary range is positive. As the
specific resistance of the filament is lower than that of the treated carbon
fUament, a longer, finer and therefore more fragile filament is necessitated.
This lamp is about 20 per cent, more efficient than the treated carbon-
filament lamp. Being inferior to the treated carbon-filament lamp in
ruggedness and inferior to the Mazda lamp in efficiency, it was practically
abandoned in 1918 after having served*a useful purpose in bridging the gap
between the carbon and tungsten filament lamps.
Sizes of metallized carbon-filament lamps ranged up to 100 watts. Effi-
ciencies were of the order of 4 lumens per watt with a total average life of
about 700 hr.
45. Relative annual demand for incandescent lamps of various
types. Fig. 12 depicts tne nistory of sales of various types of incandescent
lamps as reported by the Lamp Committee of the National Electric Light
Association. The metallized carbon-filament (Gem) lamps which filled an
appreciable share of the demand in 1907 were employed principally by cen-
tral stations in their customers' ser\'ice. The final abandonment of the
kmp in 1918 was brought about by the necessity for eliminating inefficient
hunp.s during the war. The growth of the tungsten filament (Mazda) lamp
lias been consistent from the start, a dominating position having been
a tuined in 1912.
100

90
Sec. 14-47 ILLUMINATION
imported by American manufacturers who placed the lamp upon the market
in 1906. Sizes ranged from 25 to 80 watts. Efficiencies were of the order
of 5.5 lumens per watt. The average life of 40-watt lamps on direct cur-
rent was about 600 hr.

TUNOSTEN-FILAMENT LAMPS (VACUUM TYPE)

47. Early processes of filament manufaRture. The earliest successful
manufacture of tungsten-filament lamps was in 1906. There were three
pioneer processes of filament manufacture, as follows: (a) that of Just and
Hanaman, who deposited tungsten upon a very fine carbon-filament core
afterward removing the carbon and sintering the tungsten; (b) that of Kuze,
who produced a colloidal solution of tungsten, and after bringing it to a suit-
able consistency squirted it to the desired diameter, and sintered it; (c)
that of Von Welsbach (after the osmium process) who prepared a paste of
finely divided tungsten mixed with an organic binder, and squirted it.
The thread thus formed was reduced and sintered.
48. Early American manufacture. Tungsten-filament lamps were
produced commercially in America early in 1907. These were made by the
Welsbach process. The lamps made by the General Electric Company
corresponded to the Osram lamp as produced by the Auer Company in Berlin.
Those made by the Westinghouse Lamp Company followed the processes
and construction adopted for the Osmin lamp by the Osmium Lamp Com-
pany of Vienna. The earlier styles and sizes in which the tungsten lamp
was made available were complementary to carbon-filament lamps. Thus
the larger sizes of multiple (100-130 volt) lamps were produced beginning
with the 100-watt size for multiple circuits. This most happily introduced
the lamp in a manner which led to gradual and constructive replacement,
of its less efficient predecessors. The development of the smaller sizes fol-.
lowed, as shown in Par. 49.

49. Beginning of commercial use of Mazda lamps in the United

States

Watts
ILLUMINATION Sec. 14-52

100
 t

Sec. 14-54 ILLUMINATION

being sealed into the bulb, the lamp is placed upon the pumps and while
being heated to a high temperature the bulb is evacuated. During the ex- '

haustion process, the passage of current through the filament is reduced to

a minimum. The candle-power of a lamp so produced is slightly lower than .

its rated or initial value. A brief "aging" brings it to or nearly to its true
initial value.
54. Photometry. The process of manufacture has now been stand-
ardized so thoroughly that lamps of standard sizes are made accurately ,

and are not photometered, though samples of each run are usually pho-
tometered as a check upon the manufacturing.
65. Approximate data on tungsten*
Electrical Resistivity at 25 deg. cent.
—
Hard drawn wire 6.2 microhms per cm. cube.
Annealed drawn wire^o.O microhms per cm. cube.
Temperature coefficient of electrical resistivity between deg. and 170 deg.
cent. 0.0051 per degree.

Tensile strength (lb. per

Diameter (in.) Specific gravity
sq. in.)

0.150 19.30
0.005 490,000
0029
. 530,000
0.0015 000,000 20.19

66. Current inrush. Tungsten has a positive temperature coefficient,

and the resistance is relatively low when the filament is cold. This results
in a marked inrush of current when the lamp is lighted. For illustrative
data, see Fig. 14.

3.5
3.0
S2.5
g,2.0
^^'
1.0

.5
 ILLUMINATION Sec. 14-59

69. Classification of principal tungsten vatuum lamps

Sec. 14-61 ILLUMINATION
values ascertained after the lamps have been "seasoned" by burning a
labeled volts for about 1 hr.

37 40 43
Watts
Fro. 15. — Hating of sample 40-watt tungsten-filament lamps.
61. Efficiency Rating: of Mazda (Tungsten) Vacuum Lamps
Rating Total Lumens
(watts; lumens
 ILLUMINATION Sec 14-65
is an arbitrary measure of effectiveness applied by common consent in the
interests of good maintenance of illuminating power. The significance and
the place of the 80 per cent, criterion in life evaluation may be noted in
Fig. 17 which shows that the smaller multiple lamps fail well within the
80 per cent, limit, while the larger lamps continue in service long after the
80 per cent, line has been passed.
66. Life performance. In Fig. 16 typical performance of a 40-watt
Mazda lamp throughout useful life is shown.
This is characterized by a gradual decline in
illuminating power and a gradual decrease in s
watts with corresponding decrease in effi-
ciency.
Mazda lamps when shipped from manu-
factories are only partly "seasoned." In I
this condition the filament resistance is a
little below normal. The resultant higher
watts of multiple lamps is accompanied by
slightly low light output and of course the
eflBciency is low. Operation at labeled volts g looohn.
for about 1 hr. brings the lamps to normal
"initial" condition. This 1-hr. seasoning
t^ .,„
I*iG. 16.
typical
— r, ,
Performance
40-watt Maida
of
process is not shown in the diagram.
66. Life performance; ^"^P-
various sizes
The change in illuminating power and watts. during life is shown in Fig. 17.
In general the rate of decline of light output of Mazda lamps at operating
eificienoies is smaller, but failure occurs earlier in the smaller sizes. In
order to diminish the differ
Sec. 14-69 ILLUMINATION
69. Mortality rate. The diagram in Fig. 18 shows the mortality rate
of 40-watt Mazda B lamps operated at rated initial efficiency upon CO-cycle
current in the laboratory. Each dot indicates by reference to the scale of
abscissse the hours at wnich a lamp failed, and by reference to the scale of
ordinates the approximate illuminating power just before failure. In lamps
of smaller sizes the failures tend to take place after shorter periods of burn-
ing. Among lamps of larger sizes the reverse order prevails.
 ILLUMINATION Sec. 14-74

— at least those —
having stouter filaments is that of avoiding bulb blacken-
ing, which is the life-limiting feature.
The cooling effect of an inert gas decreases the candle-power of the fila-
ment, and in this respect the gas is detrimental. To obtain tne same effi-
ciency as in a vacuum it is necessary to increase the watts and operate the
filament at a higher temperature. On the other hand the gas preesiu-e
reduces the rate of evaporation, and tne convection currents set up within
the bulb, deposit in the upper part of tue bulb such tungsten as may be evap-
orated. The cooling effect is greater, of course, in the case of tne smaller-
diameter filaments. In fact, among the smaller sizes of lamps for multiple
circuits the cooling effect is so great that these do not benefit by this im-
provement. Among filaments which operate at greater current values, the
disadvantage of the cooling effect is more than compensated by the advan-
tages listed above. The stouter the filament the greater the benefit derived
and the higher the efficiency at which it can be operated without decreasing
tne life.
74. Efficiency. The eflBciency ratings of Mazda "C" lamps as of Jan-
uary, 1920, are shown in tne following table. In comparison with other
high-power illuminants it must be remembered that these lamps are rarely
used bare and that allowance must be made for the loss of light in fixtures
—
Efficiency rating gas-filled lamps
Multiple lamps

Watts Lumens Lumens per watt

50 ^white; 450 (approximately)

75 865 11.53
100 1,260 12.57
150 2,040 13.66
200 3,100 15.51

300 4,840 16.11

400 6,700 16.76
500 8,750 17.45
750 13,900 18.48
1,000 19,300 19.33

.'•Series lamps

Nominal
Amperes candle- Lumens Average Average Lumens
volts watts per watt
power

5.5 60 600 8.9 48.7 12.32

80 800 10.9 59.9 13.37
100 1,000 13.0 71.6 13.96
250 2,500 29.7 163.0 15.32
400 4,000 47.4 261.0 15.32
60 600 7.4 49.2 12.20
80 800 9.2 60.5 13.23
100 1,000 10.9 71.6 13.96
250 2,500 23.5 155.0 16.11
400 4,000 37.6 248.0 16.11
600 6,000 56.4 372.0 16.11

7.5 60 600 6.8 50.6 11.86

80 800 8.2 61.1 13.09
100 1,000 9.6 71.6 13.96
250 2,500 21.2 159.0 15.71
400 4,000 33.1 248.0 16.11
600 6,000 48.4 363.0 16.53
15.0 400 4,000 14.9 223.0 17.95
20.0 600 6,000 16.0 320.0 18.76
1,000 10,000 25.9 517.0 19.33
Sec. 14-75 ILLUMINATION
76. Sizes and types. This improvement in tungsten-filament lamps is
applied to multiple 110- volt lamps of 50 watts and larger, to all sizes of
street series lamps of 3.5 amperes and greater, and to low voltage lamps of
1.5 amperes. Its most conspicuous result has been the extension of the in-
candescent lamp into the higher power illuminant field formerly occupied
exclusively by the arc lamp.
The principal types of gas-filled lamps are as follows:
Multiple service
ILLUMINATION Sec. 14-78
 Sec. 14-81 ILLUMINATION

o (8 ot: O
Q, a; ^ ^
S O I

> « a g^-o
^ o o t;j3 a
) O =* 0) . S <u •S ^S,
jo's
-, » O S ~i3
a H a u -^^ -g
.2 " 03 (U— £
fl 2 §
cS-f, ma)"" "3
-a
^J3 O SC a,
o t«2
c c-S

,- 2 ?; i. IB z
S Sj §
f M '-'
o o S
a o o
i> o d dj ri."
§^21

fl-2 9 3 cS «
Ma
«
>
t. n

OJ o
5-

1^

!z a
 I I —

ILLUMINATION Sec. 14-82

83. Mortality rate. The rate of burn-out of 200- watt Mazda "C"
lamps is shown in Fig. 22, each dot indicating time of failure and illuminating
power just before failure.
100
— 1 1 1
ii

I
— 1 1
1

1
1

'
'-
I

y —
.^^
I

^ ^ '_\

u 80

'•
*^ • : •

60
400 800 1200 1600 2000 2400 2800
Hours
Viii. 22. —200-watt Mazda "C" lamps. Time of failure and approximate
light output just before failure.
900 W. 30 A. Motion Picture

83. Miscellaneous forms of tungsten-

filament lamps. In its gas-filled form the
tungsten-filament lamp has been applied to a wide
variety of uses for which the incandescent lamp
formerly has not served satisfactorily. Included
among these are projector lamps for search-
lights and floodhghts and for moving picture ap-
paratus, in all of which forms the lamps are oper-
ated at relatively high efficiencies, yielding rela-
tively short lives.
An illustration of the latest form of motion
picture Mazda "C" lamp is shown in Fig. 23.
84. Miniature lamps. The tungsten fila-
ment gave great impetus to the use of incandes-
cent lamps, in miniature form. Flashlamps,
Christmas-tree lamps, automobile lamps, etc.,
have been developed with pronounced success.
NIore recently the gas-filled tungsten lamp has
iisjilaced and is continuing to displace the
va( uumtype in several miniature classes. Space
Iocs not permit discussion of the miniature lamp,
.vtiichthough a product of tremendous and grow-
iiK importance, yet involves special engineering
eatiires somewhat removed from those of general
ighting practice.
1 he principal classes of miniature tungsten-
ilaiiicnt lamps are as follows: For flash-light
ervice, 0.3 amp.— 2.5, 2.7, 2.9, 3.8 and 6.2 volts;
or service with single-cell dry battery, 0.6 amp.
-15 volts; for service with 2-cell dry battery, 0.8
.II p. —
2.7 to 3.0 volts. For automobile service

"iQ. 23. — Mazda "C" motion-picture lamp.

^ >
Sec. 14-85 ILLUMINATION
Vacuum lamps Vacuum lamps Gas-filled lamps
3 to 4 volts .... 2 c-p
9 volts 18 c-p. 6 to 8 volts.. . 21 c-p.
6 to 8 volts 12 to 16 volts...
2 c-p, 2 c-p. 9 volts 27 c-p.
6 to 8 volts .... 4 c-p. 12 to 16 volts. 4 c-p. 12 to 16 volts..
. . . 21 c-p.
to 8 volts. ... 15 c-p.
6 to volts.
12 to 16 volts. 15 c-p. . .

Candelabra types: 100 to 125 volts, 15 watts; variety of bulbs.

GENERAL CHABACTEKISTICS OF ABC LAMPS

86. The electric arc is unstable on constant-voltage supply because of
its volt-ampere characteristics whereby the voltage decreases as the current
is increased. It is essentially a constant-current device. When used upon
multiple circuits, ballast resistance, if direct-current, or reactance, if alter-
nating-current, must be placed in series with the arc to limit the current.
All arc lamps must be provided with automatic operating mechanisms to
start the arc and to feed the electrodes as they are consumed. In addition,
lamps for series service must be provided with shunt devices which protect
the lamp and maintain the circuit in case the lamp fails to operate.
86. Operating mechanisms usually are actuated by electromagnets or
solenoids, often in conjunction with weights and dashpots or other restraining
device. "Series lamps," having series magnets only, regulate for constant
current in the lamp. " Shunt lamps," employing shunt magnets only,
regulate for constant voltage. The more usual "differential lamp" is
equipped with both series and shunt magnets, and regulates for constant
relation between current and voltage. Much ingenuity has been displayed
in developing feeding mechanisms for arc lamps. Numerous methods have
been employed, among which may bo mentioned the gravity, clutch, rocker-
arm, brakewheel, clockwork, motor and hot-wire .feeding devices. These
applications are described in publications of manufacturers and the principal'
methods are described in text-books.
87. Classification of arc lamps. Arc lamps may bo classified in&i
number of ways according to the viewpoint. The classifications adopted ini
Par. 87 are comprehensive. In the following pages the several types of
arc lamps are discussed in the order indicated. Vacuum tube lamps, which
might be included in this class, are discussed later (Par. 116).

CARBON-ELECTBODE ABC LAMPS

88. The open is now regarded as obsolete.
arc In its most common form
it —
was of the direct-current 9.6-amp. type the old "full arc" to which
the rating of " 2,000 c-p., " was applied in earlier years. The arc is
about fs in. (0.48 cm.) long and of low luminosity. The end of the negative
(lower) electrode, after a few hours of burning, assumes a conical shape and
yields some little light by incandescence. The end of the positive (upper)
electrode becomes concave, and the "crater" thus formed ia the chief source
of light produced by the lamp, the process being that of incandescence.
Only the feeble light from the arc itself is produced by luminescence. The
end of the positive electrode becomes intensely hot, attaining at the hottest
part of the crater to from 3,900 to 4,000 deg. cent.*
89. Photometric and electrical data on direct-current open
carbon arc lamps
" Half
"Full arc"
arc"

Amperes 9.6 6.6

Watts 450 325
Mean spherical candle-power 410 240
Maximum candle-power 900 to 1,200
Specific —
consumption watts per candle 1.09 1.36
Nominal candle-power rating 2.000 1,200

• Weidner <fe Burgess. Bulletin Bureau of Standards, Vol. I, No. 1, 19.

1148
 -

ILLUMINATION Sec. 14-90

90. Light distribution from the open

arc. Fig. 24 shows the open carbon arc*
It willbe apparent at once that the lower elec-
trode obstructs a large portion of the light
emanating from the crater. Thecurvein Fig.
25 shows actual distribution of light cojnpared

Pure
I Carbon

L«r?e White
;Hot Cntter
Bed Hot-
Light Purple- ~PurpIe
Yellowish'' Small White
Hot Crater
Ked Hot^

Lower
f

Pure
Carbon
Fig. 25. —Distribution of light in
I
vertical plane about 9.6-amp. di-
rect-current open arc lamp. Also
estimate of distribution i f obstruc-
tion of lower electrode could be
Fig. 24. — Open carbon arc. avoided.
with probable distribution the lower electrode were transparent, t the dif-
if
ference illustrating the loss of light due to obstruction by the lower electrode.
91.
The open
Electrode life —open arc lamp.
arc lamp suffered from short life
of electrodes, unsteadiness of light, and
poor light distribution. The electrode life
was 7 or 8 hr. and it became common
practice to employ two pairs of carbons, the
second pair to replace automatically the
first pair after these had been consumed,
thereby securing continuous operation long
Red Hot enough for one night. These disadvantages
T rv LiKbt Yellow.
were sufficient to occasion the general
Very Light Purple
abandonment of the open arc lamp in favor
of the enclosed carbon arc lamp which
Bed Hot became available commercially in 1894. t
92. The enclosed carbon arc lamp
differs from the open arc i n that the supply
of air at the arc is restricted, thus retarding
the rate of consumption of carbon, and se-
curing an electrode life of 100-125 hr.; the
arc is about fin. (0.95 cm.) long, requires
from 70 to 80 volts, and adds appreciably
to the violet light produced; the ends of
'iG. 26. —Enclosed carbon
nating-current arc.
the electrodes are nearly flat.
alter- The anode
does not have a marked crater, and does
not become so hot as in the open arc. Less
sht is produced per watt. A representation of the arc of an alternating
-irrent enclosed lamp is given in Fig. 26. § The enclosed arc lamp has been

' B'ake and Couchey. "Arcs and Electrodes," Gen. Elec. Review, 1913
497.
t Trotter. —
"Illumination Its Distribution and Measurement," p. 147.
—
The Invention of the Enclosed Arc lamp L. B. Marks, Sibley Journal
t
Engineering, Vol. XXII, 1907, p. 1.
§ Blake and Couchey. "Arcs and Electrodes," Gen. Elec. Review, 1913,
497.
1149
 ,

Sec. 14-93 ILLUMINATION

manufactured in a wide variety of forms. Some of these with approximate
data are listed in Par. 93.
93. Data on enclosed carbon arc lamps

Auxiliary
si's
0.°° "
m u <o

(« a

Seriea alternating cur- Opal inner and reflector 130 3.30

rent, 6.6-amp.
Seriea alternating cur- Opal inner and reflector 155 3.09
rent, 7.6-amp.
Seriea direct current, Opal inner and reflector 260 1.88
6.6 amp.
Multiple direct cur- Clear inner
rent, 115 volts
—opal outer 165 3.33

Multiple direct cur- Clear inner

rent, 115 volta
—opal outer 240 2.98

Mult i p 1 e alternating Clear inner

current, 115 volts
—opal outer 145 2.97 70 -

Multiple alternating Clear inner

current, 115 volts
—opal outer 190 2.84 70 i

94. Status of enclosed arc lamp. The enclosed arc lamp provef
superior to he open arc lamp in (a) steadiness; (b) characteristic of ligh
distribution, and (c) electrode life. More effort was expended in develop^
ing it and equipping it with suitable glassware and, in the case of alternating
current lamps, with reflectors. In spite of its inefficiency, it prevailed ove>
the open arc lamps, and remained the standard lamp for street lighting unti]
the advent of the metallic-electrode lamp.
98. Efficiency
The
and light distribution —enclosed carbon arc lampa^
efficiency of the arc is lower in the alternating-current type. Both elea-
trodes are raised to a high temperature
but neither attains the high tempera-
ture of the anode in the direct-current
arc. The characteristics of light dis-
tribution from the two types of lamps
appear in Fig. 27. It is general
practice to equip the alternating-
current lamps with a reflector which
directs, below the horizontal, some
of the light which would otherwise
be distributed above the horizontal.
The multiple lamps are less efficient
than the series lamps. A certain
amount of ballast is necessary and this
accounts for the difference between
the line voltage (100 to 120 volts}, and
the arc .voltage (70 to 75 volts). If
the circuit ia for alternating current, a
reactance is employed, which does not
occasion a large wattage loss but
reduces the power-factor. If a di-
rect-current circuit, a resistance is Flo. 27. —
Light distribution
used, which occasion s a direct loss in vertical plane about enclosed
watts. bon arc lampa. A
96. Intensified carbon arc lamps.
The efl5ciency of a carbon arc lamp j

may be increased by diminishing the diameter of the electrodes with agiTM

current or by increasing the current with given electrodes. In intensiul

1150
 ILLUMINATION Sec 14-97

carbon arc lamps the diameter of the carbons is reduced, producing a gain
in efficiency and a light which is more nearly white and steadier than that
of the ordinary enclosed arc lamp of which it is a refinement. Such lamps
are used chiefly for lighting interiors where white light is desired, as in
clothing stores. The intensified carbon arc was developed in Europe and
exploited in small sizes operating at 2 and 3 amp., with an electrode life
of 20 hr. or less. In this country the developments were along the lines of
somewhat larger lamps operating at higher currents and longer electrode
life. IVpioal lamps of this type are somewhat smaller than ordinary enclosed
arc lamps, and are designed for either direct-current or alternating-current
service. Small-diameter electrodes (about 7 mm.) are used, and life of about
70 hr. is realized. With opal globes an efficiency corresponding with approxi-
mately 2 watts per mean spherical candle-power is obtained in the direct-
current lamp. The General Electric Company has developed a lamp of this
type for direct-current service, in which two converging 6-mm. upper-positive
carbons are used with a vertical lower carbon of 9.5 mm. diameter. This
lamp is somewhat larger and more substantially built than other lamps of the
class. The specific consumption when employed with an opal globe is
slightly more than 2 watts per mean spherical candle-power.

THE FLAME ABC LAMP

Short-burning flame arc lamp. The electrodes forshort-burning
97.
flame arc lamps, consist commonly of carbon tubes packed with a mixture
ol carbon and mineral salts. The anode is usually more highly mineralized
than the cathode, in some cases the cathode is pure carbon. As a rule
the electrodes are mounted in an inclined position illustrated in Fig. 28.
Being long and of small diameter a copper wire is sometimes imbedded
in the carbon to add to its conductivity and mechanical strength. The arc
formed between the electrodes is arched
downward by means of a small mag-
net. The arc is formed in a shallow
cup-Uke recess which becomes coated
with oxide which, being white, serves
as a goodrefiector. Theinverted cup
confines the gases and retards oxida-
tion, reducing the rate of consumption,

y Porcelain

Deposit
2000
Pig. 28. — Short-burning flame Fig. 29. -Light distribution in vertical
arc and economizer. plane about short-burning flame arc lamp
with opal globe.

aence it is called the economizer. Fig. 29 shows the light distribution from
!>,typical short-burnmg flame arc lamp equipped with an opal globe. For
inis particular lamp the following data applies: yellow-light electrodes;
imperes, 8; arc volts, 45; total watts, 440; mean spherical candle-power,
,025; watts per candle, 0.43.

98. Nature of flame arc. Impurities in the carbon are detrimental in

arc lamp of types in which the chief light production is accomplished
k
nrough the incandescence of the electrode ends. As carbon is the most

1151
Sec. 14-99 ILLUMINATION
refractory material known, impurities are always more volatile, and their
presence tends to reduce the temperature of the electrode ends. Hence, in
the manufacture of carbons for such lamps, purity is considered of first impor-
tance. In the flame arc, the purpose is to secure light from the arc rather
than from the electrode ends. The carbon is impregnated with chemicals
which, when volatilized and driven into the arc, become highly luminous.
The lower temperature of the carbon ends, due to these impurities, is imma-
terial, since little dependence is placed upon the ends for light production.
The flame arc is simply a carbon arc into which mineralized salts afe intro-
duced. These may bo of calcium, for yellow light; of barium and titanium,
for white light; and of strontium, for reddish light. The carbon electrode
serves as an electrical conductor and assures a hot and steady arc. The
chemicals with which it is impregnated include those which are efficient light
producers, and others whose functions are to promote high arc temperature
and to steady the arc.
99. Theory of light production. The electrode ends, especially the
anode, are brought to a high temperature, vaporizing the carbon and the
metallic salts. The succeeding processes of light production are largely a
matter of speculation at the present time. Some opinion favors lumines-
cence as the process by which light is produced, other attributes it to favor-
able selective radiation from incandescent particles in the arc stream. An
approved theory a.ssumes the chemicals to become dissociated by the heat of
the inner core of the arc (which is known to be hotter than the outer sheath)
and to recombine in the outer sheath with evolution of heat, which tends to
maintain the temperature of the arc. According to this view, the light is
produced by luminous particles in process of combustion, which is a condi-
tion quite similar to that existing in ordinary fiame.
100. Status of short-burning flame arc lamp. In this country the
short-burning flame arc lamp has come into use chiefly for display lighting..
Its maintenance cost has proven too high for most utilitarian purposes.

101. Flame arc lamps of medium electrode life. The obvious inad-
equacy of electrode life of the earlier forms of flame arc lamps led to attempts
to increase that life. Magazine lamps have been devised naving two to ten
sets of carbons, and attaining electrode life of 30 to 40 hr. These, however,
have not come into use in this country. The Jandus lamp devised in Eng-
land and later placed upon the market in this country attains 70 hr. It is
called a "regenerative" lamp, because the gases containing light-giving
chemicals are conveyed from above the arc through external tubes to the
bottom of the globe, again to bo entrained in the arc. The electrodes are
vertically coaxial and special in construction. The specific consumption of
the lamp is about 0.6 watt per mean spherical candle-power.

LONQ-BURNING FLAME ARC LAMPS

102. Approximate electrical data oflong-burning flame arc
one manufacture
 ILLUMINATION Sec. 14-104

The mechanism of an alternating-current enclosed flame arc lamp of one

make is illustrated in Fig. 31.
104. General features. With the development of flame arc lamp? which
have an electrode life of 100 hr. or more, the flame arc has been placed in a
position to compete with other illuminants for street-lighting service. In
this type, electrodes of about \ in. (2.22 cm.) diameter are employed
within a globe which restricts the air supply. It is known as the "long-burn-
ing" or "enclosed" flame arc. Long electrode life is secured at the expense
of some efficiency. For this type of lamp, solid impregnated carbons have
been developed in place of the familiar cored carbons employed in the original
flame arc lamps. These are available in
both yellow and white light forms, the
latter being slightly less efficient. See
Fig. 30.*
106. Electrical characteristics oi
flame arc lamps of one manufacture ap-
pear in Par. 104. To adapt the alternat-
ing-current lamps for use upon various
circuits, compensators are supplied, some-

Faiut Purple
Bright
Yellow
Small White
Hot Crater
Lower
Flarae
Carbon.

Fig. 30. —Long-burning flame arc. Fia. 31.— Mechanism of long-burning

alternating-current flame arc lamp.

Umes built in and sometimes external to the lamp proper.

_
106. Efficiency values may
be stated only in a general way. The effi-
ciencies of carbons of different makes vary. Also the efficiency of a given
make of carbons varies when used in lamps of different makes. Approximate
values for these lamps are indicated in Par. 107, but the data should be
applied in a qualified way.
107. Efficiencies of 10-amp. long-burning flame arc lamps with
"white" electrodes are as follows: Mean spherical candle-power, 700;
watts, 520; watts per mean spherical candle-power, 0.74.

THE METALLIC-ELECTRODE ARC LAMP

108. Nature of arc and electrodes. Tins lamp differs radically from
other arc lamps in that light is produced by luminescence of vapor brought
into the arc stream by electro-conduction from the cathode. The arc of one
form of this lamp is illustrated in Fig. 32. t The cathode consists of magnetic
:oxide of iron with titanium as the chief light-giving element, and other
ingredients to serve as steadiers and vaporization retarders. The anode is of
copper.
• The arc is fixed, and a small reflector is located advantageously
inithin the lamp, directing downward and outward much of the light which

* Blake and Couchey. "Arcs and Electrodes," Gen. Elec. Review, 19,31
P, 497.
t Blake and Couchey. Gen. Elec. Review, 1913, p. 497.

73 1153
1
 Sec. 14-109 ILLUMINATION
emanates from the sure in a direction above the horizontal. The metallic
electrodes are maintained at a relatively low temperature, and the arc will
not re-establish itself every half cycle as with hot carbon electrodes. This
limits the lamp to operation upon direct current or rectified current.

\
+ Solid Copper
Small Crater

Smoke <— Smoke

Very LiRht Yellow Vapor- Bluish White

Intensely White Intensely White

Large Molten Pool

Fia. 32. — Magnetite arc.

109. Metallic electrode lamps for series circuits

Approximate
Type
Amperes Volts Watts

4.0 75-80 310

Magnetite 5.0 75-80 400
6.G 75-80 510
Metallic flame. 4.0 73 290

110. Candle-power and efficiency. Par. 112 shows photometric data

on metallic-electrode lamps. The manufacturers call attention to the fact i

that the natural distribution of light from the arc is not unlike that from a
Mazda lamp, but that in adapting the lamp for commercial street lighting
service, a reflector or refractor is placed over the arc, and the light distribu-
tion is modified as shown in two of the curves of Fig. 33 at the expense of
from 20 to 25 per cent, loss of light. i

111. Light distribution characteristics. The distribution of light I

about three types of magnetite arc lamps is shown in Fig. 33, manufacturers' '

data being employed.

S.2IIIK
b ampere ^Clear 01<iti«^8*ftmUTd ElectPoiU
-I"Vb impere K«frictorvJllgli^:fliuiency El«ctivd

sano

^
Fia. 33. — Distribution of candle-power in vertical plane about magnetitt
arc lamps.

1154
 ILLUMINATION Sec. 14-112

112. Magnetite lamps.

Recent improvements!^ in electrodes of the
magnetite lamp make available increase of about
one-third in either tne efficiency or the hours per
trim as may be desired. If a larger light output is
desired it may be obtained without sacrifice of
trimming period or increase of watts. If increase
in output is not desired approximatelj' the same
illumination as that given by the standard elec-
trodes may be had with reduction in watts which
makes it possible to operate 60 lamps on a 50-light
rectifier or 90 lamps on a 75-Iight rectifier with
trimming periods increased by about one-third.
113. Regulating mechanism. In Fig. 34 are
shown the essential regulating features of the mag-
netite lamp. { The electrodes are separated when

Fig. 34.— Regulating mechanism of

magnetite arc lamp.

no voltage is applied at the lamp terminals. When

the circuit is energized the electromagnet O raises
itscore D, bringing the lower or negative electrode
.1 into contact with B, starting the arc. This
cli.ses the circuit through series coil S and short
circuits OR, releasing D
and allowing the lower elec-
trode A to drop into its position as fixed by the
clutch Q. As A is consumed, the shunt magnet P
is strengthened, withdrawing core F until finally
the shunt circuit OR is closed at MN
and the arc is
restruck. This mechanism regulates for constant
"r length.
'

Cameron and Halvorson, Transactions Illg. Ene.

>o<., 1920.
+ Steinmetz, "Radiation, Light and Illumina-
tion," p. 158.

1155
 j

Sec. 14-114 ILLUMINATION

114. The ornamental magnetite lamp is a modification of the standard

form, the regulating mechanism being placed below the arc. In efficiency
and operating characteristics it is quite similar to the standard pendant
lamp.
116. The titanium-carbide lamp was brought to an interesting stage
of development in 1909, but did not enter into commercial practice. * As
compared with the magnetite lamp it was of higher efficiency and was avail-
able in smaller units. It was withdrawn for further development without
having reached the commercial stage. No published description is avail-
able. It is understood, however, that with an electrode life of 100 hr. or
more, the lamp efficiency corresponds with about 0.65 watt per candle, its
distribution characteristic being similar to that of the magnetite lamp. The
light is yellower than that of the magnetite lamp.

TUBE LAMPS
116. Vacuum arcs. The vacuum arc is essentially a constant current
device requiring regulation as does the open arc. Its volt ampere charac-
teristics differ from those of the open arc and are largely determined by the
temperature of the arc and the resulting vapor or gas pressure. As usually
operated the voltage is constant throughout a range of current variation.
117. Low-pressure mercury arc. In the mercury vapor lamps the
mercury cathode is vaporized as soon as the arc is struck. In the column
of vapor, formed within the tube and attaining a pressure of 1 to 2 mm.,
light is produced by luminescence, the arc being relatively cool, varying
from some .500 deg. cent, in the center to about 100 deg. cent, at the outer
surface of the glass tube. Tne anode located at the other end of the lamp
tube is of iron and operates at about 350 deg. cent.
118. Starting the mercury arc. In starting the lamp the arc may be
struck by tilting the tube manually or automatically by an electromagnet
until a thin stream of mercury connects the two electrodes. When the tube
resumes normal position breaking of this stream starts the arc. One alter-
native automatic starting which had superseded the above consists in short
circuiting a small current through inductance in series with the arc. This
current is broken by a mercury switch or "shifter" magnetically operated ,

by the induction coil. The resulting cathode discharge is sufficient to start |

ionization of the traces of mercury vapor in the tube and the arc forms.
To increase the effectiveness of the starting discharge a metallic coating or ;

starting band is placed on the cathode bulb forming with the mercury inside .

a small condenser.
119. Alternating-cvurent mercury arc. While the mercury-arc is
essentially a unidirectional conductor it has been adapted for service on
alternating current in the form of the mercury-vapor rectifier. The theory <

and operation of the commercial form of Cooper Hewitt lamps for single-
phase alternating current is indicated in Fig. 35. The cathode is connected,
to the middle of the secondary of an auto-transformer \«-hile the two anodes-
are connected to the ends. Thus the two halves of the autotransformer
function alternately and the cathode is negative with respect to one or the
other anode during tbe entire cycle. Enough reactance is used in series:
with the arc to maintain the current well above zero during the voltage'
alteration and thfr change in anodes. In order to keep the power factor high'
the balance of the current regulation on fluctuating voltage is secured by
using resistance instead of reactance in series with the anode circuits.
120. Direct-current mercury arc. For operation on direct current
reactance and resistance is connected in series with the arc, and adjusted'
for an arc voltage of about 75. The methods of starting are the same as fof
the alternating-current outfit.
121. Data on low-pressure lamps. The comparability of photometric
data of mercury vapor lamps with those of incandescent lamps is open to i\\\i.-^-
tion. For what they may be worth photometric statisti<'s arc shown in the
following table:

* Birge, "The Present Status of the Arc Lamp," Pruccediiiys N. K. L. A.,

1909.

1156
ILLUMINATION Sec. 14-122
Sec. 14-125 ILLUMINATION
135. High-pressure mercury arc lamp. In order to take advantage
of the higher efficiency obtainable at high vapor pressure an evacuated tube
of fused quartz is used, as glass softens at a lower temperature than that
required. The lamp is operated upon the same basic principles as underlie
the operation of the low-pressure lamp. The cathode is of mercury and the
anode is of mercury or tungsten. The quartz tubes (burners) are 5 to 10
in. long. The arc in quartz may be started by tilting manually or auto-
matically as with the low-pressure
arc. In starting, the current is about
three times normal and the arc voltage
is low, excess voltage being taken
up by the ballast resistance. The
lamp gives relatively little light, and
that of a very green color. The cur-
rent quickly vaporizes the mercury,
increasing the vapor pressure and the
resistance of the arc. Gradually a
condition of normal operation is ap-
proached, and in about fifteen minutes
current and voltage at the arc are at
substantially the correct values. It is
understood that lamps are being de-
veloped, or have been developed, for
alternating-current service and for
series service. A laboratory equip-
ment is shown in Fig. 36. The mer-
cury arc in quartz gives a light which
is less pronouncedly green than that
from the low-pressure. arc. It is char-
acterized by an abundance of ultra-
violet radiation which the Bureau of
Standards has found to be about
double the visible radiation. As a
source of ultra-violet Ught the quartz
arc is used in paint and dye testing,
photo-chemistry, the treatment of skin
diseases, and in water sterilization.
126. Efficiency and life of quarts
lamps. Butlittle is published re-
garding ttie efficiency of the quartz
lamp. Experience in this country
shows, however, that early reports of
very high efficiency which emanated
from Europe, are not being realized in
the forms of this lamp whicli have
been developed. Twenty-one lumens
per watt seems indicated as the initial
efficiency of a 220-volt direct-current
multiple lamp. About 17 lumens per
watt is given by the 110- volt multiple
direct-current lamp. In a series type
FiQ. 36.—High-pressure mercury arc
efficiency should
laboratory equipment.
beS^d
It has been found that in the course of 1,000 to 1,200 hr. the total radiation
decreases about 40 per cent, while the ultra-violet component decreases
somewhat more rapidly. * An effective burner life of 2,000 hr. is claimed by
the manufacturers.
127. Moore tubes — nitrogen type. The Moore tube for general light-
ing purposes has been manufactured in lengths up to 200 ft. from glass tubes
about 1.75 in. in diameter. This is filled with nitrogen which is replaced as
required by an ingenious automatic valve which feeds the tubes at intervals
of about one minute. The tube ends are enclosed in a sheet-metal box con-
taining the tube electrodes, the gas tank, the gas valve, step-up transformer,
etc. The efficiency of the nitrogen tube is of the order of 100 lumens per
•Bulletin S-330, Bureau of Standards, 1918.

1158
 ILLUMINATION Sec. 14-128

foot and the consumption is about 2.5 watts per candle-power. The power
factor is about 75 per cent. The life of the tubes is very long.
128. Moore tubes—carbon-dioxide type. These tubes, which are
usually shorter when employing carbon dioxide gas, yield light whicn very
closely approximates average daylight. As the efficiency is quite low, the
use of these tubes is practically confined to color-matching purposes. A
modern simplified form with renewable tube consumes about 250 watts and
produces intensities ov§r a small area for color-matching up to 200 foot-
candles.

129. Neon tubes. A

six-meter tube operates at about 800 volts. The
tubes are of about 1.75 in. in diameter. The electrodes are relatively large
in order to reduce vaporization and avoid exhaustion of the gas. The tubes
have a limited life, which, however, is said to be sufficient for commercial
purposes. The life is longer for long tubes. The specific consumption is
about 0.6 watt per candle. The light of the neon tube is distinctly lacking
in blue radiations. In order to correct for this, a little mercury is employed
in some of the tubes, with the neon. Such tubes are said to operate at about
1.0 watt per candle. When used in certain combination with tubes contain-
ing pure neon, a light which closely simulates daylight in appearance is
obtained. A
modified form of neon tube in which tubes of much smaller
diameter are employed, is arranged to form script letters which serve for
electric signs.

ACCESSORIES FOR ILLUMINANTS | g

GENERAL PRINCIPLES '
'-^

130. The purpose commonly served by lighting accessories are as

follows: (a) redirection of light; (6; concealment (partial or complete) of
light source; (c) decoration. Local conditions peculiar to the installation
determine choice and the weignt to be given of these factors.
131. Reflectors. Since light sources commonly are located in the upper
parts of rooms, and since the Ught is utilized chiefly in the lower part of the
room, the most common form of auxiliary consists of an invertecf bowl or a
cone-shaped cover for the lamp, provided with an inner reflecting surface
designed to redirect more or less of the light downward. Such reflectors are
available in great variety; Par. 131 indicates the more common types classified
with respect to various characteristics.
132. Redirection of light. A large proportion of the light emitted by a
source may
be intercepted and much of it may be redirected in the desired
direction. The extent to which redirection is effected depends upon the
following factors (a) proportion of total flux intercepted by reflecting sur-
:

face ; (b) shape of reflecting surface; (c), properties of reflecting surface.

133. Light intercepted. Assume that opaque reflectors are made of
various shapes and with a reflecting surface which absorbs. 25 per cent, of
incident light, whatever its direction. A reflector which is substantially
flat intercepts, say, 40 per cent, of the total light flux. Another which
covers the lamp fairly well intercepts say 80 per cent, of the flux. The flat
reflector therefore occasions a loss of 10 per cent, of the total light flux,
while the other results in a loss of 20 per cent, but is much more effective in
redirecting a goodly proportion of the flux.

134. Reflector design. An ever-present obstacle in the design of reflect-

ors for general illumination purposes is the relatively large area of the light
source (lamp filament) as compared with the surface area of the reflector.
If the light source were, in effect, a point, the reflector-design
problem would
be simplified. Dealing with a source of considerable area, the reflecting
surface must be so designed as to redirect, in the desired direction, the light
which it reflects, while aflowing a minimum of flux to fall a second time
upon a part of the reflector. Improper shape of reflecting surface, however
favorable the reflection coefficient of the surface, mav impair efficiency to a
large extent by directing some of the flux back into the reflector
instead of
ciut and in the desired direction.

1159 1
Sec. 14-135 ILLUMINATION

U C O 3 o o o o o o o
OOiOiN 00 00 CO OOOO

na- goo s
o
^: ^:

0-H

«3
 ILLUMINATION Sec. 14-138

136. Reflecting siirfaces. A glossy or polished surface may reflect

specularly or regularly, rendering an imperfect image of the source. Such
surfaces are mirrors, polished aluminum, enamel and some glasses. Or
the surface, if mat or depolished, may reflect the light irregularly or diffusely,
as aluminumized steel, etched glass, etc. As a rule surfaces of the former
class are the more efficient reflectors. Among surfaces employed for reflectors
differences in absorption range from 25 to 75 per cent. Usually, the more
efficient surfaces permit of more accurate control of light redirection.
137. Concealment of light sources. This has long been regarded as
an essential of good illumination when bright light sources are employed.
Exposed light sources occasion glare and decrease visual power. One
of the serious difficulties encountered among the earlier designs of reflectors
was the exposure of the light sources. During recent years this tendency
has been overcome to a great extent, and the great.majority of reflectors now
produced conceal the source at least from ordinary view. Devices whose
primary function is the concealment of the light source are often referred
to as shades. This term is likewise applied to many lighting auxiliaries
in which the decorative feature is dominant to the exclusion of efficiency
in redirection of light. For most purposes a reflector may be of value in
concealing the light source as well as in redirecting the light.
138. Distribution characteristics. In Fig. 37 are indicated the shapes
and relative sizes of three reflectors, and the character of the distribution of
light when used with a Mazda lamp.* -
-*
Sec. 14-139 ILLUMINATION
a narrow zone, nothing can be gained by the use of an enamel reflector of
amall diameter. The maximum intensities produced by units A and B
are practically identical, but the efficiency of B in the 50-deg. or wider zones ia
considerably higher than the corresponding value for A.
"The distribution shown in curve A may be classed as intensive. By
placing the lamp somewhat lower in the reflector, a more extensive distribu-
tion of light may be secured which will be preferable for most locations re-
quiring a general illumination. This form of curve, so far as distribution
in the lower hemisphere is concerned, is practically ideal for industrial light-
ing purposes where the lamps are suspended at usual heights. The form of
this curve is desirable both because it tends toward a uniform illumination
on the work, and because the lamp filaments are well screened. On the
other hand, it must be remembered that the wider reflector, B, will in
practically all cases supply 10 or 15 per cent, more useful light than can be
obtained from a bowl-shap'ed unit in either the intensive or extensive position.
Furthermore, the shadows resulting from the use of a light source of large
diameter, such as B, are less sharp than those from A."
139. Data on reflectors. In Par. 144 are given statistics of reflectors
used with 100-watt Mazda lamps, showing the light absorbed by the reflectors,
some characteristics of the distribution obtained, and some physical data 'on
the reflectors.
BEFLECTORS FOR INDUSTRIAL LIQHTINa
140. Porcelain-enameled reflectors.* "Any practical reflecting surface
absorbs a considerable percentage of the light incident upon it. When
incandescent lamps were first used in industrial lighting, the efficiency of
porcelain as a reflecting surface was recognized, and various translucent
reflectors of this material came into extensive use. However, they were
not found entirely successful because they were lacking in mechanical
strength; in many locations breakage resulted, causing the loss of the
reflector and, which was more serious, often damaging material or injuring
employees. It was largely for this reason that they were replaced by the
metal reflectors of inferior efficiency but of greater ruggedness. Modern
porcelain-enameled steel reflectors combine the good qualities of the glass
and metal types. The surface absorbs about 3.5 per cent, of the incident
light. As usually constructed in the bowl type these reflectors have an
angle of cut-off of about 60° and in the dome type about 89°, the light
output of the latter being of course higher than that of the bowl type. The
translucent neck, a recent modification of tne dome reflectors, permits some
light to reach the ceiling.
141. RLM standard dome. For general industrial purposes porcelain-
enameled dome reflectors conforming to the Reflector and Lamp Manufac-
turers' Specifications are considered most desirable. The light output of
such units must be at least 70 per cent.; large reflecting surfaces and a 17>^°
(72}i° above nadir) cut off limit glare; and excessive downward concentration
of light is avoided.
142. Enamel-paint reflectors. "Metal reflectors with a surface of
white enamel paint are available at prices materially lower than those asked
for the porcelain-enameled products. However, owing to the relatively
rapid depreciation of this surface and to the fact that these reflectors are
seldom designed with proper regard for the efficient distribution of light,
their use is likely to result in the wa.ste of a considerable portion of the money
annually expended for lighting. A loss of even 10 to 20 per cent, of the light
in this manner will each year amount to several times the added cost for the
most efficient equipment.
143. Aluminumized reflectors. "Aluminumized reflectors have ap-
proximately the same initial efficiency as the porcelain enameled, and allow
a better control of the direction of light rays. Moreover, their cost is lower
than that of porcelain-enameled equipment. On the other hand, reflectors
of this class have heretofore failed to maintain their high initial efficiency in
service. Their use is, therefore, to be recommended only where a better
control of the light flux —
for example, a concentrated distribution is—
desired. An aluminumized surface has recently been developed which is
superior to the older forms in ma intaining efficiency.
• Bulletin 20, National Electric Lamp Association.

1162
 ILLUMINATION Sec. 14-144

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H63
Sec. 14-145 ILLUMINATION
115. "Mirrored-glass reflectors form another class of opaque units
which find some application in industrial lighting. These reflectors make
possible a control of light rays even better than that secured with the alumi-
numized units. They excel in efficiency the other classes of equipment
discussed, and the best mirrored reflectors appear to retain their efficiency
with practically no loss throughout life. Their cost, however, is higher
than for the other units, and, in common with all glass reflectors, they are
limited to those locations where breakage is not a serious matter. They
are especially valuable where a concentrated light is required."'
146. Prismatic-g'lass reflectors. Like other relatively fragile reflect-
ors these may be used only where danger of breakage is small. They are
not subject to the action of fumes or gases as some metal reflectors. They
are extremely efficient, and where high concentration of light is desired, tliey
are superior to white-glass reflectors.
147. Opaque reflectors. Certain further comments of an impartial
nature are excerpted from a paper by Powell, t and an article by Stickney
and Powell. t "The great majority of industrial reflectors are of the opaque
diffusely reflecting types. The reflecting surfaces may be of enameled
porcelain, white-enamel paint, or aluminum either painted or mat. The
enameled porcelain reflectors are especially advantageous, if of a high quality,
because of ease of cleaning, resistance to acid fume, resistance to heat,
and ability to withstand weather in outdoor service. These reflectors are
perhaps not quite so efficient when new as those finished in white paint and
as usually designed do not yield so wide a range of distribution character-
istics as do some other types of reflectors.
"Aluminum-finished reflectors offer a wide range of distribution char-
acteristics, and are efficient and satisfactory when new. In most forma they
are liable to serious depreciation due to the collection of dust, and as a result
of cleaning. One manufacturer now markets an aluminum-finished reflector
which has a coat of lacquer, which is said to facilitate cleaning and render
the surface permanently efficient.
" Mirror reflectors are of high efficiency and offer opportunities for a wide
range of design, as to light distribution. Compareti with other industrial
reflectors, they are however somewh.at costly and fragile."

REFLECTORS FOR COMMERCIAL LIGHTINO

148. Translucent reflectors. In commercial lighting opaque reflectors
are rarely used except in show windows. It is a usual requirement that con-
siderable light shall be thrown upcm the ceiling and walls which dictates
the employment of translucent reflectors. As commercial lighting offers,
perhaps, the readiest field for the sale of new types of lighting auxiliaries, a
wide v.ariety of translucent-glass reflectors has been designed. This typ)e
includes prismatic gla.ss and a great variety of white glass, as opal, phosphate
gla.ss, etc. In each type these reflectors are to be found in various sizes and
shapes, differing in light-distribution characteristic. The several types and
makes of reflectors differ among themselves in efficiency, light transmi.ssion,
etc. Where high concentration of light is required, the prismatic-glass
reflectors offer some advantage Among many of the white-gl.ass reflectors
there is little choice, except in appearance. The differences are those largely
of appearance of the glass itself, and of ornamentation. Neglecting these
two features, the white-glass reflectors of various makes are to be grouped
naturally in regard to the amount of light transmitted, it being the general
order that those which transmit the most light reflect less light downward.
As in the industrial reflectors, commercial reflectors may be procured with
either glossy or mat reflecting surfaces, the latter being preferable for almost
allpurposes from the illuminating standpoint, though they require some-'
what more cleaning than do glossy-surface reflectors.
149. Decorative qualities. Many of the translucent reflectors are of
such good design and are so ornamented that they are very pleasing in appeal* ^

ance, and entitled to a place in the class of decorative glassware. Still,

* Bulletin 20, National Electric Lamp Association.

fAn Investigation of Reflectors for Tungsten Lamps, General ElectriO|
Review, 1913, p. 717. .
!

X Data Concerning Incandescent Lamp Reflectors, Electrical World,!

September 6, 1913, p. 477.

1164
 ILLUMINATION Sec. 14-150

others, more appropriately classed as shades, are designed predominantly

for decorative effect; these are of very little value where the illumination is
to be utilized otherwise than for purposes of decoration. Among the latter
are shades of "art" glass and metal or pottery, and of various fabrics. It
would be futile to attempt to show data on such shades. On all reflectors
intended for industrial and commercial lighting including many which are
very decorative in appearance, definite engineering data are available.
Typical information of this kind appears in Par. 160.
ISO. Distribution of light in various zones about Mazda lamps
and inverted bowl reflectors*
Typical zonal distribution

Type of reflector to 60
 .

Sec. 14-153 ILLUMINATION

is less definite the case with open-mouth reflectors.
than is In the matter
of redirection of light, much may be accomplished
in an ordinary glass sphere
by varying the locationof the light source within the sphere, but the tendency
with such glassware is always to yield distribution characteristics which
approach a circle. There are some forms of enclosing glassware, however,
in which special attention has been given to this phase of the subject with
very notable success in the redirection of light. Par. 163 gives some data
upon enclosing glassware of various types.
153. Photometric data upon enclosing glassware employed with
1,000 lumen Mazda lamp*
Lumens with glassware Per cent,
light ab-
sorbed
Description
to
to90 90 to by
60 180 Total glass-
deg.
deg. deg. ware

10-in., 2-piece pressed- Alba ball 182 379 385 754 24

14-in., 2-piece pressed-Alba ball 190 384 335 719 28
12-in., 1-pieoe blown-Alba ball . 223 469 •395 864 14
12-in., blown-Alba acorn 243 476 347 822 18
12-in., cased Melilite ball 181 396 321 717 28
12-in., ground-glass ball 206 484 419 903 la
14-in., prismatic reflector bowl . 412 589 180 769 23
12-in., prismatic reflector ball . 455 618 103 721 28

INDIRECT LIGHTING
164. Cove lighting. Recognition some years ago of the need for con-
cealing brilliant light sources from view led to systems of indirect lighting
in which the light was thrown upon some reflecting surface which became
a secondary source of illumination. One method consisted in locating the
lamps within a cornice or cove concealed from view and illuminating the
room via the ceiling. By this system, control of the light was largely lost,
'

and efficiency of utilization was very low. In one case reported, only 15
per cent, of the total light produced by the lamps was delivered upon a
working plane.! While this low efficiency was perhaps an extreme and
better values have been realized, yet the cove lighting system was so
inherently low in efficiency as to be unsuccessful.
186. Indirect lighting fixtures. A more recent development of indirect
lighting is one in which the lamp is located within bowls, usually hung
centrally in a room or bay. By backing the lamps with efficient reflectors,
and controlling the direction of light, a higher order of efficiency may be
obtained and a more desirable direction of the light secured. Indirect
lighting systems possess the advantage of high diffusion, and are therefore
valued where freedom from shadow and ghire is a consideration of primary
importance. Some statistics showing the proportion of the total light pro-
duced which may be delivered upon a working plane by this system of
lighting are given in Par. 157.
156. Indirect-lightinfT fixtures in various designs. In certain designs
the lower part of the indirect-lighting bowl is rendered luminous primarily
for purposes of decoration. t Sometimes small auxiliary lamps separately
wired are employed in this part of the fixture.
Indirect lighting fixtures mounted upon pedestals have been employed
with pleasing results in interiors which lend tnemselves to such treatment.!

* "Characteristics of Enclosing Glassware." Lansingh, Transactions Illu-

minating Engineering Society, 1913, p. 447.
t
" The Elements of Inefficiencyin Diffused Lighting Systems." MiH'"'
Transactions Illuminating Engineering Society, 1907, p. 683.
t Stair and Hoevelcr, Transactions Illuminating Engineering
Socii
1916, p. 794.
•5 Curtis and Stair, Transactions Illuminating Engineering Society, 1920.

1166
 ILLUMINATION Sec. 14-156

C o-
3 lO
-^— M

>- >< o
o 3 >
Sec. 14-158 ILLUMINATION
SEMI-INDIRECT LIGHTING UNITS
168. Translucent bowls. A development of the past few years oonsisti
in the use of glassbowls enclosing the light source and reflecting most of th(
light to the ceihng, as in the indirect lighting system, while transmitting ii
various proportions enough light to give an appreciable direct component
Some data upon bowls of this type, of one manufacture, are presented ii
Par. 160. Referring to the data in this table it will be seen that the authon
have made a study of the influence of contour of bowl upon the distribu
tion of light, and likewise of the influence of optical density of glassware
Their conclusions from these figures and others given in the paper, follow
in Par. 189. Data on semi-indirect installations appear in Par. 163.
159. Effect of change of light source and bowl contour. "Th(
distribution of light is materially affected by changes in the position o
the lamps within the bowl; changing from a single lamp to a closely clusterec
group of two or three lamps does not introduce large variations in the distri'
bution characteristics, although the single lamp results in a somewhat widei
distribution above the horizontal. The ratio of light above the horizonta
to that below the horizontal in the four types of glass of the contour 3, choset
for this purpose, vary from 1.26 for the least dense (etched glass) to 6.4
for the most dense (Calla) and the effect of change in the contour of the bowli
;

is that with the shallower bowls the distribution both above and below the
horizontal is not so wide, more light being centred near the bowls whil«
with the deeper bowls there is, of course, a larger ratio horizontal."
160. Photometric data of semi-indirect glass bowls employed
with one Mazda lamp*
Per cent, of total light from lamp
which is distributed within stated
Contour, zones t
Description of glassware see Fig.
39 180 deg. 180 deg. 90 deg.
to 120 to 90 to Total
deg. deg.

Etched crystal gl
with new cut design 22 47 37 84
Druid 27 54 30 84
Veluria 36 60 25 85
36 58 24 82
30 57 24 82
28 60 24 84
Calla 44 68 11 79
46 71 11 82
41 68 11 79

12
Fio. 39. — Contours referred to
161. Reflectors in railway coaches.
3
in Par. 160.

Some information upon the dis-

4

tribution of light in a typical railway day coach has been made available b>
the Committee on Illumination of the Association of Railway Electrics
*" A Photometric Analysis of Diffusing Bowls with Varying Indirect
Component." Rowe and Magdsick, Trans. lUg. Eng. See, 1914.
1 180 deg. is the Zenith; deg. is the Nadir.

lies
 ILLUMINATION Sec. 14-162

\uso aaj

ajqBiBduioo
JO siuja^ nj
Sec. 14-163 ILLUMINATION
Engineers.* While railway-car illumination is to some extent a specia
problem, yet the behavior of most reflectors in such service is an importani
indication of what may be expected in other hues. In the tests which ar«
here recorded, the car was equipped with Mazsla lamps located in the centre
deck or monitor, and spaced at intervals of two and three seats respectively
Conditions in all respects were favorable to lighting efiSciency because thi
equipment was new and clean and operated under correct conditions. Af
indirect and semi-indirect equipments were used, it is important to note that
the coefficient of diffuse reflection of the car ceiling was 65 per cent.
Results of this series of tests make available extensive data showing for o
variety of equipments tne coefficients of ultilization, horizontal foot-candlet
and the screening angles. Open-mouth reflectors are shown to deliver upor
a 33-in. horizontal plane proportions of the total light flux ranging from 2i
to 59 per cent. Indirect lighting equipments with a 65 per cent, ceiling
deliver upon this plane about 25 per cent, of the total light produced
Slightly higher values are shown for enclosing and semi-indirect equipments

163. Latest designs in lighting units. Practical experience in em-

ployment of accessories of the bowl type which direct a great deal of ligh1
upon the ceiling has shown that efficiencies suffer by reason of low refiectior
factors of ceilings and because of dust accumulation on lamps and bowls.
The radical reduction in efficiency of such lighting due to a ceiling having
a reflection factor of only 50 per cent, is of course very serious. Many ceil-
ings with which indirect and semi-inditect units are employed have a lowei
reflection factor than 50 per cent. The expedient of providing a lightinf
unit with its own reflecting surface which will be placed at the ceiling and
upon which a large part of the upward light flux falls is of material assistance
in diminishing such losses. When such reflecting surface is provided as s
part of the unit and is specially designed to be readily cleanable, it is furthei
advantageous because it may be cleaned when the rest of the fixture ij
cleaned, whereas on such occasions the ceiling itself would not be cleaned
Such "own ceiling" lighting units therefore possess a utiHtarian value ol
importance. It is difficult, however, to bring them into harmony with the
ceiling decoration. Unless this is done, the appearance of the installation if
likely to suffer. A device of this character is included among those for which
coefficients of utilization are shown in Par. 196. , . ,

A first step in the direction of enclosing semi-indirect and mdirect bowU

consisted in placing a clear glass cover over them, which could be more read-
ily cleaned than the bowl itself. From this have been evolved several designs
of totally enclosing units of which the lower part is of diffusing glass, direct-
ing much of the light upward, and the upper part of clear glass, permittinf
the flux to pass upward with a minimum of absorption. Some of these
units are, however, designed to provide an upper reflecting surface to coiled
much of this upward tending flux and redirect it downward. A one-piece
unit of this character is illustrated in the coefficient of utilization table
Par. 196. As is often the case, it is difficult in the design of such units tc
reconcile the requirements of utility and efficiency with those of astliotics
Still another recent development in lighting units consists of a bowl oi
other shaped reflector for directing much of the flux upward, to the lowei
part of wliich a translucent plate is attached permitting a part of the flu:
to pass directly downward. The underlying idea of such designs is to reduct
the flux di-stributed more or less horizontally, which in large areas is of mini
mum utihty and in smaller rooms serves only to illuminate the walls, and t(
direct most of the flux cither upward or downward. Units of ttiis type an
covered by fabric shades or variously dressed to pro\'ide a pleasing exterior
The unit in another design consists of a simple glass bowl dressed as desired

164. Artificial daylight units. The Moore carbon dioxide tube (Par
127) produces light which without modification may be considered the
tru'

equivalent of daylight, serving the most exacting requirements of oolo

matching. The spectrum is discontinuous but the lines are so nunicrou
and so close that for all practical purposes tne spectrum may be regarded a
continuous. In hue the light lies between sunlight and clear north-sky light

* RailvMy Electrical Engineer, October, 1913, and Report of 1914 Com

mittee of Association of Railway Electrical Engineers.

1170
 ILLUMINATION Sec. 14-165

Daylight may be simulated ih a manner satisfactory to the eye by com-

bining illuminants of a variety of hues, as tungsten filament and mercury
vapor lamps. The pronounced line spectrum of the latter, however, renders
such light unsuitable for color matching purposes.
'
Incandescent illuminants in general produce light which is redder than
'natural light. Color filters which absorb selectively the longer wave lengths
may be employed with such illuminants to obtain the equivalent of any
'quality of daylight. Most artificial daylight units are of this kind. The
?as-filled tungsten lamp is usually the source and bluish glass color filters
lare used to suppress the red end of the spectrum.
f
One combination is a "noon sunlight equivalent." About 50 per cent.
IDf the light from a Mazda C lamp is absorbed. Tne filtered remainder is
Fj satisfactory substitute for sunlight. Another combination is a "north
"skylight equivalent." About 80 per cent, of the light from a Mazda C
;
amp is absorbed in this unit. On this account it is employed only to illumi-
late small areas for the most exacting color matching purposes.
A blue bulb "daylight" lamp (Mazda C-2) offers a popular compromise
jetween daylight and artificial light. As this absorbs only about one-third
'
the light of the Mazda "C" lamp, its use becomes practicable for larger
ireas such as show-windows. It is customary when using these lamps to
ihoose the next size larger than the size of clear bulb lamps which would be
smployed.
When light of a particular hue is required the most significant efficiency
_
the relative efficiency as compared with other units, if any, which produce
ight of the same hue. It may be a real economy to make a large expenditure
obtain only a little light of the required quality.

ACCESSORIES FOE SPECIAL PURPOSES

166. Show-window lighting. For show-window lighting and certain
'ther purposes an asymmetrical dis-
ribution of light is usually required,
"xample of reflector designed for
ueh a purpose is shown in Fig. 40.
166. Street lighting. Various
uxiliaries for redirecting part of the
ght produced by street illuminants
ave been developed. Some of the
lost effective in this respect are to
found among the newer designs
auxiliaries for Mazda type C (gas-
iled) series lamps. Illustration of
liis is given in Fig. 41. In some
reet illuminants, as the magnetite
;Qd metallic-flame arc lamps, a re-
3ctor is built in the lamp casing.
'i others, the diffusing globes with
hich the lamps are equipped are
shaped as to modify the distribu-
n characteristic materially.
hese are inconspicuous methods of
icomplishing a measure of light re-
rection which usually is less marked
an that accomplished by the use
external reflectors.
167. Glass plates. Translucent
ass plates consisting either of
osted glass, opal glass, so-called art
ass, ribbed glass or prismatic glass
e largely employed as skylights and
diffusing screens for artificiallight-

in
Some data upon
coefficient of
the transmis-
such glasses are
Fig. 40. —
Asymmetrical distribution,
adapted to show-window lighting.
iren in Par. 169.

1171
Sec. 14-168 ILLUMINATION

168. Olass for redirecting daylight. Ribbed and prismatic glass i

used to a large extent in industrial lighting for directing into largo rooms

Fig. 41.- -Distribution of light in vertical plane about lamp equipped wit
prismatic refractor for street lighting.

greater amount of skylight than would otherwise be available. Some tcs'

by Professor Norton are commented upon in the Johns Hopkins Univcrait
Illuminating Er.gineering Society Lecture Course on Illuminating EnginoeJ
ing* as follows:
"We may increase the effective light in a room 30 ft. (9.14 m.) deep <
more, to from three to fifteen times by using factory-ribbed glass instead <

plane glass in the upper sash of the window. By using prisms, instead (

plane glass, we may, under certain conditions, incre.-vse the effective ligl
fifty times. The gain in effective light on substituting ribbed glass or prisn
for plane glass, is much greater when the sky angle is small, as in the cai
of windows opening upon light shafts or narrow alleys. The increase in tl
strength of the light directly opposite a window in which ribbed glass (
prisms have been substituted for plane glass is at time such as to light a des
or table 50 ft. (15.24 m.) from the window better than one 20 ft. (6.1 m
from the' window had previously been lighted."

'Edwards. "The Lighting of Rooms through Translucent Glass Cei

ings," I. E. S. Transactions, 1914, p. 1014.

1172
 t

ILLUMINATION Sec. 14^169

169. Light from Madza lamps transmitted through glass plates

Mounting
height to
Trans-
spacing dis- Character
mission
tance-ratio Trade name
efficiency of glass
necessary for
per cent.
elimination
of spotting
45 Light opal Alabaster Cathedral
46 Yellow and Iridesjcent No. 6
iridescent.
39 Opal Alabaster llluminal
65 Clear Cristallia llluminal
35 Very light Alabaster Moss
opal
63 Clear Defies No. 1

44 Yellow Deflex No. 1|

43 Opal light Opalescent No. 139, G.L.L.
54 Clear Cristallia No. 40
10 33 Opal Pattern No. 40, Opal No. 65
11 50 Clear Pattern No. 41
12 40 Yellow Pattern No. 41, Amber
13 29 Opal Pattern No. 41, Opal No. 65
14 36 Clear Cristallia No. 42
15 37 Opal Pattern No. 42, Opal No. 65
16 22 Violet Pattern No. 42, Violet
17 41 Clear Cristallia No. 43
18 39 Yellow Pattern No. 43, Yellow No.
21.
19 30 Opal Pattern No. 43, Opal No. 65
20 34 Clear Cristallia >^o. 45
21 28 Opal Pattern No. 45, Opal No. 65
22 18 Dark yellow Pattern No. 45, Yellow 3X
23 41 Clear Cristallia No. 46
24 31 Opal Pattern No. 46, Opal No. 65
25 66 Clear Multiflora Crystal
26 46 Opal light Multiflora Opal No. 65
27 37 Yellow Multiflora Yellow
28 35 Opal Multiflora No. 68
29 36 Opal Opal, light
30 35 Opal Opal, medium
31 28 Opal Opal, dark
32 69 Clear Deflex No. 6
33 45 Clear Pattern No. 6, Honey Comb
34 36 Clear Pattern No. 7, Bee Hive
35 35 Opal Pattern No. 44, Opal No. 65
36 57 Clear Ripple No. 3
170. Headlights. Space does not permit specific treatment of light pro-
sotion. Searchlights, locomotive headlights,! automobile headlights! and
lOving-picture projectors offer distinctive problems.
||

• Marks. " Principles and Design of Interior Illumination," Vol. II, p. 660.
t Impossible to eliminate spotting with any reasonable ratio.
% Report of Committee on Locomotive Headlights, Railway Electrical
ngineer, October, 1913.
i McMurtry, Headlamp Design and its Effect upon Glare Reduction,
tiletin Society of Automotive Engineers, April, 1917.
I Illuminating Engineering Practice, 1916, I. E. S., U. P., p. 213.

1173
Sec. 14-171 ILLUMINATION

ILLUMINATION CALCULATIONS
GENERAL CONSIDERATIONS
171. Light flux. According to approved concept, light is regarded ai
luminous flux.* The output of a lamp is its total luminous flux. Tht
brightness of a diffusely reflecting or transmitting surface is proportions
to its specific luminous flux. The intensity of illumination received oi
any surface is the flux density. Thus
luminous flux is analogous to magnetic
and electrostatic flux. Comprehen-
sion of light flux is facilitated by con-
sidering a point source to be located at
the centre of an imaginary non-reflect-
ing sphere. The total luminous flux
produced by a source of 1 c-p. radi-
ated uniformly, is divided by the num-
ber of unit solid angles or steradians in
the sphere in order to arrive at the
unit of luminous flux which is the lu-
men "equal to the flux emitted in a
unit solid angle (steradian) by a point
source of 1 c-p."
172. Distribution of light. In
practice, light is rarely radiated uni-
formly, and itis therefore necessary to
consider the flux to be distributed in a
great variety of ways. The deter-
mination of light distribution charac-
teristics of sources, is a regular part of
illuminating engineering practice, and
most calculations performed involve
this distribution characteristic.
Fig. 42 are illustrated four different
In Fia 42.— Four distributions of
given flux.
distributions of a given luminous flux.
The curves show a section of revolution. The circle (curve A) indicates unl
form distribution from a punctiform source; curve B shows distribution fromf
theoretical line source, distributing no light at the poles. Curve C shows th
distribution from a uniformly radiating circular disc, and curve D shows ' .

light-distribution characteristic typical of a certain class of reflectors.

COMPUTATION OF TOTAL FLUX, OR MEAN SPHERICAL

CANDLE-POWER
173. Zonal areas. In Fig. 4.3, curve D from Fig. 42 is reproduced. Th
polar diagram at the left shows the flux density or intensity in any directior:
jn the vertical plane, considered. Referring to the representation of a spher
on the right, it will be noted that the total area of a zone of a given altitude a
the equator is much greater than the total area of a similar zone near th
pole. The flux density, or intensity, of the light distributed throughou
each zone, is indicated in the distribution curve to the left. The area c
each zone must be multiplied by the mean flux density, in order to obtai
the total flux distributed throughout the zone.
174. Rousseau's method. Rousseau's method of determining the tot^
flux distributed through the zone, is the basis of most such computation*
This method is indicated in the middle of the diagram. The zone latitude
as represented upon the sphere, are projected upon a rectilinear diagram, upo
which the zone widths then become proportional to the areas of the zone upO'
the sphere. The curve of light distribution, when plotted upon tliis diagrac
in the manner indicated, will comprehend an area proportional to the toti
'

Trans, ifig. Eng. Society, 1907, p. 414.

 ILLUMINATION Sec. 14-175

luminous flux. The mean altitude of such a curve is proportional to the mean
flux density (which is to say, the mean spherical candle-power). Further-
more, the area comprehended in any zone by the curve, is proportional to the
Bonal flux, and the mean altitude of the curve within that zone is proportional
;o the mean flux density or candle-power within that zone. The area com-
Drehended by the curve may be obtained by the use of a planimeter, or
)y averaging altitudes at short equal intervals. It is apparent, therefore

Fig. 43. — Relation between flux and intensity.

itflux values may be obtained from the light distribution curve without
tireparation of a Rousseau diagram, by averaging the flux density or
iil'r-power values at angular intervals corresponding to equal intervals
Rousseau diagram. Such angles are given in Par. 176. Macbeth
!

epared polar coordinate paper on which such angular intervals are

-, led.

'5. Angles from vertical axis at which values may be taken from a
light distribution curve and averaged to obtain mean fluz
density or mean candle-power in each hemisphere

Ten points Six points

ISdeg 63 deg. 24 deg,

32 deg 70 deg. 41 deg,
41 deg 75 deg. 54 deg
49 deg 81 deg. 65 deg,
57 deg 87 deg. 75 deg,
85 deg

176. Mean
zonal-candle-power constants. When photometric values
light distribution are available but have not been plotted to form a light
itribution diagram, the flux computation may be carried out by the appli-
liion of the constants in Par. 177, which are proportional to the areas of the
I'eral zones of which the test angles are representative. In using these
istants, find the product of each candle-power value and the constant for
angle. Divide the sum of all such products by two to determine mean
lericalcandle-power. Multiply the mean spherical candle-power by 12.57
obtain total lumens. To determine mean hemispherical candle-power
ploy same constants except for the 90-deg. value where the given con-
nr, should be divided by two. In this case, do not divide the sum of the
"ducts by two.

1175
Sec. 14-177 ILLUMINATION

177. Constants for computation of mean spherical candlo-powe

or total flux from light-distribution data
10 deg. zones
 ILLUMINATION Sec. 14-182

182. Zonal constants approximate only. Iq using zonal constants it

must be remembered that the candle-power is assumed to represent the mean
intensity throughout the zone. In many cases this assumption is not strictly
justifiable. Hence this is only an approximation method.
183. Typical zonal values. Fig. 44 is a reproduction of a typical test-
data sheet bearing on the right a graph of the light distribution in a rtiean
vertical plane about a source, and on the left corresponding zonal-flux values.

ju»nip - 250- Watt Bowl-Frosted Metallized Filament

[Holder- Form "A"

Photometric Distance - 10 Feet
ouditious - Lamp and Auxiliary Botated

Dimensions of
Lamp and Auxiliary

44. — Photometric test sheet showing light distribution and values of

intensity and flux.
184. Spherical reduction factor. In rating some types of illuminants,
tably incandescent lamps, it has unfortunately been customary to adopt
a basis the mean flux density or candle-power in a horizontal plane through
i source. Whether rated in this way or by the candle-power in some other
ection or plane, it is always desirable to reduce the values to total light
X for some purposes. Hence reduction factors are commonly given with
Be illuminants, and the term, "spherical reduction factor," has come to be
plied especially to the ratio between mean spherical candle-power and mean
risontal candle-power of incandescent electric lamps. (See Par. 30.)

1177
Sec. 14-186 ILLUMINATION
CALCULATIONS OF ILLUMINATION INTENSITY
186. Classification of methods. AssumiDg that light distribution dati
such as those presented in Fig. 44 are available, it becomes possible to eon
pute the illumination produced upon any given plane by the light source i

any given location. For the sake of simplicity it will be considered that tl
light source, whose distribution is indicated in the diagram, is mounted ov(
the centre of a horizontal plane which is to be illuminated. For such con
putations there are three customary methods. The flux of light delivere
upon the horizontal plane will be the sum of that directed toward the plai
from the source and that reflected to the plane from ceiling, walls, etc.
186. Flux method (direct light). For many purposes an approximal
calculation of the flux delivered upon the plane of reference is adequat
In such oases it may serve to determine the approximate square feet of tl
plane to be illuminated and to estimate the total flux which will reach sue
plane. For example, assume that a certain room has a floor area 12 ft. 7 ii
by 12 ft. 2 in., and that it is desired to estimate the light flux delivered upon
horizontal plane 36 in. above the floor from a light source located over tl
centre of the area, and 6 ft. 4 in. above the plane of reference. * Roughly, tl
flux delivered within an angle of 45 deg. above the horizontal will fall upo
this plane. Applying zonal constants (Par. 181) to the candle-power value
in Fig. 44, we have either or both of the following:

Angle
 ILL UMINA TION Sec. 14-189

llluminant absorbs 20 per cent, of the total flux produced, there will be a
joefficient of utilization of 376/(779/0.8) = 0.39 per cent.
189. The coefficients of utilization in the following table are repre-
jentative of stjuare rooms equipped with a sufficient number of lighting
^anits and so placed as to produce reasonably uniform illumination. In
3ach case the upper figure applies to an extended area, namely, one in which
;he horizontal dimension is at least five times the distance from floor to
,;eiling. The lower figure applies to a confined area, one in which the floor
.iimension is but five-fourths of the ceiling height. The utilization factor
or a rectangular room is approximately the average of the factors for two
i^iquare rooms of the large and small floor dimension respectively.
190. Coefficients of utilization*

Ceiling, reflection factor

Sec. 14-192 ILLUMINATION
192. Further data on coefficients of utilization. Messrs. Harrisc
and Anderson* have made available extensive data based upon experinien
in a test room and adapted to practical requirements. Summary take
from this paper is presented in Par. 196 and 196. These data show tl
extent to wnich increasing heights of ceiling and of lamp mounting increai
the coefficient of utilization with all forms of Ughting units. They she
tne increasing importance of high reflection factor of ceiling as more of tt
light flux is directed toward the ceiling, and they show the relatively lef
important effect of walls in influencing the coefficient of utilization, this laf
of course becoming more important when the rooms are very small. The dat
are for new and clean equipments. (For depreciation data see Par. 161.)
193. The flux method. From the accompanying data it is possible t

form a reasonably accurate estimate of the influence of ceiling and wal

upon coefficients of utilization. Hough estimates of tne flux ultimate!
reaching a plane of reference may be made with fair accuracy after a litt
experience.
In many cases it is desirable to invert the order of computation, and begii
ning with the desired illumination intensity upon a given plane, arrive (

an estimate of the total light flux to be produced. Taking the case assum«
in Par. 186 and assuming that an average illumination intensity of 5 foe
candles or 5 lumens per square foot is required, we may carry out such
computation in simple manner. The area of the room is 153 sq. ft., whi(
multiplied by 5 foot-candles gives 765 lumens to be applied upon the plai
of reference. It may be assumed that this can be accomplisned by usii
lighting equipment which, while directing most of the light toward the plan
will stiU transmit sufficient to illuminate the ceiling and walls acceptabl
With sdch equipments it is reasonable to expect that 50 per cent, of tl
lignt may be delivered upon tne plane of reference. Therefore twice tl
applied lumens should be generated, or 1,530 lumens. This will be produce
by a 150-watt Mazda "C" lamp of about 2,050 lumens, thus leaving
margin of about 25 per cent, for depreciation due to dust and falling-off
the light output of the lamp during life.
194. Absorption of light method. An alternative method of compu
ing light flux for an illumination installation is the "absorption of ligh
method, t This is based upon the fundamental consideration that all
the light within a room being absorbed, the illuminants must produce tl
sum of the light flux absorbed by the various surfaces. That is to say, ti
average incident flux upon each surface multiplied by the coefficient of Hg
absorption characteristic of that surface and by the area of the surface w
yield the total flux absorbed by that surface, artd tne sum of the flux a
sorbed by all exposed surfaces witnin a room must aggregate the total fli
to be produced by the lighting unit. (In such case of course, the absorptji
of light involved in the use of an auxiliary must be added to this aggregate
ascertain the total amount of light to be produced by the illuminant propei
Referring to the room already mentioned J we find the data necessary
verify this method. These are summarized below.
Absorption of light in a given room

Surface
 ILLUM-I NATION Sec. 14-195

195. Coefficients of utilization

The proportionof the total light from the lamps reaching the plane of the
work is the coefficient of utihzation of an installation. For a given reflector
3quipment the coefficient is dependent upon the color bf the ceiling and walls,
ind upon the "Room Ratio," which is the relative width of the room corn-
Dared with the height of the light sources above the level of the work. Thia
;able of coefficients applies to installations having sufficient lighting units
.tymmetrically arranged to produce reasonably uniform illumination.
Square rooms. To find — coefficient of utilization,
: 1. Determine room ratio.
For direct installations (first 16 units of table),
. _ width o f room
2 X height from plane of work to lamps
For indirect and semi-indirect installations, (last 4 units of table),
_ . wid th of room __^_^
""
1>^ X height from plane of work to ceiling
2. Find coefficient in proper column of ceiling and wall colors opposite this
com ratio value.
Rectangular rooms. Find the coefficient as above for a square room
the narrow dimension and add one-third of the difference between this
alue and the coefficient for a square room of the long dimension.
(Ceiling Ujki(7or.)
,CJu (Reflcctine Viluc) of|,

/"=^

A m
-^

^
^
SllirUinr Bird
Sec. 14-196 ILL UMINA TION

196. Examples illustxating use of table of coefficients (.Par. 195).

(a) Find the coefficient of utilization for an RLM
dome, clear lamp
direct installation in a rectangular room 40 ft. X 120 ft.; ceiling height
27 ft.; lamps mounted 20 ft. above the plane of work; plane of work 3 ft
above the floor; ceiling color, light; wall color, medium.
For a square room, narrow dimension,
40
Room ratio = ^-rr^x = 1-00 Coefficient = 0.43.
For a square room, long dimension, .lil

Room ratio =
^
120
= 3.00 Coefficient
Coefficient of utilization for the rectangular room with
= 0.62.

RLM
^.3
dome
clear lamp units is then, 0.43 >^(0.62 - 0.43) = 0.49.
+ .4n,s.
(6) In the same room with an indirect, clear lamp installation, find th(
coefficient of utilization as follows:
For a square room, narrow dimension,
40
Room ratio = ,, . . „. = 1.25 Coefficient = 0.21.
IH X ,
24
For a square room, long dimension,
120
=
Room ratio
mX 24
3.75 Coefficient =
Coefficient of utilization for the rectangular room with indirect, cleai
0.35.

lamp units is then, 0.21 >i 1,0.35 - 0.21) = 0.26. Ans.

+
 ILLUMINATION Sec. 14-197

197. Absorption of light in a griven room

Lumens
Surface
Incident from all CoeflBcient of
directions absorption
Absorbed

Ceiling 280 0.14 39

Walls.... 672 0.57 382
36-in. horizontal plane.. 376 1.00 376
Total 797
198. Point-by-point method. The third method of conaputing illumi-
nation, the " point-by-point" method, is laborious but it is best calculated to
yield results which are accurate in detail. By this method an exact compu-
tation is made of the intensity of light directed upon any surface by the light-
ing equipment, and to this is added an estimated amount for the diffused
And indirectly reflected light which supplements the direct light.
199. Illumination intensity. The determination of intensity at any
point when the distribution of light is known, involves the application of
'two fundamental laws, the inverse-square law (Par. 200) and Lambert's
cosine law (Par. 201).

Fig. 47. — Illustration of inverse-square law. Fig. 48.

200. The inverse-square law (Par. 199) is demonstrated in Fig. 47 and 48

n which it is apparent that at twice the distance the given flux of light radiat-
ng from a point source covers four times as great an area and therefore its
lensity is one-quarter as great. Proof of this law is as follows: let E = Ii>»
ensity, in foot-candles; i'' = Flux, in lumens; S = Surface, in sq. ft.

p= ^ = J^ (6)
S 4xrs

(7) or - = - (8)
that is E varies as l/r.*
201. Lambert's cosine law (Par. 199).
If, however, the plane surface upon which the
lightfallsisinclinedfrom the normal, the flux
of light incident upon the surface will vary
as the Cos of its angle of inclination. This
is known as Lambert's cosine law.

E-'^ (9)

where / is the candle-power, the angle of in-

$ is
clination to normal, and d is the distance from
source to surface. This reduction in incident
flux due to inclination of the surface is illus-
trated in Fig. 49 in which it is seen that if the
— Illustration of co- surface is inclined 60 deg. from the normal, the
sine law. incident flux will be halved (Cos 60 deg. = 0.5).

1183
Sec. 14^202 ILLUMINATION
202.
 ILLUMINATION Sec. 14-203

203. Computation of illumination intensity at any point. In com-

puting the illumination intensity or flux density upon any surface, the dis-
tance from the light source to the surface is computed, the candle-power ia
divided by the square of the distance in order to obtain the normal illuiaina-
tion intensity, which is multiplied by the Cosine of the angle of inclination
of the surface in order to obtain the flux density or illumination intensity
for any desired inclination.
/.Coa2«
in ft.-candles or lumens qq)
per sq. ft.

in ft.-candles or lumens q j\
pet aq. ft.

Ev<
Sec. 14-206 ILLUMINATION

of a surfacewhich is not a perfect diffuser may vary with angle of view, but
large
if it is enough to cover the field of view, its apparent brightness will not
vary with distance.
406. Eelation of brightness to incident light. This may be stated
only for a projected area of a perfectly diffusing plane surface for which
b = mE where b is the brightness; m is the coefficient of diffuse reflection;
and E is the incident flux. Brightness is expressed in lamberts. A perfect
diffusing surface emitting or reflecting 1 lumen per sq. cm. has a brightness
of 1 lambert, equivalent to 2.054 candles per sq. in.

APPLIED ILLUMINATION
THE FUNDAMENTALS OF VISION
207. Contrast vision. We see things by reason of contour, relief and
color, i.e., shade perception and color perception. According to Fechner'a
law of sensations we perceive a fixed fractional difference of the total, irre-
spective, within Umits, of the amount of the total sensation, and the sensa-
tion is proportional to the logarithm of the stimulus. This minimum per-
ceptible contrast is usually of the order of 1 per cent., and, with increasing
brightness within wide working limits, the visual power increases but slowlj
208. Color sensations. Ocular discernment as presented in the Young-
Helmholtz theory is based upon three primary sensations red, green and blue,
:
 ILLUMINATION Sec. 14-211

or best vision under any condition of light intensity; (b) induction, the
name applied to that enect of contrast which causes a dark surface to appear
darker when in juxtaposition with a brighter surface or vice versa; (c) Pur-
kinje effect, the tendency of the eye to become more sensitive to light of
short wave lengths than to light of long wave lengths when the intensity is
low. Due to the last-mentioned effect, with the same low intensity of light,
blues and greens appear brighter than does red. See also Par. 10^12.
211. Threshold vision. In many ocular tests the point of minimum
perception is the basis adopted. These are known as "threshold" or
"limen" tests, and are applied to determine visual acuity, flicker, etc.
Visual acuity is generally expressed in terms inversely proportional to the
visual angle subtended by the observed object at threshold value, unity being
taken as an angle of 5 min. Visual acuity is tested by determination
of the smallest discernible object, as a letter, under a given low intensity of
illumination; or the greatest distance at which a given object under a given
intensity of illumination may be discerned; or the minimum illumination at
which a given object at a given distance may be discerned. Flicker tests
usually consist in the determination of the minimum change in intensity
upon an observed object which may be perceived with a given rate of flicker,
or the minimum rate of flicker which may be detected with a given change in
intensity. Threshold tests of shade perception are also applied. The line
of divi.sion between such tests and visual acuity tests is not clearly indicated,
since some visual acuity tests in one sense are shade perception tests. In
all such tests the accuracy attained is of a lower order than that attained in
comparison tests where one surface is brought to the same brightness as
another surface in juxtaposition to it.
212. Psychology of vision. Vision is a combined physiological and
psychological process. For example, the eye as an optical instrument pro-
duces upon the retina an inverted image of an object viewed. This applies
the stimulus to produce the sensation. The mind interprets before the
object is rightly perceived. Therefore the subjective phenomena associated
with vision are of prime importance; unfortunately they are but little under-
stood by lighting practitioners. The observer's conception of the appear-
ance of objects, images of which are impressed upon the retina, depends
upon the mental interpretation of such images in the light of tradition,
memory and experience.

CHARACTEKISTICS OT ILLUMINATION
213. Steadiness vs. fluctuation in light. Reliability in an illumination
system is a first requisite. Of a like obvious character is steadiness. Un-
steadiness is distressing and perhaps injurious to the eyes in spite of the pro-
tective features with which they are provided. Unsteadiness of light, as
encountered in flames which fluctuate with atmospheric disturbances, is not
found in electric illuminants as a rule, though arc-lamps exhibit somewhat
jsimilar tendencies. Unsystematic fluctuations in the arc may be due to a
wandering of the arc. This propensity changes the light-distribution char-
acteristics, notably in the open carbon-arc lamp; or results in vaporizing
» more or less luminous material from the electrode, as in the flame-arc lamp
and metallic-electrode lamp. Requirements in indoor lighting are such as
to bar badly fluctuating light sources from general use. The requirements
"or exterior lighting are less rigorous in this respect, and therefore arc-lamp
Juctuations which could not be tolerated for most indoor purposes, do not
»nstitute serious objections for some classes of exterior lighting.
Incandescent lamps are subject to unsystematic light fluctuations only
vhen operated upon a circuit which carries a varying power load as, for
ixampie, elevator motors. Systematic light fluctuations occur on
Jternating-current service. Incandescent lamps are characterized by greater
hermal stability than arc-lamps, and these cyclic light fluctuations are
herefore less serious. For incandescent lighting, 35 cycles appears to be the
pproximate lower frequency limit for satisfactory service of all classes,
nough for many purposes 25 cycles lighting has been found satisfactory.
214. Intensity or flux density is an all-important fundamental to be
"^^Wansidered in illuminating practice. Sufficient intensity of light must be

1187
Sec. 14-215 ILLUMINATION
provided to serve utilitarian purposes, to enable the eyes to accotti'plisli their
—
function without undue fatigue, and to create pleasing effects three purposes
which must be served in the order of their importance in all installations. To
accomplish this it may be necessary to provide an illumination of uniform
intensity, or the flux may have to be distributed dissymmetrically. Shadows
are important, contrasts must be correct and a careful study of the inten-
sities necessary to produce brightness of the right order is essential to success
in lighting installations.
216. Illumination intensities for various classes of service. Experi-
ence is teaching that economy is promoted by the adoption of much higher
intensities in industrial work than have heretofore prevailed. Every re-
ported experiment shows increased production, diminished shrinkaKe and
satisfied employer and employee when a change to Jiigher intensities has
been made in installations where the judgment of competent engineers has
guided the selection. But there is lacking information to show whether
such higher intensities are lower than or higher than the intensity yielding
the greatest economy of production. The best guide available at the present
time is to be found in the Code of Lighting of the Illuminating Engineering
Society and in the several State Industrial Lighting Codes which are modeled
upon the Society Code. Some of the state codes prescribe detailed minima
for a variety of industrial operations. The Code of the State of Oregon
shows preferable intensities for a great variety of operations. Some repre-
sentative values are given in Par. 219.
216. Direction. The best direction for the strongest component in any
illumination system is peculiarly a matter for determination after study of
local conditions. In natural lighting there is usually a strongly directed
component, the only exception being a condition of diffused light such
as that produced by mists, rain, etc. A great variety of directions for this
principal component is experienced, ranging from one almost directly
downward at mid-day in the summer to one which is almost"horizontal just
after sunrise or just before sunset. It is probable that the most pleasing
direction for daylight conditions lies well between these two extremes.*
The direction of light in interiors illuminated from side windows is unnatural
and in many instances is neither pleasing nor comfortable. This is especially
true of offices in high buildings where nothing but the sky is visible through
the window from a point well in the interior of the room.
217. Direction of light affects appearance. A suitable direction
for lightis very important in industrial work where the avoidance of shadows
and the avoidance of glare are of paramount importance. The appearance
of a room is very largely dependent upon the direction of the light. t In
ornamentation, relief designs are absolutely dependent upon the relation of
light and shade. J Usually they require not only a noticeable directed com-
ponent but also they require that the direction of that component shall be
correct. So also, in the general appearance of a room and of the objects
contained in it, shadows are important and their proper direction is a proini-
nent factor in determining the final appearance of the room. The direction
of incident light is, to some extent, a determining factor in the extent and
characteristic of the reflection from surfaces. ||

218. Diffusion. See Par. 220. If light from a point source passes-
through crystal gla.ss or is reflected by a mirror, the rays are uniformly diver-
gent, that is characteristically radiating. If the crystal glass or the mirror bei
replaced by an etched glass and a mat reflecting surface respectively, the
uniform radiating characteristic is lost, the rays are scattered, and further:
propagation takes place in a multiplicity of directions. Such light is called*!

•"Distribution of Luminosity in Nature." Ives and Luckiesh, Tr

Illg. Eng. .Soc, 1911.
f Ives. " Some Home Experiments in Illumination," Trans. Illg. 1-
Soc, 1913, p. 2;58.
X Luckiesh. "Importance of Direction, Quality and Distribution of Light,'
Proceedings American Gas Institute, 1913.
II
" The Effect of Variation of the Incident Angle on the CoeflScientof Dif-
fuse Reflection." Gilpin, Trans. Illg. Eng. Soc, 1910.

118S
 ..

ILLUMINATION Sec. 14-219

diffused light. If the surface which occasions the diffusion is of large area
and the illuminated object is relatively close to the diffusing surface, it ia
illuminated by diffused light. If, however, the object is relatively far
removed from the diffusing surface, it is illuminated by light from essentially
one direction, the rays are nearly parallel, and the light is but little diffused.
Hence, diffusion is a relative term, and the subject is difficult to treat in a
definite way.

219. Illumination intensities prescribed in factory lighting codes

I. E. S. New York Oregon

Code, 1917, State,* Code, 1919,
Operations
"Ordinary 1918 "Preferable
Practice" "Minima" Intensities"

Rough manufacturing:
Machining, assembling, punch
work, etc., foot-candles
Foundries:
Fine molding, grinding, ma-
chine molding, foot-candle
Core making
Foundries, foot-candles ....... 1-9
Rough manufacturing involving
closer discrimination of detail,
foot-candles 3-6
Fine manufacturing:
Lathe work, pattern and tool
making
Light colored textiles, etc 3-12
Jewelry 8-t
Printing:
Job presses 3-12
Lithographing
Engraving
'
Shoe manufacturing:
'
Most processes
Inspection and finishing. . .

Light 3-12
Dark 8-t
Electrical manufacturing 4-12
Special fine work:
Watch making, engraving,
drafting, dark colored tex-
tiles,etc _
10-15 8-t
Dark colored textiles:
Most processes
Weaving, knitting, inspect-
ing
Office work 4-8 4-12
Stairways, passageways, halls . . 1-2
Storage spaces i-1
Roadways and yard thorough-
fares

aao. Various degrees of diffusion.

See Par. 218. Perfect diffusion
t obtained within a hollow sphere whose inner reflecting surface is
light is
;at. Some
plane-reflecting surfaces are nearly, if not quite, perfect diffusers
'
light. Perfect diffusion may be represented graphically by a circle, tangent
?on the diffusing surface. Imperfectly diffused transmission or refiectioa

• Tentative and not at present mandatory,

t Upper limit not decided upon.

1189
Sec. 14-221 ILLUMINATION
may be represented by various curves having radials elongated in the direo
tion of regular transmission and reflection, indicating correspondingly lesse;
distribution in other directions than is provided by perfect diffusion.
A variety of reflection characteristics
is illustrated in Fig. 53, ranging from
perfect diffusion to a combination of
regular and diffuse reflection charac-
teristic of glossy paper.
221. Need for diffusion. Diffusion
tends to avoid glare and to solten
shadows. Its accomplishment in-
volves the substitution of secondary
lightsources which are relativelylarge
and therefore of low brightness when
compared with the source of light.
Artificial lighting is usually inferior to
natural light in respect to diffusion, t
In practically every installation there
is a real necessity for introducing arti-
ficial means of diffusing the light.
222. Color in its physical aspects
has been treated in the discussion of
the production of light (Par. 27). The
spectrophotometric values of light
from the several common illuminants
have been supplemented by color-sensa-
tion values as determined with color-
mixing instruments. Referring fur-
ther to the subject in its physiological
relations, it may be noted that there
are three primary colors, namely: red,
green, and blue-violet, using pure Fig. 53.— Various degrees of diff us
spectrallight. With these three colors, reflection. Lightincident45deg.be
light of any desired color value may be low horizontal, surface being verti
produced. In his ability to modify cal. A, perfect diffusion; B.reflec
the color of light, the illuminating en- tion from glossy paper; C, reflectioi
gineer has at his disposal a means of from semi-glossy paper; D, reflectioi
enhancing the attractiveness of an in- from mat paper.
terior as will be brought out more in
detail under discussion of congruity in illumination. Par. 232. It also is
i

field in which there is an opportunity for profiting by certain peculiarities o

vision (Par. 208).

PHYSIOLOGICAL AND PSYCHOLOOICAL EFFECTS OF

ILLUMINATION
223. Contrast. Once the correct general inten.sity of light (Par. 216
is secured, all other aspects involved in direction (Par. 217), diffusion (I'ai
218) and color (Par. 222) as well as in the distribution of the light to produc
various intensities, must be so manipulated as to secure the proper degree
of contrast. The more the subject of good illumination is considered, th
more prominently does contrast force itself upon attention as a fundaments
which must be served if an installation is to be successful. This applie
both to contrast of light and shade and to contrast of color. Contra.«t c
light and shade resolves itself into a question of varying brightness, embrac
ing the range of brightness values from a brilliant incandescent-lamp fila
ment or an arc, down to the deepest shades within view. The unsh!ide<

• " The Diffuse Reflection and Transmission of Light," Transac

Nutting.
tions Eng. Soc, 1912.
Illg. ttt
, .j
tLuckiesh. "Investigation of Diffusing Glassware, Electrical World
Nov. 16, 1912 and April 26, 1913.
1190
 ILLUMINATION Sec. 14-224

incandescent lamp glowing outdoors in the daytime does not appear very
bright against a background of sky, and may be viewed directly without
discomfort. The same unshaded lamp burned at night in a roorn which is
decorated in light colors, will prove annoying, while if burned in a room
of which the decorations are of low reflecting quality, as dark woodwork,
the lamp will prove positively intolerable. In the three cases the brightness
of the lamp remains the same, and it is the varying contrast with its sur-
roundings which erplains in the one case, absence of discomfort and in the
other extreme case, the most serious kind of ocular discomfort.

224. Need for concealing light sources. In Par. 31 brightness

values for various unshaded light sources are given. It will be observed, for
example, that these range from less than one candle-power per sq. in.
for the Moore tube to 4,000 candle-power per sq. in. for the magnetite arc.
This is, indeed, a wide range in brightness. When, however, it is remembered
that the brightness of a very well-lighted wall, decorated in some light
tone is of the order of 0.003 candle-power per sq. in., it will be seen that the
variations in brightness of commercial light sources are small in compari-
son with the contrasts between any of them and the surfaces with which they
are likely to be surrounded in practice. Herein lies the necessity for shading
light sources in order to protect the eye against excessive contrasts. Entirely
capable of protecting itself against excessive brightness, the eye is not able to
see the objects of relatively low brightness and at the same time guard itself
against the very high brilliancy of an exposed light source. There still
remains the necessity for avoiding the intrusion of reflected images of the
light sources in the ordinary field of view. A well-shielded light source may
be exposed in the direction of a polished table top, the surface of which may
reflect an image of the light source, subjecting the eye to almost as great
strain as though the actual source were exposed. Glossy paper, shiny
materials to be worked upon, polished woodwork, etc., are likely to introduce
this sort of difficulty. Nature's surfaces as a rule are not shiny; artificial
surfaces are likely to be shiny. In abolishing glossy paper, polished wood-
1 work, etc., a long step is taken toward the elimination of excessive contrasts
in artificial lighting. It is not possible, however, to abolish all such surfaces,
and in other cases it is not done. It is, therefore, desirable to conceal the
'
light source further. Accordingly, the improvement of a few years since in
1 providing translucent reflectors which largely cover incandescent lamps and
Bhield them from direct view, has been supplemented more recently by frost-
ing the lower part of the bulbs of the lamps and the interior surfaces of the
reflectors in order to soften and diffuse the light. Consequently, when
reflected images are encountered, their brightness is rendered of as low
lan order as practicable. More recently still, bowls have been employed,
either opaque or translucent, which intervene between any point of observa-
tion and the light source proper, softening and diffusing the light and direct-
ing a part or all of it toward the ceiling, whence it is further diffused and
reflected downward.
226. Olare due to light source. Excessive brightness and light out
put of surfaces or objects within the field of view give rise to glare. Where
the light source itself is within view, or a more or less imperfect image is
viewed upon a polished surface, the effect is much the same (Par. 223).
Glare may actually reduce one's visual power temporarily; it may occasion
idiscomfort and eyestrain; or if continued long enough, it is thought likely to
impair visual organs. The effect of temporary reduction in visual power
has been studied extensively.* In Fig. 54 is shown the reduction in visual
power due to the presence of an exposed lamp in a dark room. The observers
viewed a dimly illuminated test object. The presence of a 16-candle-power
bare lamp 2 deg. from the test object reduced the observer's abiUty to discern
the test object to about the same extent as would follow a reduction in
Jlumination of 80 per cent. As the light source was removed from the
observed object, its detrimental influence became less marked, falling ofif
Tapidly until the angle of separation was 4 deg., and thereafter at a slower.

i
• Sweet. " An Analysis of Illumination Requirements in Street Lighting,"
loumal of the Franklin Institute, May, 1910.

1191
 Sec. 14^226 ILLUMINATION
rate until at about 15 deg. the effect disappeared. Because of the very
exaggerated conditions of dark surroundings and dimly illuminated test
object, the results here obtained show diminished visual power far beyond
that which would likely be experienced in practice. They illu.strate the
effect, however, and are suggestive of the need for concealing the light source.
It is to be noted that, though no reduction in visual ability could be meas-
ured when the source was removed 15 deg. from the centre of the field of
"
view, yet the discomfort and E^nnoyance due to its presence were very severe.

loor

yl- 18 C.P. Lami -Leisure JyObserv ition

£ . 16 q.P. Lami -Hasty O jscrvatioo

'^ C-150 O.P, Lamp-Leisurely ObBervktion

B/. /
2 4 6 8 10 12 11 16

VUiuU Augle-Uegiees

Fia. 54. —Influence of glaring light source in decreasing visual power.

226. Qlare due to reflected image of light source. Glare due to images
of light sources reflected from shiny surfaces is probably more productive
of harm in the present stage of practice than is glare directly due to exposed
light sources. While the imperfect rendering of the image by the
usual polished surfaces decreases the brightness materially, yet the loca-
tion of the reflected image is often so near the centre of the field of vision as
to be much more serious than an exposed light source further removed.
Viewing a glossy paper at the critical angle in which the image of the light
source is reflected to the eye, it may be impossible to read print. This effect
is diminished by altering the position of the object or of the observer, but, due
to minute irregularities of the surface of the paper, there is still likely to be
an appreciable regular reflection toward the eye. Likewise, paper which
is only sUghtly glossy may reflect regularly toward the eye an appreciable
section of the image of the Ught source without introducing so serious an
effect as to prompt the observer to change position. Such conditions are the
source of much discomfort and dissatisfaction experienced in artificial light-
ing. If they are to be avoided, light sources must be shielded both from
immediate observation and from possibilities of reflection from glossy
surfaces.
227. Reflection Factors. If it be assumed that softly diffused light is
distributed generally throughout an interior producing uniform illumina-
tion, contrasts are dependent wholly upon the reflecting qualities of the
illuminated surfaces. As these are usually less readily changed than the
distribution and quality of the light, it is desirable to consider them before
determining upon tfie degree of uniformity which should be achieved in light
distribution. Uniform illumination with uniform decorations in an interior
would be undesirable from every standpoint. Uniform illumination with
heavily contrasted decorations and fittings may be acceptable. It is there-
fore of interest and value to obtain information on the reflection factors of
various surfaces, such are contained in Par. 228.

1192
 ILLUMINATION Sec. 14-228

o
Sec. 14-229 ILLUMINATION
229. Shadows. Further contrasts are encountered in shadows. The
more generally the light is distributed, the lighter are the shadows; the more
generally the light is diffused, the less sharp are the shadow contours.
Both depth of shadow and sharpness of outline are of importance in contribut-
ing to the effect of contrast. When properly treated, relatively deep shadows
are of importance in contributing to perspective and in producing a satisfying
effect. In some kinds of industrial work, in office work and in some other
classes of work all but very soft shadows should be avoided. Rolph ' has
concluded that for working surfaces when the shadow has sharply defined
outline, it should not be more marked than 15 per cent., while if the outline
isquite indefinite, as with well-diffused lighting, it may be as much as 50 per
cent.
230. Color contrast. The remaining aspect of contrast is the important
one of color. Pleasing color contrasts are of value in affording rest for the
eye, in lending perspective, and in preventing monotonous effects. The
color effect of a given surface depends to no little extent upon the color of
other surfaces in the field of view with which it is contrasted. Also, very
slight modifications of the light may produce marked changes in the appear-
ance of the colored surfaces. The choice of the correct color for the light
employed in a particular case is therefore essential to successful illumination
from the decorative standpoint.
231. Permissible contrasts. In general, authorities state that bright
objects to which the eye is subjected should not exceed 4 or 5 c-p. per sq. in.
(0.62 to 0.78 c-p. per sq. cm.) if physiological requirements are to be met.
This applies to interiors at night. The limitation is relative rather than
absolute. One authority,! while asserting the impracticability of fixing any
standard, suggests that if the brightness of the object upon which the eyes are
employed is of the order of 10 times that of surrounding objects, physiological
requirements will be met satisfactorily.
232. Congruity. The requirements of esthetics are for illumination
and an illuminating equipment which shall be pleasing to the senses and in
harmony with the character of the premises illuminated. In buildings of
notable architectural design the equipment should not only be suitable for
its surroundings but the illumination should produce such combinations of
light and shade, such contrasts, such color effects aa will bring out in true
proportions the important architectural features of the building, and will
render its ornamentation in the manner conceived by the architect. In
churches the illuminating equipment and the illumination must be of a
character which is in keeping with the religious purposes for which the
building is designed. In manufacturing establishments, effective illumina-
tion should be provided from simple, practical equipments. Incongruity
of fixture, auxiliary, or illuminant; or unsuitability of light in quality, in-
tensity, direction, etc., may mar an otherwise efficient illuminating system.
233. Pigmentary colors. Color of light, like color in decoration, is an
aspect which affords many opportunities for skillful use by the illuminating
engineer. In pigments, red, yellow, and blue of certain kinds and in certain
proportions will produce white or any other desired color. They are some-
times referred to, therefore, as the primary colors, though, in a scientific
sense, pure prismatic colors, respectively, red, green, and blue-violet, are the
primary colors. The colors used for decoration are, however, dependent
for their appearance upon the quality of the light by which they are illu-
minated.
It will be obvious, of course, that pigments which appear to the eye
similar as regards color may be quite different physically, and that there-
fore their rendering under light of various colors may be markedly different
from that here indicated. This is a field of application in which nothing
may be taken for granted; only by trial can the appearance of a given pig-
ment under a given light be determined. In decoration, therefore, a knowl-
edge of the quality of the light employed is of first importance. It is
essential that light be provided of such color value as will produce the
effect desired in decoration.

•Rolph. Trans. Illg, Eng. Soc, 1912, p. 242.

t Cobb. "Physiological Points Bearing on Glare," Trana. Illg. Eng. Soc,
1911.

1194
 3
6
7
5

ILLUMINATION Sec. 14-234

SS4. nitra-Tiolet light. Some alarm has been felt by physiologists

! lest ultra-violet lightfrom our ordinary illuminants should prove harmful to
; the visual organs. appears
It to be quite clear, however, that nothing of this
i kind is to be feared. Recent investigations* show that little is to be appre-
I
hended on this score. The ultra-violet radiation from commercial illumi-
nants is shown in Far. 235.
The data in this table arrange illuminants according to their ultra-violet,
radiation. Luckiesh, studying the same subject at about the same time,
arrived at the following conclusion:
" It appears that when glass is used over any commercial light source there
can be very little harmful effect when moderate intensities are used. Consid-
ering the greater intensities of daylight, protection, if necessary in any case, is
really needed against it rather than against artificial illuminants except in the
case of special use of the latter light sources."

METHODS OF ILLUMINATION
336. Direct lighting. The fact that light sources are usually placed
higher than the surfaces to be illuminated and that a downward direction of
the hght is rather generally desirable under such conditions, has led to the
236. Ultra-violet radiation

Ergs per sec. i)er sq.

Light source
cm. per foot-candle

Quartz arc {" Alba" globe) 4.3

Graetzin 11.7
" Gem " lamp, 100- watt 14.8
Cooper Hewitt (glass) 15.5
Sunlight (direct) 16.1
Acetylene flame 18.4
Tungsten lamp (100-watt) 22 .

Nernst lamp (globe) 25 .

JVIagnetite (glass) 30 .

Magnetite (quartz) 36.3

Old-quartz lamp (bare) 38 .

New-quartz lamp (bare) 87 .

Carbon arc (quartz) 91.0

\common use of inverted-bowl or cone-shaped reflectors. These have been

idiscussed at length in Par. 131 of this section. The fact that much of the
lli^ht of such equipments is reflected toward the objects to be illuminated
jwithout the interposition of reflecting or transmitting media, has led to the
iadoption of the term "direct lighting" for installations so equipped. The
iemployment of direct-lighting equipments usually facilitates the delivery of a
maximum percentage of the total light upon the surfaces to be illuminated.
'So important has it been considered to promote this end, that the term "effi-
ciency of utilization" (Par. 188) has sometimes been applied to the ratio of
light delivered upon a working plane to total light produced within a room.
This term has sometimes been applied to such ratios in installations where
the importance of illuminating other surfaces is as great or greater than that
of illuminating a working plane. Such misuse of the ratio of light delivered
upon the working plane to light generated has brought it into disrepute,
which has been the greater because of occasional application of the term
"illuminating efficiency." This term is especially inappropriate by- reason
of the fact that other considerations than intensity of light have come to be
regarded as of perhaps equal importance, though they are disregarded in
arriving at the "illuminating efficiency" by the method indicated above.
The ratio of utilization, or the per cent, of light flux delivered upon a working
plane, other things being equal, is greater when direct-lighting equipment is
employed than under other circumstances. It is more difficult, however, to

• Bell. Electrical World, April 13, 1912.

Luckiesh. Electrical W&rld, June 15, 1912.

1195
Sec. 14-237 ILLUMINATION
obtain that degree of diffusion of light which is essential to the avoidance oi
glare and the elimination of excessively deep shadows. Direct^lighting
equipment does not always yield, therefore, the most effective illumination
obtainable from a given amount of light produced within a room.
237. Indirect lighting. Some of the worst difficulties encountered in the
use of direct-lighting equipments were eliminated by the use of so-called
"indirect-lighting equipments," in which the light sources are entirely con-
cealed from view and the light is directed upon a reflecting surface such ae
the ceiling, which reflects and diffuses it. The reflecting surface in such sys-
tems becomes the apparent light source, and, being of large area, its bright-
ness is very much lower than that of the real source. In consequence, shad-
ows are softened, immediate glare effect is much diminished, and glare due
to reflection from specular surfaces is likewise diminished. Indirect-lighting
equipments produce conditions which are much more conducive to comfort-
able vision than are those usually attending the use of direct-lighting equip-
ments. It ie, however, much more difficult to control the light, and a much
greater portion of the light is usually lost before becoming effective.
238. Semi-indirect lighting. Equipments intermediate between these
two in respect to effectiveness of light direction, diffusion of light, soft-
ening of shadows and reduction of glare, have been classed broadly as "semi-
indirect lighting" equipments. These consist usually of translucent bowls,
translucency varying widely and brightness of bowl varying in a correspond-
ing manner. In point of fact there is very little difference between lighting
effects obtained with some indirect-lighting equipments and some .semi-
indirect lighting equipments because, in both, large proportions of the light
are directed toward the ceiling, whence they are diffused throughout the
room. Enclosing globes also are likely to produce results of much the same
order. When the translucency of the semi-indirect bowl is so low that its
brightness of transmitted light is not greater than that of the ceiling, the light-
ing effects are likely to be quite similar to those which obtain when indirect-
lighting fixtures are employed.
239. Intermediate types of lighting equipment. In brief, opaque
reflectorswhich allow little light to be distributed elsewhere than upon the
working plane are distinctively direct-lighting equipments and form one
extreme of a range upon the other extreme of which indirect-lighting equip-
ments may be placed. Between these two extremes are a great variety
of equipments, all of which distribute part of the light upon the ceiling and
part of it downward. It is difficult to differentiate among these intermedi.ate
equipments from the standpoint of illuminating results. Most such equip-
ments, however, may be located in one of three classes, namely (a) inverted
:

bowls or cones; (b) totally enclosing glassware; (c) translucent bowls.

240. Local illumination. The tendency in recent years has been to
depend upon general lighting as far as possible and to supplement it by local
illumination only where unavoidable. It is well to do so because with local
illumination it is difficult to avoid glare either from the source directly or from
the illuminated surface. When, however, it is necessary to illuminate locally
some surface, which must be very brightly lighted, every precaution should be
taken to avoid the evils just named. The application of diffusing media and
care in locating the light source will go far toward accomplishing this; and
satisfaction is doul)ly assured if, in addition, there is an ample general illumi-
nation supplementing the local illumination.
ILLUMINATION DESIGN
241. The purpose to be served. In laying out an installation a first
—
step so simple and obvious that its mention might appear unnecessary is to
determine the purposes to be served by the lighting installation. Usually one
—
does not simply "light a room." He provides lighting in order to make a
store attractive to the prospective customer and to promote the sale of goi"l-'
to illuminate the work on the machine and promote its prompt, accur.atc
safeaccomplishment; to facilitate clerical work, promoting speed and ai
acy without fatigue to the clerks; or to enhance the beauty and charm , . ^
room in a residence. As a rule there are two or more principal objects to Ije
attained in every installation. And the practitioner who familiarizes him-
self thoroughly with the conditions underlying the requirements established
by these objects takes the first essential ntcp iu successful lighting design.
1190
 ILLUMINATION Sec. 14-242

242. Choice of illuminant. Usually general conditions narrow the

choice to two or three illuminants. In a residence any other illuminant than
incandescent lamps would be unsuitable. In a steel mill the choice would
probably be narrowed to Type C Mazda or mercury lamps. In a store
either Mazda lamps or intensified carbon arc lamps would be employed,
etc. In a street either magnetite or Type C Mazda lamps would probably
be considered. Reliability, simplicity, efficiency, color of light, steadiness,
cost (first, operating and maintenance) and size usually determine this choice^
243. Choice of auxiliary. Cost, ease of cleaning, ruggedness, efficiency
new and maintained, light-directing quahties, diffusion, color, size and appear-
ance have to be considered. Obviously, the importance of each qualification
depends upon the nature of the installation.
244. Spacing and height. In industrial and commercial lighting it is
generally considered that the spacing should be something like 50 per cent,
greater than the vertical distance from the plane of illumination to the light
aource. This is a sufficiently good relation to form a point of departure in
planning an installation. In large rooms it is useful to divide the floor area
into squares or approximate squares. Desirable sizes of these squares are
given in Par. 246. * One light source may be placed over the middle of each
such square. Often, however, the squares or rectangles which form the unit
of space to be lighted are established by the confines of the room or by the
pillars or beams which make the division of the room into bays. In such
cases it may be practicable to treat the space as a unit or it may be necessary
to subdivide it into say four rectangles. Where uniformity of illumination or
a distinctly downward direction for the light is desired, smaller rectangles
should be adopted. Other things being equal, smaller rectangles should be
used for direct lighting and larger ones for indirect lighting because in the
latter case, the actual light source (ceiling) is higher and the diffusion is
greater. In general, the adoption of smaller rectangles, which means more
frequently spaced smaller light sources, results in greater uniformity less
marked shadows and less glare, while larger rectangles and larger illumi-
nants afford more pleasing appearance. Balance between these two depends
upon local conditions.
245. Desirable sizes of squares
Desirable length
Kind of room Ceiling height
of side of square

Armories 12 to 16 ft. 12 to 16 ft.

Auditoriums 12 to 16 ft. 12 to 16 ft.
PubUc halls Over 16 ft. 15 to 26 ft.
Rinks Over 16 ft. 15 to 26 ft.
Stores 8 to 11 ft. 8 to 11 ft.
Stores 11 to 15 ft. 10 to 16 ft.
Stores Over 15 ft. 14 to 22 ft.
—
Offices
— with desk
without desk
lights .

lights.
. . . 10 to 20
9 to 12
ft. 12 to 18 ft.
Offices ft. 7 to 11 ft.
—
Offices without desk lights. 12 to 16 ft. 9 14
to ft.
Offices— without desk lights i
Over 16 ft. 11 to 18 ft.

246. Amount of light to be provided. Assume that it is desired to light

» room which 20 by 12.5 ft. and 12 ft. high. The ceiling is white and the
is
stalls An average horizontal illumination of 4 foot-candles or
are buff.
umens per sq. ft. is desired. Under such conditions it is reasonable to esti-
nate that 50 per cent, of the light flux produced in the room can be delivered
ipon a horizontal plane with sufficient diffusion for most purposes, and with
imple light upon ceiling and walls. About 30 per cent, should be allowed for
ioterioration due to dust, etc. Therefore the light to be delivered upon the
M)-in. horizontal plane is to be considered as about 35 per cent, of the total
ight to be produced. The area of the room is 250 sq. ft. (20 by 12.5 ft.).
Fhis multiplied by 4 foot-candles, or lumens per sq. ft., yields 1,000
umens, which, being 35 per cent, of the total to be produced, gives 2,860
umens as an approximation of the total flux required.
• "Handbook on IncandescentLamp Illumination," GeneralElec. Co., 1913.

H97
Sec. 14-247 ILLUMINATION
A check upon the correctness of this estimate is had by the absorption of
light method (Par. 196).

Surface
ILLUMINATION Sec. 14^249

03 03
 '

Sec. 14-249 ILLUMINATION

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1200
 ILLUMINATION Sec. 14^250

cleaned at regular intervals, hence a fixed charge should always be included

for this service. Lamps which require frequent trimming are cleaned at the
same time, and the cost is included under the maintenance charge.
"The energy cost can usually be readily computed, but will, in the case of
some electric illuminants, depend upon the voltage of the circuit, since this
determines either the wattage or the power-factor. The effect of power-fac-
tor is seldom considered, although it governs the investment in generators,
transformers, and wiring, and, in a small degree, energy required. To the
central station or isolated plant, the volt-amperes required by a given lamp
are perhaps as close a measure of the cost of service as the actual wattage
consumed. When the consumer is purchasing energy on a kilowatt-hour
basis this factor, of course, is eliminated so far as he is concerned."
Principles of cost accounting in illumination may be laid down and with
discriminating application may serve to yield correct cost values. So largely,
however, are costs in lighting dependent upon local conditions, and so greatly
do these conditions vary, that it is unsafe to apply in one installation cost
data obtained somewhere else, unless the differences in condition are first
considered and allowance is made in the data for differences in such condi-
lions. But httle in the way of reliable impartial cost data has been published.
350. Cost of light in relation to other expenses. The total cost of
irtificial lightas a part of the cost of living or as a part of the total cost of
jperation of a business enterprise is very small. In 1912 the Department of
Commerce and Labor in a bulletin entitled "Retail Prices 1890 to 1911"
ihows that as an average of 2,567 workingmen's famihes in 1901, the average
soBt of lighting per annum was $8.15 out of a total cost of $7()8.54, or 1.06
yet cent, expended in lighting. The report of the Commission of Labor for
1903, as presented at the 58th Congress, offers statistics compiled from the
lipenditures of 11,156 workingmen's families; these show that the cost of
ighting in workingmen's homes averaged then 1.13 per cent. The average
or any group, in a classification according to wages earned, was found not to
l^art from this value to any great extent.
151. Proportion of lighting costs to total operating costs. (1913)

Approximate cost of
artificial lighting in
Class of lighting installation
proportion to total
operating costs

Small wage-earner's home

ing to total income
— ratio of cost of light-
1 per cent.

Well-conducted large manufaotiiring establish-

inents which are well lighted with modern illum-
inants —
ratio of cost of artificial lighting to total
cost of output exclusive of selling expenses 1 to J of 1 per cent.

Large retail mercantile establishments

total lighting cost to total sales
—ratio of Probably less than
1 .0 per cent.

Small stores —ratio of total lighting cost to total 2 per cent.

Modern loft buildings 1 to 2 per cent.

Street lighting appropriations by municipalities are of the order of 60

;ents to $1 per inhabitant per year.

PHOTOMETRY
FUNDAMENTAL PEINCIPLES
i52. Disappearance or discrimination photometers. Various pho-
nieters have been devised based upon determination of the threshold of
sion. Some involve the discrimination of fine detail and are known as
sual-acuity photometers. A well-known example is the "illuminometer"

76 1201
 y

Sec. 14-253 ILLUMINATION

or reading distance instrument, which has been employed to some extent foi
street-lighting work. In this instrument the criterion is the maximum dis-
tance from the light source at which a given fine print may be read or th«
size of print which may be deciphered at a given distance from a light source
In another type the criterion is the perception of a given contrast, and maj
involve either the adjustment of the contrast for disappearance or the adjust
ment of the illumination for disappearance of contrast. An example of thii
is the "illuminometer" of Kennelly and Houston.* Still a third typo o
disappearance photometer has, as a criterion, the minimum perceptibli
flicker, and involves adjustment of the rate of flicker to determine disap
pearance or adjustment of the illumination to determine disappearance o
flicker. These several types of photometers and others involving, in i

modified form, the application of the same principles, are impracticabli

for measurement of illuminatioD because, like any threshold or limen tes
apparatus, they are subject to errors which are ocular or mental in origin am
are of an order so great as to make the instruments useless as photometers
These errors may be reduced by circumscribing the use of the instrumen
with precautions which limit the physiological variables. Even when th
utmost precautions are taken, errors of the order of 2,t jjer cent, are to b
expected. It is sometimes asserted that discrimination photometers are to b
looked to for the ultimate determination of illuminating value. This ha
not been demonstrated however. The true field for such apparatus and on
in which their utility is considerable, is in the study of vision.

263. Physical laws underlying photometry. Regarded as a physica

measurement, photometry rests upon the application of the law that ligh
from a point source varies inversely as the square of the distance (Par. 200
and that the illumination of a plane surface varies as the cosine of the aninl
of inclination to the incident ray (Par. 201). These laws must be applie(
with discrimination and with strict regard for their practical limitations
The inverse-square law holds good only when the light source is relativel;
small with reference to the distance from the source to the illuminated sui
face. If the distance is less than five times the maximum dimension of th
source, material divergence from the inverse-square law will result. Th
law may not hold good for relatively short distances when reflecting o
refracting devices are employed to concentrate the light in a particular direc
tion, as, for example, when a parabolic reflector is employed with an incan
descent lamp or, as a more extreme example, a search-light. The cosin
law applies to any plane surface insofar as the incident light is concerned
In many cases, however, the incident light is judged by the reflected or th
refracted light. In such applications, the cosine law holds good only if th
surface is a true diffusing surface, altogether free from regular reflectioi
characteristics.
264. Ocular characteristics affectingf photometry. In the com
parison of lights of similar color, the process is not unlike other physica
measurements since visual peculiarities do not affect the result. In hctero
chromatic photometry, in which lights of different colors are compared
ocular characteristics must be borne in mind, and the measurernents must b
carried out with due regard to the requirements which they impose. Th
three characteristics of greatest importance are as follows: (a) the Purkinj
effect (Par. 265); (b) yellow-spot vision (Par. 286); (c) partial color blind
ness (Par. 267).
266. The Purkinje effect is the name applied to the p-eater sensibilit
of the human eye to blue and green light at very low intensities than to red o
yellow In accordance with this characteristic, if a mercury-vapc
light.
lamp is adjudged equal in illuminating power to a tungsten-filament lam,
when the two are compared at a distance of 10 ft., the mercury-vapor lam^
would be adjudged of higher illuminating power than the tungsten lamp :j

the comparison were to be made at a great distance.

266. Yellow-spot vision. The central portion of the retina of the i

the yellow spot, comprehends a visual angle of 6 to 8 deg., throughii

which the eye is less sensitive to green and blue light than is the surrouiuliih
portion of the retina. If a comparison of a mercury-vapor lamp and
'

tungsten lamp of equal power were to bo made upon a surface so small as t

• Electrical World, March 9. 1895.

1202
 ILLUMIN'ATION See. 14-257

allwithin a visual angle of 6 deg., the mercury-vapor lamp would be adjudged

)flower illuminating power than the tungsten. While a relatively higher
^valuation would be accorded the mercury-vapor lamp if the illuminated
urface were to be enlarged so as to comprehend a visual angle of say 24 deg.
M7. Partial color blindness is often encountered. Eyes of certain
ttdividuals are found to be less sensitive to light of a given color than are
.ormal eyes. The characteristic sensibiUty of the eye to light of different
dors and of a given intensity when plotted diagrammatically is known as the
iminosity curve* (Par. 10). If an observer's sensibility to red is low, as
hown by the luminosity curve for his eye, he would, of course, adjudge the
luminating power of a mercury-vapor lamp to be relatively high as com-
ared with that of a tungsten lamp.
SS8. Psychology in photometry. In all photometry and especially in
|eterochromatic photometry, observers whose eyes may have quite similar
laracteristics sometimes secure markedly different results, due to the fact
jiat they form different concepts of the appearance which two illuminated
irfaces must assume when they are balanced. Usually, an observer forms
coDoept and adheres to such concept until persuaded that it is improper,
his is a matter of memory, tradition, and, sometimes, of external influence,
is common experience that observers who work together in photometry
nd to form similar concepts and to agree in their observations under all
^nditions. Sometimes the concept agreed upon by such observers is the
obable correct concept reached as a consensus of opinion. On the other
\nA it may be the concept of one observer which another observer has been
fluenced, unconsciously, to accept.
M9. Heterochromatic photometry. No
final determination of the
lative illuminating power of lights of different colors has been made. It
^^ls probable that there cannot be any one factor to express this relation
cause the illuminating power of hght of different colors depends, first,
on the intensity at which it is employed and second, upon the purpose
which it is employed. Conditions are ripe, however, for the establish-
|mt of arbitrary standards of light of different colors to serve for purposes
heterochromatic photometry. Much work is being done on the subject
d reliable standards representing the best assignments of values which
ve been made will shortly be available. With such standards, consisting
her of sources yielding light of various colors or of color filters for modifying
5 fight of a given source, heterochromatic photometry is reduced to the

mparison of fights of similar colors, under which conditions the ocular

aracteristics affecting the problem may be largely ignored.

STANDARDS OF LUMINOUS INTENSITY

160. now in use. All primary standards
Primary standards which
employed in practical photometry are flame standards. Flame standards
esteemed rather highly in the gas industry because their candle-power is
isidered to vary more or less as does the illuminating gas flame with
inges in atmospheric conditions. Flame standards include the Hefner
ip, the Pentane lamp, the Carcel lamp and candles. AU are capable of
Iding accurate results when employed with strict regard for their limita-
tts. The material of combustion must be carefully selected in accordance
h strict specifications. The construction must be accurate; good venti-
ion and freedom from drafts is essential; accurate adjustments and cor-
tions for variations from standard atmospheric conditions are funda-
ntally important. For detailed description see any text-book on
jtometry.
|61. Proposed primary standards. The need for a primary standard
ight which shaU have a definite value and be absolutely reproducible has
to a number of interesting proposals. Without referring to a number of
posals which have been given a trial, without attaining sufficient sucess to
.-rant their adoption, it may be said that there are two recent proposals
BOnsiderable merit. Steinmetzf has suggested that the red, green and
e fine radiation of the mercury arc, aggregating one watt, be adopted as
'— dard of light. Ivesf has recommended one watt radiated in energy
Ives. Philosophical Magazine, T>ecemheT, 19\2.
Transactions A. I. E. E., 1908, p. 1319.
Transactions Illg. Eng. Soc, W12, p. 376.

1203
Sec. 14-262 illumination

ofmaximum luminosity. Both suggestions depend for successful applicati

upon the accurate measurement of radiant energy, and Ives' suggesti
involves further the accurate transfer from green to white light throu
heterochromatic photometry.
262. International candle and its equivalents. An important st
toward international agreement upon a unit of light was taken through t
cooperation of the Illuminating Engineering Society and the Bureau
Standards in 1909. While the Hefner lamp is the official unit of light
Germany, yet the simple relation 1 Hefner = 0.9 international candle w
agreed upon as the result of the same international cooperation. The f
lowing relations now hold: 1 international candle == 1 Pentane candle*
Bougie decimale=l.ll Hefner unit = 0.104 Carcel unit.
263. Representative standards. Seasoned incandescent lamps c«
brated in international candles and held in the custody of the Governme
laboratories in England, France and the United States are for all praotii
purposes the official standards of light in these countries. AccuraU
calibrated lamps derived from these standards may be procured from t
Bureau of Standards and from testing laboratories for use as refcreu
standards.
264. Reference standards. It is customary in important photomet
work to procure a number of reference standards calibrated in internatioi
candles and to use these occasionally for the verification of other standai
which are in daily use and which are known as working standards. Thj
in turn are used for the occasional calibration of comparison standards whi
are burned continuously in a photometer. All electric incandescent lai
standards have a limited life; hence lamps which are used for continue
comparison purposes must be verified occasionally and the repeated use
the working standards employed in such verifications in turn limits th
period of constancy. A complete range of reference standards and worki
standards is important if comparison standards are to be relied upon 1

accuracy.

PHOTOMETERS AND PHOTOMETRIC APPARATUS

266. Physical or non-ocular photometers. In the measurement
radiant energy there are employed, at various times, the thermopile, _(
radiometer, iind the bolometer. These are affected by radiation of varic
wave lengths in several characteristic ways, and, for some classes of physi
investigation, have very imporfant uses. The photo-electric cell, i
selenium cell, and the photographic plate also have been investigated witl
view to employment as substitutes for the eye in conjunction with a iiho
metric device. In addition to characteristics \yhich impose serious liinl
tions to their use for practical work, these devices arc open to the furtl
objection that radiation within the visible spectrum does not affect th
the same proportions as it does the human eye. Their sensibility cha:
istics do not conform to the luminosity curve of the human eye. The
electric cell, for example, is most sensitive in the region of 0.44/i in thi
end of the spectrum; the selenium cell, on the other hand, is most si'
to radiation in the region of 0.7/j, which is in the orange-red region
spectrum. It is possible to correct these devices by employing color
of such characteristics as to alter the sensibility curve to the desired
It is understood that those who are engaged in the study of these J
feel encouraged to hope that they may yet prove their value in some cl:
photometric work. Up to the present time, however, they have I'
scientific interest rather than of utility, in so far as ordinary photon)
concerned.
266. Photometric devices —
ocular. Itisacharacteristicof the hum
eye, termed "induction" that a uniform dark surfiicc placed next a licrh
surface appears darker in the region immediately adjacent to the !

surface than it does in the region farther removed. It follows t

bringing two surfaces to equivalent brightness, the contrast will

more marked if the surfaces can be brought into close juxtaposition,
the contrast is more marked, equivalency can be established with r
accuracy. Utmost precision in such adjustments is attained if the t-i.
are made continguous and without distinguishable sep.'vration. A p""
metric device (sometimes called a sight ht>x) is an appliance for pronioti

1204
 ILLUMINATION Sec. 14-267

he brightness equivalency adjustment which ia the essence of photometry,

'he more usual types may be classified as comparison devices, contrast
evices, and flicker devices.
267. Comparison devices. For a description of many simple photo-
letric devices which are of historicinterest, see text-books. * The comparison
S

Fig. 55. —Lummer-Brodhun photometer, comparison type.

jvice inmost general use at the present time is the simple Lummer-Brodhun
ibe, which is illustrated in Fig. 55. Light from lamp, L, falls upon one side
white plain surface, <S, and is in part reflected through mirror, M, and
.at part of the two prisms, P and Pi, which are in optical contact, to the
'6, 0. Light from the other lamp, Li, falls upon the other side of S, is
fleeted from the mirror, Afi, to the prism. Pi. That part of it which falls
jon the part of the prism which is in optical contact with prism P, passes

Lummer-Brodhun contrast prism.

rough P and absorbed, while that which falls upon the remainder of the
is
^pothenuse face of Pi, is reflected to the eye O. Portions of the two
rfaces of S are therefore brought into juxtaposition, as indicated in the
igram, and without perceptible line of separation. This form of photo-
rtric device is excellent where rapid settings are desired, but is not quite
iial for precision work, to the Lummer-Brodhun contrast device.

'Especially "Illumination — Its Distribution and Measurement," Trotter.

1205
Sec. 14-268 ILLUMINATION
S68. The Luxnxner-Brodhun contrast prism is employed in the sai
manner as the comparison prism illustrateci in Fig. 55. Its constructii
is different, however, as illustrated by the plan in Fig. 56. The hypothenu
face of one prism is ground away in three places, as indicated, and the alt<
nate halves of the outer faces of the two prisms are covered by thin gls
plates, G and Gi, which absorb 7 or 8 per cent, of the light which pass
through them. The photometric field appears as illustrated in Fig. 56, t
light from one side of photometric surface S being represented on the left
the diagram and by the trapezoid located in the right half of the field, tl
being 7 or 8 per cent, less bright than the other half of the field. Similarl
the light from the other photometric surface, Si, is represented by the sen
circle in the right of the figure and by the trapezoid in the left half of t
figure, the latter again being 7 or 8 per cent, less bright. With the contra
cube in proper adjustment and of proper optical characteristics, a phot
metric balance should bring to equivalent brightness trapezoids, S and
and also semicircle S and Si; in addition, the contrast between trapeze
Si and semicircle S should equal the contrast between trapezoid S and sen
circle Si Devices of this type have highest known sensibility for ph
tometry where no considerable color difference is involved.
269. Bunsen contrast photometer. In the Bunsen photometer
translucent screen normal to the photometric axis is rendered of high
translucency at the centre, and the appearance of the opposite surfaci
when illuminated by the two lamps between which it is located, is observ
through mirrors placed about 140 deg. from one another, as illustrated
Fig. 57. The greater translucency of the centre of the screen may be ma
by the application of hot paraffin, or, as in the Leeson disc, may be aecoi
plished by cutting a round or star-shaped hole in the disc itself and pasti
thin rice paper over both surfaces. Care and skill in the construction of t
disc are essential to precision of operation. As in the Lummer-Brodh
contrast photometer, the Bunsen photometer presents to view two contrt
fields. If properly constructed with mirrors of equal absorbing power,
condition of balance should bring equality of brightness and equality
contrast.
The Bunsen photometer is pre-
ferred by some for routine lamp
testing where highest precision in
individual measurements is not so ^'l^/^,^
important as good maintenance of
accuracy throughout the day's
work. It is inferior to the Lum-
mer-Brodhun photometer in sen-
sitiveness at low intensities. It is
somewhat easier to make settings
with the Bunsen photometer than
with the Lummer-Brodhun pho-
tometer in comparison of lights
of markedly different colors for
the reason that the illumination
of each surface of the disc is due
in part to transmitted light from
the other surface. Where colors
differ, there is a tendency to blend
and decrea.se the color contrast be-
low the actual contrast encountered
Fio. 57. — Bunsen photometer.
with a photometer like the Lum-
mer-Brodhun, where the lights are not mixed.
270. Flicker photometer. In flicker photometry the criterion of a
justment is the disappearance of the flicker effect, or rarely, the equality
two flicker effects. The flicker photometer is used as a rule only.whe
lights of markedly different colors are to bo compared. Due to persislcn
of vision, the colors, though markedly different, tend to blend when pi
sented to the eye in rapid alternation, and the color differences cease to
perceptible, while differences in brightness of the two surfaces are still visib
It is thus possible to make comparisons of markedly different lights wi
much less difficulty than when the equality-of-brightness method is employe
and different observers are much more likely to secure similar results, becau

1206
 ILLUMINATION Sec. 14-271

sihe criterion rests upon a physiological effect and leaves room for less differ-
isnce of opinion or less variation of concept than does the equality-of-bright-
iiess metnod. Ives* has found that witn the fUcker photometer, blue and
>reen light is adjudged of lower illuminating power when compared at low
Intensities with red and yellow light. This is a reversal of the Purkinje
'ffect (Par. 265) which obtains in equality-of-brightness measurements at
I'ery low intensities. He concludes, as the result of his investigations, that
she flicker photometer offers the best means of dealing with heterochromatic
ihotometry, but its use should be limited by specifying a standard intensity
t which comparison shall be made, a standard visual angle for the pho-
ometric field, and observers who are free from peculiarities of color vision,
incidentally, a similar prescription applied to any kind of photometry would
omuch toward standardization. Ultimately, heterochromatic photome-
y must be based upon the illuminating power as judged by some such
iterion as equality of brightness or power to reveal detail. The disappear-
nce of flicker cannot be considered as an ultimate criterion. However, a
icker photometer once verified and accepted in a given form as a reliable
evice for heterochromatic photometry, should prove very useful in that
ass of work because of the readiness with which settings can be made.
S71. Forms of flicker photometer. Roodf devised the first flicker
hotometer, which consisted of a wedge, the two faces of which formed the
hotometric surfaces, which were viewed alternately through a revolving

-5X

Elevation of flicker attachment.

A. Front lens. J. Front of eye-piece.
B. Collar for lens. K. Eye-piece.
C. Collar to hold telescope rigid L. Collar on eye-piece,
in head. A'^. Lamp socket.
D. Belt. O. Rotating collar for lamp.
E. Rotating prism. P. Eye lens.
F. Rotator bearing. Q. Collar for lens.
H. Stationary bearing for rotator. W
Wires to lamp. .

a. 58. —
Kingsbury-Ives Flicker attachment for Lummer-Brodhun pho-
tometer head.

The Whitman photometer is provided with a wheel, portions of

lose rim are inclined in opposite directions. As the wheel revolves, it
ssents to the eye photometric surfaces illuminated in turn by each source
ider comparison. The Simmance-Abady photometer operates on a similar
Jftiple. The Schmidt and Haensch flicker photometer is a refinement of
original Rood photometer. Kingsbury J has devised a flicker attach-
(nt for a standard Lummer-Brodhun photometer head which is constructed
accordance with the principles of standardization suggested by Ives (Par.
D). This attachment is illustrated in Fig. 58.

Philosophical Magazine, November, 1912.

f Science, Vol. VII, p. 757.
t^Kingsbury. Jour. Frkln. Inst., 1915, p. 215.

1207
Sec. 14-272 ILLUMINATION
372. Means of changingr intensity of light for photometric ad
justment. The principal nK^hods of adjustment of the intensity o
illumination upon a photometric surface are variable distance, variabli
inclination of the surface, variable rotating sector disc, variable diaphragms
polarizing devices.
273. Variable distance. This adjustment may be accomplished by mov
ing the photometric device between fixed lamps; by fixing the photomctrl
device and moving the comparison lamp; or by joining the photometric de
vice with the comparison lamp and moving both as a unit. The fir.st men
tioned method is that ordinarily employed in commercial photometry of in
candescent lamps. The moving comparison lamp is often used in portabl
photometers and in tests of lighting auxiliaries where it is desired to maintaii
a fixed distance between the photometer and the light source under test
The movement of the photometric device and the comparison lamp as i

unit is sometimes employed in precision photometry where it is desirabl

to maintain a fixed intensity of illumination upon the photometric surface
In all applications of the variable-distance method of adjustment, it ii

necessary to keep in mind the limitations of the inverse-square law (Par

253) and to guard carefully against errors due to light reaching the photo
metric surface after being reflected or refracted from other surfaces in such i

manner aa to interfere with adherence to the inverse-square law.

274. Variable rotating sector disc. Serious mechanical difficulties ari
encountered in constructing a rotating sector disc whose apertures may b
varied precisely during rotation. Even if such a device is construrtec
8ucces.sfully, it is inherently of low precision in the smaller aperture adjust
ments where a slight angular adjustment error may involve a large error ii
the total percentage of light transmitted. One of the interesting application;
of this iclea is embodied in the Beckstein photometer (Par. 284) in whicl
the beam of light is rotated about the centre of a stationary sector disc whow
angular openings are adjusted as desired.
275. Variable diaphragms. Unlike the variable-distance method am
the variable rotating sector disc method, the variable diaphragm method i,

dependent exclusively upon empiric calibration. However, when used ii

conjunction with a uniformly bright surface, as a diffusing surface or lens
it is a very useful device, and capable of very accurate calibration. It
principal use in commercial photometry is in portable photometers.
276. Methods of employing photometric apparatus. The photo
metric devices which have been described may bo used upon bars for th-
measurement of candle-power in one direction, or with integrating device
for the measurement of total flux, or in portable photometers. In all sucl
applications, any of the methods of varying the intensity which have bee:
described, may be employed. The principles are the same and the applica
tions differ only in accordance with the dictates of convenience an«
practicability.
277. Photometer bars. In the measurement of horizontal candle-powc
and in the measurement of distribution of light about a source, it is customar;
to employ a track upon which carriages supporting lamps or photornctri
devices, may travel smoothly and ea.sily. The Reichsanstalt bar i.s a:
approved type which, with various modifications, may be procured froir
any manufacturer of photometric appliances.
278. Light- distribution apparatus. A considerable variety of appli
ances for facilitating the determination of radial distribution of light
is available. These appliances include the Dibdin photometer; device
employing respectively one mirror, two mirrors and three mirrors; th
Matthews photometer, employing a ring of mirrors and apparatus in w*ic
the test plate is revolved about the source. For detailed description
text-books on photometry and manufacturers' catalogues. All such ;i

ances are designed to facilitate the determination of the intensity of lij:i

various angles in the vertical plane. Since the inverse-square law '.iv'.-
not always apply strictly to light from reflectors at the short distances a
which the light is utilized, it is good practice to maintain a fixed distanc
between the surfaces of the photometric device and the centre of the ligh'
source.

1208
 ILLUMINATION Sec. 14-279

INTEORATINQ PHOTOMETEES
279. General description. An integrating photometer yields in a single
neasurement the value of the total flux of light or the mean spherical candle-
)0wer of a light source. In general, most such devices, by optical or
nechanical means, reduce the intensity of the light, at various angles to
he vertical of the light source, in proportion to the area of the zone which
he angle bisects, and provide a summation of such reduced intensities for
he several angles throughout the vertical plane of the source. The inte-
Tating sphere intercepts and provides an indication of the total light
iroduced by the source,
''erhaps the earliest inte-
.rating photometer was
londel's lumeter. *
Cennellyt also devised an
pparatus for mechanical
btegration. The instru-
ments of Matthews and
Ilbricht, and especially the
itter, which are used at
he present time are de-
ttribed in text-books.
S80. Ulbricht integrat-
ng sphere. The inte-
ating sphere devised by
Mbricht has been found to
the most accurate and
I

actical form of integrat-

M photometer It has
en shown that if a light
)urce be located within a
oUow sphere having a dif-
ising inner surface and be
reened from a given ele-
ent of that surface, the
ijmination of such ele-
ent, being due entirely to
Fig.
total
—
59. Integrating sphere for measuring
lumens or mean spherical candle-power.
tfuse reflection, will be in-
jpendcnt of the location
'
the light source and its distribution characteristic. In practice the
Ibricht photometer is a hollow sphere, usually 40 or 80 in. in diameter,
is equipped to facilitate the introduction of the light sources to be meas-
red. It is provided with a suitable screen which is located between the
?ht source and a window which forms one surface of the photometric device.
tie general arrangement of the sphere is indicated in Fig. 59. The inte-
ating sphere is now recognized as the approved appliance for the determina-
on of total light flux or mean spherical candle-power.
PORTABLE PHOTOMETERS
Test plates. As portable photometers are generally designed for
281.
le measurement of illumination intensities, they are equipped with test-
ates which form one of the two photometric surfaces of which the bright-
!8ses are compared. As such plates must receive light at all angles above
le horizontal and from all directions, obedience to Lamberfs cosine law
*ar. 201) is important, and the deviation of most surfaces which it is practi-
ible to use from such law constitutes a material error. When the test-plate
translucent, and for photometric purposes is viewed from beneath, errors
this kind are irrespective of azimuth and are a function of the angle of
cidence of the flux under test. When the test-plate is viewed from the
ie on which the test flux is incident, directional errors intrude and are in
kliticn to those of inclination. Deviations from true value encountered
the measurement of light flux incident upon the test-plate at various angles
Blondel. "La Determination de I'intensite moyenne spherique des
jnrces delumiere," Comptes rendus, March and April, 1895 and L'Eclairage
ectrique.
t Houston and Kennelly. " Electric Incandescent Lighting," p. 461.

1209
Sec. 14-282 ILLUMINATION

are shown in the following table. In order to avoid these systematic oi

unsystematic errors to which most measurement of illumination is liable, i
compensated form of either transmitting or reflecting test-plate has beei
devised* one form of which is illustrated in Fig. 60.

Fia. 60. —Compensated photometer test-plate.

In order to compensate for the deficiency in brightness under light inci

dent at very acute angles, a part of such flux is brought to bear upon thi
lower surface of the test-plate, enhancing the brightness of the observec
surface. The amount of this compensating flux is subject to adjustmen
and the test-plate can therefore be made as accurate as it is possible t<
measure its brightness. Comparison of measured deviations from the cosini
law for two different uncompensated test-plates and for one compensate
plate are shown in the following table:
Test-plate Errors

Angle of
 ILLUMINATION Sec. 14-284

S84. Macbeth illuminometer. This instrument, of which the struc-

tural features are indicated in Fig. 61, is designed for the measurement of
[Bumination intensities and brightness, combining reasonably high accuracy
with a fair degree of portability. It is accompanied by a complete equipn
ment for the supply, control and measurement of current for the operation
of the comparison lamp and with a reference standard for recalibration.

Fig. 61. — Macbeth illuminometer.

he scale of the illuminometer yields direct readings from 1 to 25 foot-candles,
range which is increased from about 0.02 to 1,200 foot-candles by the use
: neutral glass absorbing screens. The optical device is a Lummer-Brodhun
uKe and the comparison lamp is designed to operate in conformity with
fie inverse square law according to which the scale is calibrated.

285.' Sharp-Millar photometer. This is available in two sizes, respec-

VI ly 12 and 24 in. long. Fig. 62 shows the essential features as embodied

Small Sharp-Millar photometer.

the smaller siase. The photometric device P, consists of a Lummer-Brod-
in cube or a microscope glass, mirrored except for a central aperture,
^king through this aperture from ocular aperture O, the observer sees
ther the attached test plate T, which is upon the end of a rotating tube,
the detached test plate Td. The photometric surface, as seen through
'ij tube, is surrounded in the photometric field by a portion of translucent

ass comparison window W . The illumination of window W varies in-

irsely as the square of the distance to moving comparison lamp C. The
>lue of a setting is indicated upon a direct-reading translucent scale, illumi-
ited from within by the comparison lamp. A system of baffle screens,
- 1, etc., protect the window against stray light. The range of the instru-
1211
 —
Sec. 14-286 ILLUMINATION
ment is fereatly extended by the use of the absorbing screens, A and Af.
which may be rotated about the photometric device, F, reducing either the
test or the comparison Ught. For the measurement of candle-power, a pari
of the rotating tube R which carries the test plate is reversed, tliereby pro-
viding a protection for the test plate against all extraneous light, permitting
it to be illuminated by the light source alone. For the measurement o)
brightness, the tube R is removed, and any object B is viewed directlj
through the photometric device. The constancy of the comparison lamp
is assured by the employment of a bridge within the photometer, the lamp
forming one arm. A sensitive telephone receiver or a galvanometer is used
to determine the point of balance of the bridge. When no click is heard
upon the interruption of the telephone circuit or when the galvanometei
ceases to deflect, the bridge is balanced, and the resistance of the comparison
lamp is that required by the calibration of the photometer. The resistance
characteristic of .a tungsten lamp is such as to make this method of contro
sensitive.
SPECTROPHOTOMETERS AND COLORIMETERS
286. Spectrophotometers. The essential features of a spectropho
tometer are indicated in Fig. 03. Some light source is adopted as a basis o:
comparison and is located at the end of collimator tube C, where it is em-
ployed to illuminate a diffusing-glass plate. The light source to be testec
IS permitted to illuminate a similar diffusing-glasa plate, which is fre(
from selective absorption and is located at the end of collimator tube C\. }.
variable-opening slit is located at the end of each collimator tube. At th<
intersection of the axes of the two collimator tubes, the photometric device
P, is located. The light from the two sources which is traiLsmitted and re
fleeted from the photometric device, pas.ses through a dispersing prism, D
and into the ocular tube, O. This tube may be moved through an arc abou
the dispersing prism, and so located as to intercept light of any wave lengtl
throughout the visible spectrum. At any desired wave length a comparisoi
may be effected, and the light from either source may be varied to securi;
equality. This adjustment may be made by means of the slits at the end
of the collimator tubes or by means of a variable rotating sector diSc,* o'
by varying the distance between the light source and the translucent-glasi
plate at the end of the collimator tube. In most spectrophotometry it i,

difficult toobtain sufficient light to make it possible to attain high precision ir

Bettings This is especially the case with measurements made near eithe i

end of the spectrum. To an extent not encountered in ordinary photometry;

spectrophotometry is liable to systematic and accidental errors, effects oi
stray light being notable among the errors of the former class. Results o
Bpectrophotometric tests show rclativeintensities
of light in the several wave lengths throughout
the visible spectrum (Par. 27). These are difficult
to comprehend and interpret unless one is well
versed in such work. Usually it is necessary to
refer spectrophotometric differences to differences
in color with which one is well acquainted (as that
between the Mazda and carbon lamps) in order
to form a fairly good concept of magnitude.
287. Colorimeter. It is generally considered
that there are throe primary color sensations (Par.
OLi
208). In colorimetry, three glasses corresponding
to these sensations, respectively red, green and
blue, are interposed between the light source to bo
studied, and a device which mixes the transmitted
lights and brings the resultant combined lightinto
J
uxtaposition with some comparison light for color
match. Diaphragms, or variable- width slits, are
employed to secure the proper relative proportions Fia. 63. Scheme ii

of red, green and blue light. In the Ives colorini- spectro-photometer,z"

etert variable width slits are employed with the
colored glasses. The adjustment scale for each slit is calibrated fromOt
100. With each slit opened to the maximum, the resultant mixture appest;
•Hyde. AstrophysicalJoumal, May, 1912.
t Ives. Journal Franklin Institute, 1907, p. 164.

121S
 )

ILLUMINATION Sec. 14-288

white when average daylight is received upon the colored glasses. Color
sensation values are expressed in terms of such maxima. The colorimeter
may be employed in the study of light from line spectrum sources, whereas
the spectrophotometer is limited to the study of continuous spectrum or ap-
proximately continuous spectrum sources. Sensation values (Par. 27) may
(be shown with the aid of the Maxwell triangle, Fig. 64.
Il In this diagram, several illuminants are located as to color, and are shown
in comparison with the theoretical black body at several temperatures. The
9um of the expressions of color sensations is unity. The sum of the per-
pendicular distances from the three sides of an equilateral triangle is equal to

Color triangle. For key to numbers see Par. 27.

h altitude of the triangle, which also is taken as unity. Hence, the three
lor sensations for any illuminant may be indicated by a point on the tri-
Isle. The dotted line represents the color of the black body at several
Inperatures.
PHOTOMETRIC ADJUNCTS
Standardizing equipments. An adequate supply of reference
ladard lamps is important. As far as practicable, these should be of the
lie typesand sizes as the lamps to be tested. For use with a portable
ntometer there should be a standard lamp box, in which the lamp is
llosed and in which, preferably, there is some device for facilitating the
llblishment of a standard distance between the lamp and the photometer.
189. Photometer scales. In practical photometry, the desirability of
ling all photometers direct-reading will be obvious. In the case of a fixed
I'tometric device and a moving comparison lamp, the scale is computed in
ordance with the simple application of the inverse-square law. A funda-
ital distance is established at which a given light intensity will be indi-
d. Distances for other intensities are obtained by the simple application
ie inverse-square law, thus:

(13)
ji \d

1213
 '

Sec. 14-290" ILL UMINA TION

In the case of a fixed distance between the test and comparison lamps and a
photometric device moving between them, the midway point is assigned the
value at which it is desired to maintain the comparison lamp. All other
points are determined in accordance with the following equation:

d ^— ''''
Vf^+i
It
where d is the distance between the test lamp and the photometric device, D
is the distance between lamps, le is candle-power of the comparison lamp and
/( is the candle-power of the test lamp.

290. Color filters. Where light sources of a variety of types are to be

tested, it is desirable to have an adequate range of color filters which will tend
to eliminate most of the problems of heterochromatic photometry. These
should have authoritative calibration. Both glass and liquid-solution color,
filters are being developed on comprehensive scales.

291. Kequired accuracy in electrical instruments. Too much cart;

cannot be devoted to the electrical measuring instruments employed in pho-'
tometry. To emphasize this it is necessary only to repeat that with Mazds
lamps the candle-power error involved in a 1-per cent, voltage error is i
per cent., and that the corresponding error due to a 1-per cent, ampere erroi
IS 6 per cent. Practically all portable voltmeters and ammeters have appre-
ciable scale errors. The extent of such errors should be determined by secur
ing calibration curves for the instruments, and corrections should be mad(
accordingly. Some instruments have temperature coefficients which ir tro
duce material errors at times. Also some voltmeters and ammeters an
influenced appreciably by external fields. All the precautions taken ii,
electrical measurement should be applied in the use of electrical instrumenti'
for photometric work.
292. Rotating: sector discs. In most laboratory photometry it has bee)
found desirable to use a number of sector discs which are interchangeabl
on the rotating shaft and which have fixed angular openings, yielding trans
mission coefficients of respectively 0.1, 0.01, etc. Such employment of th
rotating sector disc promotes ultimate accuracy, since, if adjtfttable di -i

are used, the opportunity for undetected adjustment errors is consideral)li

and the adjustment accuracy is low with small angular openings.
293. Absorbing screens form a valuable adjunct to photometric equir
ment. Their transmission coefficient, however, is not accurately control
able, and a simple decimal value is therefore rarely obtained. Absorbin
screens should transmit without diffusion, and should be free from serioi:
selective absorption. Unfortunately, the usual absorbing screens having Id
coefficients of transmission, have considerable selective absorption.
294. Baffle screens. In practically all photometry it is essential to guar
the photometric device against stray light. Opaque screens having suitsilil
proportioned apertures are largely employed for this purpose. A series i

these screens, painted black (for most precise work they may be coveri'
with black velvet), is used, for example, on a photometer bar. Where i;
photometric device or the comparison lamp travels along a track, fl
screens must be re-located as occasion requires. A most satisfactory met 1

is to so install them that they will be adjusted automatically to the moverrn

of the lamp or photometer carriage. This may be accomplished by mountii
them upon lazy tongs, as in several types of commercial lamp-tosting pi:
tomotcrs, or allowing them to slide upon the track, being pushed in fro:
of the lamp as it approaches the photometric device, and drawn after t

lamp by cords or otherwise as it recedes, as in the Sharp-Millar photomct

An alternative to the use of baffle screens is the employment of black vol\
to cover all surfaces which may possibly reflect stray light to the phot
metric device.
296. Rheostats. The easy fine adjustment of the current or voltage "!
lamp is important to precise work in photometry. Too much care cannot
expended in providing thoroughly satisfactory rheostats for this purpi
Step rheostats are un.satisfactory unless the steps are of such low resistan
in relation to the magnitude of the current, that the change per ster
extremely small. A helix of resistance wire, with the coils well insulai

1214
 ILLUMINATION Sec. 14-296

wound upon an insulated tube and mounting a sliding collar having a

multiplicity of contact points, is the most generally acceptable form of
rheostat for photometric work.
296. Lamp rotators. It is usually desired to obtain mean angular inten-
sity of light rather than the light in some particular direction at a given
angle. Wherever the nature of the illuminant permits, it is desirable, there-
fore, to rotate the light source during test, allowing the eye to integrate the
intensities to obtain a mean. Most forms of illuminants can be rotated.
The speed of rotation of coursfe depends upon the extent to which the light
distribution is asymmetrical. If the distribution is approximately symmet-
rical, a low speed of rotation will suffice. This being the case, it has been
found practicable to rotate almost all types of illuminants, including most
arc lamps and some forms of gas lamps. The lamp rotator therefore be-
comes a valuable adjunct in a photometric laboratory. It must be good
both mechanically and electrically. As the moving electrical contact re-
quired for the supply of the lamp may involve some potential drop, it is
customary in the best construction to provide auxiliary moving contacts
either of the brush type or of the mercury-cup type, in order to allow the
measurement of voltage immediately at the lamp terminals.
PHOTOMETRIC TESTING
297. The substitution method of photometry consists in calibrating
a photometer by means of a standard lamp of as nearly as possible the same
characteristics as the lamps to be tested, and substituting the lamp to be
tested for the standard lamp. A skilled photometrist employing a pho-
tometer of exact construction which is perfectly screened and is used with
correct electrical instruments for determining the electrical conditions of cir-
cuits which are free from potential drop, may- obtain correct results in the
practical comparison of a test lamp against a standard lamp. Whatever the
methods employed, every care should be exercised to secure these favorable
conditions for photometry, but if, in spite of care, some conditions exist
which are not exactly as they should be, it is quite possible that the substitu-
tion method may result in cancelling the effect of such conditions and avoid-
ing erroneous results. By using standard lamps of the same sizeiand type aa
the lamp to be tested, the substitution method results in correcting both er-
rors of illumination and errors of electrical measurement. If stray light from
a 100-candle-power lamp adds 5 per cent, to the illumination of a photomet-
ric surface when a moving photometric device is set at 100 on a scale, it will
.;have the same effect when a standard lamp of the same size is used. If then
i
a comparison lamp be calibrated for temporary use by means of the 100-can-
[ die-power standard lamp, it will be adjusted 5 per cent, too high. When
. the 100-candle-power test lamp is measured, the light of the comparison lamp
, against which it is balanced and the light from the test lamp will both be 5
per cent, too high. The result will be a correct setting. If, a voltmeter be
employed which has an error of 1 per cent., the effect of the error will be
'cancelled in the same way if the substitution method is followed. Where
:
considerable photometric work is to be done, the provision of an ample range
of reference standard lamps, in order to permit the extensive application of
the substitution method, is true economy.
298. Oood practice in measuring illumination. It is well to be pro-
vided with reference standard lamps and a box equipped with baffle screens or
.black velvet to prevent stray light, in order to produce illumination of known
intensities from the standard lamp upon the photometer test plate. It is
well to have sufficient standardizing equipment of this kind to permit of the
verification of the photometer scale at a few points throughout its range and
also the verification of photometer absorbing screens. The same equipment
rmay be used in verifying the brightness calibration of the photometer, pro-
Anded a standard surface of known qualities is obtained with the standard
lamps. In such calibration, light of a known ;ntensity is thrown upon the
standard surface and the corresponding brightness of the surface is computed
(Par. 206), employing its coefficient of diffuse reflection.
In some illumination work it is sufficient to measure the intensity of illumi-
uation at certain points in a room, and it is usually sufficient to measure the
brightness of certain objects in the room, as far as data on brightress are
concerned.More frequently, however, it is desired to know the average
maximum and minimum illumination intensities on certain planes, and to
1215
Sec. 14-299 illumination
derive the coefficient of utilization (Par. 188). In such instances it is cua-i
tomary to divide the plane of reference into rectangles, usually providing 20
to 30 such rectangles for the room, or for each bay in the room. A deter-
mination of the illumination intensity is then made at the centre of each such
rectangle. The mean of such values is usually a fair approximation of the
average intensity for the entire plane. Where a detached test plate is em-
ployed in the measurement of illumination on a horizontal plane or at any
given angle of inclination to the horizontal, it is often desirable to employ an
automatic-leveling test plate. In the measurement of horizontal ilhimina-
tion in interiors, a plane 30 or 36 in. above the floor is usually selected. A
complete study of a room used, for example, for office purposes, should
include the average horizontal illumination on such a plane; the uniformity
of such illumination intensities; the brightness of the walls, light sources and-
other especially prominent objects within view; and measurements of either
illumination intensities or brightness on desks to show depth and nature of
shadows encountered.
299. Precautions for avoidance of error. The following suggestions
are commended by experience, and, if followed, are likely to result in the
avoidance of some of the most common errors.
Reduce color differences by the use of authoritatively calibrated color
filters (Par. 290).
Follow the substitution method (Par. 297) as closely as practicable.
Provide reference or working-standard lamps of the same size and type as the
lamps to be tested.
Consult the characteristics of the light source under test and adapt prac-
tice accordingly. For example, allow an arc lamp or a large series incandes-
cent lamp to burn for a short period in order to attain working temperaturt
before making measurements. In testing arc lamps whose values vary
through a cycle corresponding with the feeding period, make certain thai
results are average for such period.
Verify photometer-scale calibration by tests of standard lamps.
Repeat verification at reasonable intervals even though photometer has no!
been used in interim.
Verify indications of electrical instruments used.
Observe strict cleanliness of apparatus. Dust on transmitting glasses
increases coefficient of absorption. Dust on black velvet reflects light.
Verify a few test results by tests upon other apparatus. It is relatively
simple for an observer to repeat settings with a given photometer. Make
certain that such settings are in accord with results determined by others
employing different equipment.
In tests of reflectors make certain that the light source is strictly in accord
with the manufacturer's standard of construction, both as to type and
dimensions.
Assure correct location of the reflector with reference to the light source
Slight variation in any of these conditions may affect the result materially.
In tests for candle-power and in light-distribution tests, look along thf
f)hotometric axis from the position of the photometric device to the test
amp and to the comparison lamp. Make certain that all of the light
emanating from the light sources in the direction of the photometric device
reaches the photometric surface. Make certain that no other light reaches
t ho surface, that is, avoid stray light.
300. Sampling. In sampling for test purposes, whether the samples b(
lamps, lighting auxiliaries, or illumination installations, it is important that
the samples be unquestionably representative of the product which is to b(
judged by the results of the test. It is also essential that the samples be
sufficient in number to guard against the exertion of undue influence upon thf
final result due to the presence of an eccentric individual among the samples
It is hardly possible to judge intelligently in these matters unless one i.'

thoroughly acquainted with the characteristics of the product which is beinv

sampled. No small part of expertness in testing lies in the succe.ssful sam-
pling of the product to be tested. Lamps, reflectors, etc., are not uniform,
and very misleading results may follow upon injudicious sampling.
301. Principles of comparison. In comparing illuminants it is impor-
tant to bear in mind first, that some illuminants require more adaptation anc
suffer in efficiency more in adaptation for a given service than do other illumi-
nants; and, second, that some illuminants deteriorate more largely in effi-

1216
 ILLUMINATION See. 14-302

ciency during life than do others. For example, a magnetite arc lamp as
equipped is well adapted to street-lighting service, and its efficiency in the
condition delivered by the manufacturer is substantially its service efficiency.
On the other hand, incandescent lamps may have to be equipped with globe
or reflectors or both before application to street-lighting service, and their
efficiency as shipped by the manufacturer is materially higher than is their
service efficiency. As another example, the candle-power depreciation of a 25-
watt Mazda lamp is less during its life than is the candle-power depreciation
of a 100-watt Mazda lamp. Conclusions based upon initial laboratory
values should be modified where necessary before determining upon rela-
tive merit of two different kinds or sizes of illumihants for a given class of
service. Likewise, lighting auxiliaries are not always directly comparable on
the basis of their initial laboratory values. The deterioration of reflecting
surfaces may be rapid. Some surfaces collect and retain dust more largely
than do others, and, in consequence, their deterioration of light is greater in a
given period.
302. Discussion of results. In discussion of test results it is rarely
possible to draw unqualified conclusions as to relative merit between appli-
ances or installations which are of more or less the same order of merit. In
any test all that is demonstrated is that a sample or a set of samples or an
installation has been found, in a given instance, to be superior in certain
respects. It is dangerous to draw sweeping conclusions from tests. To do so
may mislead when test data are applied to appliances or installations which
have not actually been tested. In discussing results of tests and drawing
conclusions from tests it is well to be cautious in accepting the basis of
measurement as a final indication of value. The candle-power of an incan-
descent lamp is one direction or in one plane is not necessarily an indication of
the illuminating power of the larnp. In the long run, the total light flux or
the mean spherical candle-power is most nearly a correct indication, but even
this measurement may fail to indicate the real value of an illuminant for a
certain class of service. It may be shown that the minimum normal illumi-
nation intensities provided by two installations of illuminants for street-
lighting service are equal, but this does not demonstrate that the two sys-
tems are of equal value. One may deliver twice as much light as the other
upon the street. The mean horizontal illumination may be in the long run a
reasonably good measure of street-lightirig effectiveness, but even this meas-
ure may fail to indicate the facts for certain classes of service. In short, tests
of illumination should be conducted and conclusions should be drawn from
such tests in accordance with the dictates of common sense and good engi-
neering practice.
BIBLIOGRAPHY*
Physics of light.
SOS.
——
Wood, Robert W. "Physical Optics." Macmillan Company, 1911.
LoMMEL, Db. EuGEirE. "The Nature of Light with a General Account of
D. Appleton & Company, 1892.
Physical Optics."
—
Maclaubin, Richahd C. "The Theory of Light: A Treatise of Physical
Cambridge University Press, 1908.
Optics."
—
Wbiqht, Lewis. "Light: A Course in Experimental Optics." Macmillan
Company, 1892.
Maclaukin, Ricbabd C. — "Light." The Columbia University Press, 1909.
Nutting, P. G. — "Outlines Applied Optics." P. Blakiston's Sons & Co.,
of
1912.
—
Houston, R. A. — "Studies in Light Production," 1913.
Thompson, P. "Light, Visible and
S. Macmillan Company.
Invisible."

LoviBOND, Joseph W.— "An Introduction to the Study of Color Phenom-

leha." Spon and Chamberlain, 1905.
—
Houston, R. A. "A Treatise on Light."
S04. Principles and theory of illumination.
—
Johns Hopkins Pbess. "Lectures on Illuminating Engineering." Johns
Hopkins University Lectures, 1910.
I
—
Steinmetz, C. p. "Radiation, Light and Illumination." McGraw-Hill
iBook Company, Inc., 1909.

* Compiled in part from list compiled by N. D. Macdonald for Committee

30 Education, Illuminating Engineering Society.

77 1217
Sec. 14-305 illumination
—
HoGNER, Paul; Translated by Eck, Justus. "Light, Radiation and Illu-
mination." D. Van Nostrand & Company, 1909.
Abney, Capt. W. de W.— "Color Vision." William Wood & Company,
1894.
—
Rood, Ogden N. "Students' Text-book of Color." D. Appleton & Com-
pany, 1908.
—
Cliffobd, C. R. "Color Value." Clifford and Lawton, 1907.
LucKiESH, M.
01.5.
—
"Color and Its Applications." D. Van Nostrand Co.,

Illununants.
Hertha. — "The Electric Arc."
i05.

I ION,
IDLER, J. AND LusTGABTEN, J.
/I

Nostrand
.
& Company,
Child, Clement D. —1911.
— D. Van Nostrand & Company.
"Electric Arc Lamps; Their Principles,
Construction and Working." D. Van Nostrand & Company, 1908.
Johnson, J. H.— "Are Lamps and Accessory Apparatus."

"Electric Arcs."
D. Van

D. Van Nostrand & Company,

Solomon, Maurice. — "Electric Lamps."
1913.
— D. Van Nostrand
Fleming, J. A. "Electric Lamps and Electric Lighting." D. Van
& Company.
Nostrand & Company, 1894.
—
Hutchinson, Jb., Rollin W. "High Efficiency Electrical lUuminants
and Illumination." John Wiley and Sons, 1911.
—
Ogley, Daniel H. "Incandescent Electric Lamps and Their Appli-
cations." Longmans, Green & Company, 1914.
Gasteb and Dow.— "Modern Illuminants & Illuminating Engineering."
Macmillan Co., 1915.
306. Lighting: practice.
Bell, Louis.— "The Art of Illumination." McGraw-Hill Book Company,
2nd Ed., 1912.
—
Barrows, G. S.- "Electrical Illuminating Engineering." D. Van Nos-
trand & Company, 1908.
Matthews, R. Borlasse. —
"Electricity for Everybody." Electrical Press,
Ltd., London, 1912.
—
Bloch, a.- "Elementary Principles of Illumination and Artificial Light-
D. Van Nostrand & Company, 1914.
ing."
—
Clkwell, Clarence E. "Factory Lighting." McGraw-Hill Book Com-
pany, Inc., 1913.
—
GoDiNBZ, L. L. "The Lighting Book." McBride Naat & Company, 1913;
—
Horstman, Henry C. and Tousley, Victor H. "Modern Illumination,
Theory and Practice." Frederick J. Drake & Co., 1912.
—
MoLEswoRTH, H. B. "Obstruction to Light." Spon and Chamberlain,
Atkinson, William. — "The Orientation
1902.
Buildings or Planning
of Sun- for
John Wiley and Sons, 1912.
and Lansingh, V. R. — "Practical Illumination." McGraw-
light."
Cbavath, J. R.,
Book Company, Inc., 1907.
Hill
—
Taylor, Fbederic H. "Private House Electric Lighting." Percival
Marshal & Co., London, Spon and Chamberlain.
Bloch, Dr. L.; Translated by Clinton, W. C.— "Science of Illumination."
D. Van Nostrand & Company.
—
King, Wm. B. "Tables for the Computation of Illumination." D. Van
Nostrand & Company, 1908.
I. —
E. S. U. P.
Book Co., 1910.
"Illuminating Engineering Practice." McGraw-Hill

307. Photometric measurements.

Bohle, Herman. — "Electrical Photometry and Illumination." J. B. Lip-
pincott Company, 1912.
Trotter, Alexander Pelham.^ — "Illumination: Its Distribution and
Measurement." Macmillan Company, 1911.
—
WicKENDEN, Wm. E. "Illumination and Photometry." McGraw-Hill
Bot)k Company, Inc., 1st Ed., 1910.
Stine, Wilbur M. —
"Photonietrical Measurements." Macmillan Com-
pany, 1909.
Palaz, a.; Translated by Patterson, G. W. and M. R. "A Treatise: —
on Industrial Photometry with Special Application to Electric Lighting."'
D. Van Nostrand & Company, 189fi.

1218
 SViOIT

SECTION 15

INDUSTRIAL MOTOR APPLICATIONS

CONTENTS
{Numbers refer to Paragraphs)
Machine Tools 1 Refrigerating Plants 310
Wood-working Machinery 41 Textile Mills 329
Traveling Cranes 71 Paper and Pulp Mills 346
Klectric Hoists 91 Electric Derricks and Excavat-
i;ievators _
110 ing Machinery 364
I'ower Pumps '
155 Brick Manufacture 391
Air Compressors 174 Printing, Binding and Linotype
I alls and Blowers 193 Machinery 420
( Dai and Ore Handling Ma- Flour Mills 433
ihinery 213 Beet Sugar Mills 438
I
.Ipherage Systems 234 Laundry Machinery 457
il Mills 247 Small-motor Applications 488
ent Mills 262 Motor Control 502
.1 Mining 280

1219
 SECTION 15

INDUSTRIAL MOTOR APPLICATIONS

MACHINE TOOLS it
i BY LEON P. ALFOBD
Former Editor American Machinist, Member, American Society of Mechanica
Engineers
1. Definition. The term "machine tools" cannot be accurately defined.
Broadly they are machines used to work and shape metals. A legal definition,
taken from the Underwood tariff law, Par. 107, reads as follows: " M.ichine
tool as used in this paragraph shall be held to mean any machine operated
by other than hand power which employs a tool working on metal."
2. The two principal classes into which they divide are distinguished
by the kind of motion of the work or cutting tools. This motion may be either
rotating or reciprocating. In the former instance the speed is usually con-
stant throughout each operation, and the energy absorbed is used in over-
coming the friction of the machine and in doing useful work in cutting or
forming metals. The exceptions are machines that accelerate during the
cutting operations, such as squaring-up lathes and lathe-type cutting-off
machines. In the second class the power is subject to great fluctuations
during a working cycle. For, in addition to the friction losses and useful
work done there are large, regular demands for energy with which to retard
and accelerate heavy parts of the machine, or the pieces which are being
shaped.
3. The
friction losses in rotating machines, such as lathes, boring
mills, drilling machines, milling machines, grinders, and the like vary almost
directly as the speed, the gear ratio re-
— maining constant. The loss in the gear-
28 ing and feeding mechanism comprises the
larger part of the friction losses.
24
4. The friction losses in recipro-
20 cating machines, such as planers,
shapers, Blotters, and the like, are very
.16 small in comparison with the losses due to
o, inertia. In fact the inertia losses often
«12 exceed the useful work to such an extent
as to determine the size of motor (this is
especially the case with short-stroke ma-
chmes). Fig. 1 shows a power curve
taken by G. M. Campbell for a 60 X 60
in. X 20 ft. Pond planer. It shows the
power input when running light plotted
with time. The cutting-stroke speed
was 25 ft. per min. (7.6 m. per min.) and
the return-stroke speed 60 ft. per min.
(18.3 m. per min.).
6. Oroup drive and individual drive.'
Motor applications to machine tools divide into two classes, groiip drives and
individual drives. It is impossible to lay down a general principle to be
followed in the selection of drive for a given case, for there are many
modifying factors. Very large machines (those located under a crane) i^

all machmes requiring variable-speed drive are commonly provided \^

individual motors. Small and medium-sized machines are usually arran^
in groups and driven from a line shaft which in turn is driven by a constani-
spfod motor. If there are a number of reciprocating machines in the group,
it is not uncommon to add a fly-wheel to the motor.
 INDUSTRIAL MOTOR APPLICATIONS SeC. 16-6

6. A comparison of lineshaft and individual- motor drives,* for

machine tools is given in the following table:

Individual motor Advantage of in-

Item Lineshaft drive
drive dividual motor

1. Power con- Constant friction! Friction loss (motor L e s's power re-
sumption. loss in shaft, belts! and tool only) use-| quired,
and motor, power' ful power only!
for cutting. while working.
|
|

2. Speed con- No. speeds = No. No. speeds = No. More speeds pos- i

trol. cone pulleys X No. controller points X sible; tirne saved in |

gear ratios. No. gear ratios. '

speed adjustments. '

3. Reversing. Clutch and crossed

1
Re versible con-! Time saved in re-
i belt. i
troUer. 1 versing.

4. Adjusting Stopping at any Can be started in Time saved in set-

tool and definite point veryl either direction' ting up and lining
work. difficult. and stopped at any up.
!

i point. I

5. Speed Large speed incre-i Small speed incre- Time'saved by ob-

ad-
justment. ments betweenj ments between taining proper cut-
pulley steps. controller steps. ting speed.

6. Size of out. Limited by slipping Limited by strength Time saved by tak-

belt; large belts of tool and size offing heavier cuts,
hard to shift. motor. ,
j

7. T me i to! t i
Much less time re-
complete! quired as indicated
a job. for previous items.

8. LiabilityjSlipping
slipping or break-ilnjury machii Much less liability
break-Injury to machine
to acci- ing belt; injury toj tool, cutting tool
toi to accident.
dents. rnachine tools, cut-j or motor,
ting tool or prime i

mover.

9. Checking Close supervision Accurate tests pos- Causes of delay and

'

economy required, very dif- sibleby means of remedies easily lo-

of opera-: ficult to locate graphic meter- cated without per-
tions. causes of delay. which records au- sonal supervision.
tomatically all de-
lays and rate of
cutting.

:10. Flexibility iLocation determin- L o c a t i o n deter- Greater conven-

of loo a- ed by shafting, and; mined by sequencejience in handling
tion. changes difficult, fof
I
operatio
n!and increased eoon-
1
I changes readilyjomy of operation;
! made. imore compact ar-
irangement possible.

7. Motors for individual drives have been tentatively standardized

Mr a committee of the National Machine Tool Builder's Association confer-
iing with a committee of the American Association of Electric Motor Manu-
acturers. Although the design data were agreed upon in substance early in
910, the motor manufacturers have failed to use it in the manufacture of
jheir product. An abstract of the report of these committees appears in
ar. 8.

• Robbins, Charles. Trans. A. S. M. E., Vol. XXXII, page 182.

1221
 1

Sec. 16-8 INDUSTRIAL MOTOR APPLICATIONS

8. Standardized specifications for indiTidual-drive motors.

(a) Horse power. Ten sizes are considered necessary for practically
all requirements of electric drive for machine tools. These sizes are as fol-
lows: 1, 1.5 (for direct current only), 2, 3, 5, 7.5, 10, 15, 20 and 25.
(b) Voltages for direct-current motors should be 115 and 230 volts.j
For alternating-current motors the voltages should be 110 and 220 volts.
(c) Horse-power ratings. Where approximately standard load condi-
motors are to be given a continuous constant horse-power rating.
tions exist,
For variable-speed motors used under intermittent service conditions, the
standard 2-hr. continuous-duty rating is to be used for ordinary shop
conditions.
(d) Direct-current motor speeds. Variable-speed motors are to be
standardized for two ranges, namely, 2 to 1, and 3 to 1. The following table
includes the recommended speeds for variable-speed direct-current motors.

Speeds Speeds
Horse power
Ratio 2 : Ratio 3 : 1

r.p.m. r.p.m.
1 1,500-750 1,500-500
u
2
1,500-750
1,500-750
1,500-500
1,500-500
3 1,500-750 1,500-500
5 1,200-600 1,200-400
7i 1,200-600 1,200-400
10 1,200-600 1,200-400
15 1,200-600 1,200-400
20 900-450 900-300
25 900-450 900-300

(e) Alternating-current motor speeds. The foUowing table gives

the recommended speeds for polyphase 60-cycle alternating-current motors.

Horse Horse I

Speeds
Speeds power
power I

1,800 and 1,200 10 1,200 and 600

1,200 15 900 and 600
1,200 20 900 and 600
1,200 25 900 and 600
1,200 and 900

(f) Frequency. In considering constant-speed alternating-current motors

60 cycles is to be used as the basis.
9. Methods of applying motors to machine tools.* ''"•
(a) Bench lathes should be driven from a countershaft attached to
bench and driven in its turn by motor. Any type of motor may be ii

except the series-wound or the heavily compounded motors. It is essen

to locate the machine in the most advantageous manner without regard ;..

the position of the shaft. ;

(b) Speed lathes should be driven from a self-supported countershaft;

or by a direct-connected motor. In the latter case a variable-speed machine
is to be preferred.
(c) Engine lathes. For these both variable-^peod and constant-speed'
motors are used although engine lathes are usually group-driven. Where
individual motors are used, each is placed on a bracket attached to the lathe,
and connected to it with a geared or chain drive.
(d) Heavy engine lathes, forging lathes, etc., should be driven by
direct-connect(;d direct-current motors. The position of the motor should
be low to reduce vibrations in its support. The output of these lathes' may be"
increased from 20 to 25 per cent, by motor drive.

• DeLeeuw. A. L. Traru. A. S. M. ft., \<A. XXXII. page 137.

1222
 ' 6
5
3 .

INDUSTRIAL MOTOR APPLICATIONS See. 15-10

I
(e) Axle lathes, wheel lathes and drivinjr-wheel lathes shou d be
driven by direct-current motora.
(f) Chucking lathes usually are not motor-driven. If motora are used
they should be of variable speed.
(g) Automatic screw machines in small sizes should be group-driven;
in the larger sizes they should preferably be driven by variable-speed motors.
(h) Sensitive drilling machines in general should not be motor-driven.
I
However, if machine is placed in an isolated location, a motor may be directly
I
applied to the machine itself or the machine may be driven through a counter-
[ shaft, from a motor on the floor.
[ (i) Vertical and radial drilling machines are usually group-driven un-
less they are isolated. If such machines are motor-driven, the variable-
speed type should be selected. The motor may be direct connected to the
machine itself or set up to drive the machine countershaft.
(j) Boring machines, if used for specialized work, are preferably belt-
driven. If used for a variety of operations, a variable-speed motor is
desirable.
(k) Grinders should be driven by constant-speed motors belted to the
grinder countershafts.
(1) Planers, particularly those of small size, if located under a crane,
should be driven by variable-speed motors. A recent development is the
reversing-motor planer drive which ia now being extensively tested, and
*
promises to prove successful.
(m) Shapers, slotters, etc., should usually be group-driven,
(n) Knee and column-type milling machines in the large sizes should
be driven by variable-speed motors, especially if used in "gang" operations,
(o) Planer-type milling machines should be motor driven. Either
the constant-speed or the variable-speed types will prove sati-sfactory.
10. Values of horse power required to cut metal*
Lathe-type tools.

Af , • , !
Horse power required to remove
xMaterial
^ ^^ j^^ p^^ ^-^^
i
.

Brass and similar alloys . 2 to 0.

Cast iron. . 3 to .

Wrought iron j
""
r. /^
Mild steel (0.30-0.40 percent, carbon)
Hard steel (0.50 per cent, carbon) '

1 . 00 to 1 25 .

Very hard tire steel 1.5

Drills

1.1 .-,
Aiatenai I
Horse power required to remove
i

^ ^^ j^^ ^j. ^^^^

'.I t',.

Brass and similar alloys >;.,,..... . 4 to .

Cast iron. I
0.6 to 1.0
Wrought iron „
j

^'^
^
Mild steel (0.30-0.40 per cent, carbon)!
'Hard steel (0.50 per cent, carbon) . . .
.
2 . to 2 .

Very hard tire steel 3.0

11. Determination of horse power required for machines under

roup drive. A table of power values for machine tools is given in Par. 12.
values are the result of tests made by the author under actual shop
'hese
editions, and apply to small and medium-sized machines only. The
atput of the factory where the investigation was made was light automatic
fachines. The parts operated on during the tests were iron and steel
fitings, drop forgings and bar stock. Manufacturing conditions were
ighly developed, and the degree of finish allowed was small. Because of
M'se conditions the power values are still useful although they were obtained
el'ore the common use of high-speed steel in cutting tools. The values
'
Robbins, Charles. Tra 7is. A. S. M. E., Vol. XXXII, pp. 199 to 209.

1223
 .

Sec. 15-12 INDUSTRIAL MOTOR APPLICATIONS

have been checked by their application to a number of factories whose total
power load was known. This showed that, for a group of machines, the sum
of the power values given in the table is about 20 per cent, higher than the
average working load. This is because of the intermittent service of tools
for various reasons, or the departmental slip.
12. Power machine tools in groups (see Par. 11)

Observed Observed
horse horse
Kind Size
power; power;
maximum average

Boring Machines:
Bullard, single head .... 36 in. 0.78 0.52
BuUard, double head. . . . 42 in. 1.72 1.08
Cam Cutters:
Brainard No. 2 0,67
Brainard No. 4 0.48 0.32
Brainard No. 6 0.48 0.32
Lathe type, single head . 0.32
Lathe type, double head. 0.50
Cutting-off Machines.
Hurlbut- Rogers lis in. 0.12
Hurlbut-Rogers 2 in. 0.28 0.14 to 0.18
Hurlbut-Rogers 3 in. 0.34 .20 to 22 .

Drilling Machines:
Prentice Bros, radial. . . . No. 0.72
Prentice Bros, radial .... No.. 1 3.18 1.12
Sensitive ]

Woodward & Rogers. single- [ 0.31

spindle
D wight-Slate 2-8pindle
Woodward & Rogers. Sensitive
0.35
3-spindle I
Woodward & Rogers 4-8pindle 0.48
Woodward & Rogers 6-spindle 0.71
Prentice upright 16 in. 0.25
Prentice upright 18 in. 0.35
Prentice upright 20 in. 0.42
Prentice upright 22 in. 0.59
Blaisdell upright 24 in. 0.47
Blaisdell upright 26 in. 0.22
Blaisdell upright 28 in. 0.25
Blaisdell upright 30 in. 0.30
Blaisdell upright 34 in. 0.45
Blaisdell upright 36 in. 0.53
Blaisdell upright 46 in. 0.63
Blaisdell upright 60 in. 0.83
Gear Cutters:
Brainard No. 4i 0.15 toO.32
Gould & Eberhardt No. 3 i
0.20
Brown & Sharpe No. 3 '

0.20
Grinders-. \f
Brown & Sharpe cutter and
reamer grinder No. 3 I
0.32
C. H. Besl„- & Co. Gardner
grinder No. 4 i
. 53
Brown & Sharpe plain No. 11 0.80
Brown & Sharpe surface No. 2 40
.

Brown & Sharpe surface No. 3 0.50

Brown & Sharpeiuniversal No. 1 . 60
Brown & Sharpe universal No. 2 i 0.76
'Diamond wet tool grinder I
0.97'
Leland & Faulconer wet grinder. 0.41 to 0.82
1
t

Carrying 1 20-in. wheel. t Carrying 2 24-in. whuols.

1224
 .. .

INDUSTRIAL MOTOR APPLICATIONS Sec. 15-12

12. Power machine tools In groups. — Continued

Observed Observed
horse horse
Kind Size
power; power;
maximum average

Drop Hammers:
Blondell 40 1b. 0.10
Pratt & Whitney 250 lb. 2.00
Pratt & Whitney 400 lb. 2.50
Pratt & Whitney 600 lb. 3.00
Pratt & Whitney 800 lb. 3.50
Pratt & Whitney 1,000 lb. 4.00
Billings & Spencer 1,500 lb. 5.00
Power Hammers:
Bradley 100 lb. 1.50
Bradley 150 lb. 1.75
Keyseater:
Baker Bros No.'4. 0.64 0.28 to 0.32
Lathes:
Reed boring lathe 20 in. 0.35
Reed boring lathe 30 in. 0.41
Reed engine lathe 12 in. 0.24
Reed lathe 14 in. 0.48 0.26
Prentice 16 in. 0.34
Reed 16 in. 0.48 0.36
Blaisdell 18 in. 0.39
Blaisdell 20 in. 0.44
Reed 22 in. '6;37' 0.32
Reed.. 24 in. 0.25
Blaisdell 24 in. 0.31
Prentice 28 in. 0.31
Draper 38 in. 0.58
Reed speed lathe . 10 in. 0.10
I
Reed speed lathe 14 in. 0.12
Putnam squaring-up lathe 15 in. 0.25
Gisholt turret lathe Size H. 0.70
Potter & Johnston semi-auto-
matic ^.-.^..^ 33 to 0.63
Jones & Lamson flat turret 2X24 in. 20 to 1 80
Milling Machines: '
t'Tiiii! 'f to' -'.f'V'.

Brainard No. 1 0.47 0.30

Brainard No. 3 0.64 0.26
Brainard No. 4 ,19 to 0.29
Brainard No.4i 13 to . 19
Brainard No. 6 0.26
Brainard No. 7 0.83
Brainard No. 14 0.25
Brainard No. 15 0.25
Becker vertical No. 3 0.26
Becker vertical No. 5 0.55
Becker-Brainard No. 3 17 to . 25
Brown & Sharpe No. 1 0.15
Brown & Sharpe No. 2 0.25
Brown & Sharpe No. 5 0.30
Reed . No. 7 0.83
Pratt & Whitney hand No. IJ 0.20
Planers:
Whitcomb 17 in. 2.01 00 too. 43
Whitcomb 22 n. X 5 ft. 2.34 16 to 0.53
Putnam 22 n. X 5 ft. 1.44 0.70
Putnam 24 n. X 6 ft. 0.84
Putnam 26 n. X 5 ft. 1.59 0.81
Putnam . . 30 n. X6 ft. 4.91 1.31
Putnam 30 n. X 8 ft. 5.46 1.56
Powell 36 n.XlO ft. 4.00 1.60
Pond 50 n.X9 ft. 2.94 1.14

1225
Sec. 15-12 INDUSTRIAL MOTOR APPLICATIONS

12. Power machine tools in grroups. — Continued

Kind
 .
..

INDUSTRIAL MOTOR APPLICATIONS Sec. 16-15

16. Bolt and nut machinery

(a) Bolt cutters — motor A, B or C (Par. 13)

Style Size (in.) Horse power

1. li. li 1 to 2
Single 1J.2 2 to 3
2i,3i 3 to 5
4, 6 5 to7i
Double 1, U 2 to 3
3 to 5
2, 2J
Triple 1, Ij. 2 3 to7i

(b) Bolt pointers —motor B or C

U. 2i 1 to 2

(c) Nvt tappers —motor A, B or C

Four-spindle 1,2
Six-spindle. . 2
Ten-spindle . 2

(d) Nut — motor B or C

facer

1,2 2 to 3

16. Bolt heading:, upsetting and forgingr machines

Motor A,* Bt or C% (Par. 13)

Size (in.) Horse power

i toli 5 to 7\
\\ to 2 10 to 15
2| to 3 20 to 25
4 to 6 30 to 40

17. Boring and turning mills

Motor A, B or C (Par. 13)

Size (in.) Horse power

Average work. Heavy work

37 to 42 5 to 7i 7\ to 10
50 7i 7i to 10
60 to 84 7i to 10 10 to 15
Size (ft;)
7 to 9 10 to 15
10 to 12 10 to 15 30 to 40
14 to 16 15 to 20
16 to 25 20 to 25

Speed variation is sometimes desired when different sizes of bolts are

K«ded on the same machine.
t Compound-wound, direct-current -motor.
j Wound secondary or squirrel-cage motor with approximately 10 per
nt. slip.

1227,
 Sec. 16-18 INDUSTRIAL MOTOR APPLICATIONS

18. Bulldozers

\
 INDUSTRIAL MOTOR APPLICATIONS SeC. 15-21

21. Drilling machines— multiple spindle

Motor A, B or C (Par. 13)

Size of drills (in.)

No. of spindles Horse power

A toi 6 to 10 3
A tof 10 5
A toi 10 71
J to J 10 10
i to 1 10 10 to 15
2 4 7i
2 6 10
2 8 15
Sec. 16-23 INDUSTRIAL MOTOR APPLICATIONS
23. Orinders. —
Miscellaneous — motor BContinued
or C (Par. 13)
 INDUSTRIAL MOTOR APPLICATIONS SeC. 15-26

26. Milling machines

B Motor A, B or
Sec. 15-27 INDUSTRIAL MOTOR APPLICATIONS
27. Pipe threading and cutting off machines
Motor A, B or C (Par. 13) j
 INDUSTRIAL MOTOR APPLICATIONS SeC. 15-31

31. Presses, hydrostatic wheel

Motor B or C (Par. IS)

Size (tons) Horse power

100 5
200 7i
300 7i
400 10
600 15

Presses for notching sheet iron or steel, motor A, B or C, j to 3 horse

HJwer.
32. Punchingr machines
Motor B* or Ct (Par. IS)

Dia. (in.) Thickness (in.) Horse power

i 1
i 2 to 3
i 2 to 3
3 to 5
f
I 5
1 5
1 7i
U 7i to 10
U
2
10 to 15
10 to lo
2i 15 to 25

33. Bolls —bending and straightening

Motor Bt or CS (Par. 13)

Width (ft.) Thickness (in.) Horse power

i 5
5
/» 7i
i 15
i 25
10 H 35
10
24
U 50
1 50

34. Saws, cold and cut-oS

Motor A, B or C ^Par. 13)

Size of saw (in.) Horse power

20 3
26 5
32 7J
36 10 to 15
42 20
48 25
^mpound-wound motor.
Tound secondary or squirrel-cage motor with approximately 10 per cent.
n the larger sizes.
tandard bending roll motor.
Vound secondary induction motor.
1233
Sec. 15-35 INDUSTRIAL MOTOR APPLICATIONS

36. Shaperi, single head

 INDUSTRIAL MOTOR APPLICATIONS Sec. 15-37

Plate shears

Motoi— B*orCt
Size of metal cut Length of stroke
Horse power
(in.)
Cuts per min. (in.)

iX 24 35 3 10
1 X 24 20 3 15
2 X 14 15 4i 30
1 X 42 20 4 20
liX 42 15 4i 60
UX 54 18 6 75
UX 72 20 5i 70
liXlOO 10 to 12 7J 75

Tin-plate squaring shears

Motor — B or C
 Sec. 15-38 INDUSTRIAL MOTOR APPLICATIONS

Fio. 6. — Reversing direct-connected motor drive.

« 123ff
 INDUSTRIAL MOTOR APPLICATIONS SeC. 16-39

I
S9. The direct-connected adjustable-speed reversing motor is the
•
most recent development in motors for machine tools. It has been applied
\
and tube drawing machines and large
to planers, slotters, key-seaters, wire
[boring mills. Its advantages lie inincreased production and saving of
[power. Figs. 2 to 6, inclusive show five planer drives. * These curves are
drawn to the saiiie scale and show the power required to drive "light" and
with normal cuts, see Par. 38.
40. Power required by portable armature drills
(Andrew Stewart, before Glasgow Techn. College So. 8oc.)

Size
Sec. 15-43 INDUSTRIAL MOTOR APPLICATIONS

the motor. The squirrel-cage motor is simpler and somewhat more rugged
but has the disadvantages of having a fixed slip, of requiring a comparative!;
large current at starting and, with high slip, of radiating a large amount o
heat. Both types are in satisfactory service but slip-ring motors are ii
more common use especially for the larger sizes of saws.
43. The average horse power required by band mills usually varie
from 75 to 125 h.p. but to take care of heavy cuts and maintain the speed
motors of from 150 to 250 h.p. are usually supplied for each saw. Thes'
motors should preferably be of the 3-bearing belted type and with speeds f ron
about 570 to 850 rev. per min. The following table shows the characteristic
of motors which are now installed in saw mills and giving satisfactory service

Motor
 INDUSTRIAL MOTOR APPLICATIONS Sec. 15-47

Motor
Saws Drive Remarks
ioree poweri Rev. per min.

200 850 6-32 in. Belted

150 850 8-32 in. Coupled
75 1.700 8-24 in. Coupled Larger motor required
for stock over 2-in.
thick.
50 1,700 Coupled See test below
til in.

50 850 6-24 in.

I
Belted Saws run 1,590 rev. per
min.
30 3,480 2-6 in. Coupled Lath edger

Test on the above 50-h.p. coupled motor showed a friction load of 6 kw.
th a feed of from 180 to 190 ft. per min., on hemlock stock, the following
jults were obtained:
uts in 3-in. stock 68 kw., peaks reaching 75 and- 80 kw
uts in 6-in. stock 68 kw., peaks reaching 75 and 80 kw
47. Trimmers. The driving shafts of trimmers can be readily driven
coupled squirrel-cage motors and speeds of 680 to 850 rev. per min. are
etomary. The following are instances of successful applications.

Motor
Sec. 16-50 INDUSTRIAL MOTOR APPLICATIONS

Test on a No. 1 hog driven by a 75-h.p., 690-rev. per inin., slip-rin,

coupled motor gave a friction load of 25 kw. Average load with feed fron
two band mills, 40 to 50 kw. Peaks 90 kw. ^

Unless the hog is carefully fed the motors are subject to severe Iom
fluctuations.
50. Miscellaneous
Drop cut-off saw, 72 in. diam., 510 rev. per min.; 20-h.p. 570-rev. per min.t
motor, belted^ ^ «

Lath boTter, 5 12-in saws; 40-h.p., i,760-rev. per min. motor, coupled
.

Log haul7230~ft. total length, 100 ft. on 60 per cent, grade; 30-h.p., 1,130-ij
rev. per min. motor, belted. |j

Conveyors in mill; 5 to 15 h.p. according to conditions, usually back-geared |j

or belted through a counter-shaft.

Covel band saw grinder; 3-h.p.. 1,120-rev. per min. motor, back-geared.

PLANING MILLS
61. Selection of motor. Standard squirrel-cage induction motors ar
satisfactorily applied to almost all machines used in planing and other wood
working estabhshments with, perhaps, the exceptions of large band resaw-
of great inertia, heavy planers and matchers with considerable static frictio
which must be overcome at starting, and in cases where each individut
motor requires a large percentage of the generator capacity. For thes
special cases slip-ring motors are used. The data in the following paragraph
give the average sizes and the power requirements of machines as supplier
by several of the leading manufacturers. Nearly all of these machines hav;
met practical service with the motors as indicated, although for very ligbi
or for very heavy service, smaller or larger motors, respectively, are som«j
times used. |

02. High-speed induction motors. Various machine designs hav;

been made for planers, jointers, shapers, etc., using 2-pole (3,000 r.p.ni
eliminating belts and niakin
j

60-cycle squirrel-cage motors with a view of

the motors integral with the machines. This speed has been found too lo"
for most cutting heads, but the advantages of self-contained units warrante
in many cases the installation of induction frequency changers which wit
two- or four-pole induction motors would give the desired speed. >!'
applications are satisfactorily taken care of with frequencies from lOd
cycles giving motor speeds from 6,000-10,800 r.p.m., but frequenci.
high as 300 cycles are sometimes used for small grinders or carving machu.c.
Special attention should be given to mechanical details, such as beanne
lubrication, alignment and balance when using high-speed motors. Ft
a description of the construction and operation of induction-frequen<?
changers, refer to Sec. 7, Par. 364.
63. Band saws
Scroll and rip

Wheel diam. Max. width of Aver, horae

Feed (ft. per min.) power
(in.) saw (in.)

30 Hand 2
34-38 Hand 3
40 60-150 10
42 Hand 5
42 60-200 15
48 Hand 7J

1240
 INDUSTRIAL MOTOR APPLICATIONS SeC. 15-54

r 44-in. band rip and resaw. Berlin No. 282 44-in. X4-in. wheel, C80 rev.
f^ermin., geared to a 15 h. p. 1,120 rev. per min. squirrel-cage motor. Fric-
(;ion load 4 kw. Resawing 6-in. to 8-in. poplar, 24 ft. per min.; average load,
'

12 kw,
.Tl-in. Mershon saw, 540 rev. per min., belted to a 20-h.p
band resaw.
,ll'() min. squirrel-cage motor; friction, 5.5 kw.
rev. per Resawing oak
\ in ft. per min.; average load, 18 kw.;
to 6 in. wide, 70 peaks, 21 kw.
Horizontal band resaw. Berlin No. 287 hopper feed, width of hopper
.'I) in. belted to a 40 h.p., 850-rev. per min. squirrel-cage motor; friction load,
;

'
kw.; tests, sawing oak.

Load (kw.)
Feed
Width (in.) (ft. per min.)
Average Peaks

13i 30 32 50
24 22 44 50

54. Circular saws

Cut-off saws Combination benches, dado, etc.

Diam. (in.) Aver. h.p. Diam. (in.) Aver. h.p.

10-14 3 12-16 5
16 5 20 7i
•16 7i
24 7i
30 10
t32 25
36 15

Rip saws
Diam. (in.) No. of saws jFeed (ft. per min.) Aver. h.p.

Hand 5
Hand 7J
65-200 10-15
50-160 20
Hand 20
50-160 30

Self-feed rip saw. 13-in. saw, 2,250-rev. per min., belted to a 10 h.p.
rOO-rev. per min. squirrel-cage motor; friction load, 2.5 kw.

Stock Feed (ft. per min.) Aver. load (kw.)

1 in. oak 73 5
1 in. oak 116 7.5
1 in. oak 150 9.2
2 in. hemlock 150 12.5

Resaws
Diam. (in.) Feed (ft. per min.) Aver. h.p.

24-30 30-80 15
36-42 30-80 20
48 30-80 30

^ Double cut-off or trimmer.

Double automatic cut-off.

1241
Sec. 16-55 INDUSfittAL motor APPLICAftONS
 INDUSTRIAL MOTOR APFLICATIONS SeC. 15-60

60. Outside moulders or stickers

Cap. (in.) No. of heads j
Feed (ft. per min.)| Aver. h. p.
Sec. 15-63 INDUSTRIAL MOTOR APPLICATIONS

63. Shapers
—3
Single spindle h.p. —5
Double spindle h.p.

64. Lindermsn automatic dovetail glue jointer. This machine tn;

be driven by one motor and countershaft, or by three motors. Size;
given by the maximum length of lumber which can be jointed.

Size, ft.
 INDUSTRIAL MOTOR APPLICATION H Sec. 15-74

Jib cranes comprise suitable jibs or booms, provided with motor-

74.
driven hoisting tackle. In some cases, also, a motor with suitable gearing
provided for swinging the jib into different positions.
is

76. Electric locomotive cranes comprise a jib or boom, usually carried

by a turn-table which is mounted upon trucks. Frequently individual motors
are provided for raising and lowering the boom, for rotating the boom, for
hoisting the load, and for propelling the machine along the tracks. In
other cases only a single motor is used, the different functions being set into
operation through mechanical clutches.
76. Miscellaneous. Under this head may be mentioned charging cranes
for open-hearth steel furnaces, skip hoists for elevating and dumping ore,
:coke, etc., into blast furnaces, also special cranes and unloaders for un-
loading bulk cargoes, such as ore or coal, from vessels.
77. Types of motors. The type of motor rnost commonly used for
I
operating the various motions of cranes is the series-wound, direct-current
:notor. The series-wound motor is admirably adapted to the purpose
Decause under heavy load it has the tendency to slow down, thus relieving
;he power station of a heavy load fluctuation; on the other hand, in the
:ase of light loads, the motor speed increases, thus producing what is generally
;nown as a "lively" crane. Compound-wound diroct-current motors
ire used only in special cases. Where alternating current is available, and
t3 conversion into direct current would entail a very considerable expense,
iilternating-current motors niay be used. The preferable type of alternating-
rurrent motor for this service is the slip-ring type, in which resistance is
ntroduced in the rotor circuit in order to obtain variation in speed. This
ype of motor affords much better results, as far as torque and speed varia-
ions are concerned, than the squirrel-cage motor, the torque of which de-
reases very rapidly as the voltage applied to the terminals of the primary
.inding is reduced. The speed range of both of these types of alternating-
urrent motors is limited and hence they do not produce nearly so active a
rane as one equipped with direct-current series-wound motors. In many
irgc industrial plants, covering considerable areas, energy is generated and
:stributed in the form of alternating current. The motors which require
flight speed variation are operated directly from the alternating-current
.3, while synchronous converters or motor-generator sets are installed to

!uce direct current for the operation of cranes, hoists, and other machines
hirh must operate through a wide range of speed and under greatly varying
ad.
78. The selection of the proper normal rating of hoist motors*
'
be used is in general a difficult problem on account of wide variations in
rvice requirements, particularly as to the matter of frequency of operation
~ an illustration, two extreme cases may
be taken: Ist, that of a crane
lied in an engine room or pump house, the crane having been installed
nally to assist in erecting the heavy machinery, being subsequently
only at varying and infrequent intervals for lifting parts of machinery
:

:i it becomes necessary to make adjustments or repairs; 2nd, the case of

. veling crane provided with a lifting magnet for handling pig-iron or other
luetic material in bulk, or equipped with a grab bucket for handling
ul, sand, slag, etc. There are instances of the operation of cranes of this
pe four tirnes per min., practically 24 hr. per day for indefinite periods, the
ted load being practically constant in value and almost equal to the rated
pacity of the crane. It is obvious that in the first case cited, the heating
the motor windings presents a small problem, while in the latter case this
m is of paramount importance. Of course the torque exerted by the hoist
the maximum load which will be encountered, must be taken
)tor in lifting
both cases. If possible the cycle of operations should
o consideration in
considered as follows: 1st, the time required to hoist with maximum load;
I

^, the period of rest at the upper limit of travel; 3rd, the time of lowering;
fi, the period of rest at the lower limit of travel before the next cycle is
lirted. The current required in lowering with a mechanical brake, or the
tltent required in dynamic braking (Par. 83 and 637) must also be taken into
risideration. These figures known, they may be plotted in terms of time
111 current, so that the square-root of the mean-square current may be

['See "Horse Power of Crane Motors," Machinery, Dec, 1913, page 286.

1245
Sec. 15-79 INDUSTRIAL MOTOR APPLICATIONS
determined. Since practically all series-wound motors are given fair
definite ratings in terms of current which the motor can carry continuous
for 1 hr. without overheating, the proper motor may thus be selecte
In many cases, however, such as in the design of cranes for ordinary machin
shop service, where the full capacity of a hoist is brought into play infi
quently, th judgment of the crane designer must be relied upon to determii
the proper size of the hoist motor. Many crane builders find it convenie:
from the viewpoint of standardization of manufacture, to build trolleys
a given hoisting capacity in duplicate. In some applications of the
standard cranes the hoisting motor may have much greater capacity than
required, while in other cases the work which must be performed by the hoi
may prove to be greater than was anticipated, necessitating adjustmen
in the field.
79. The magnetic brake. The hoisting motor of a crane is usual'
provided with a magnetic brake. This brake is so arranged that only wh<
power is applied to the hoisting motor is the brake released. At all oth'
times the brake is set either by means of a weight or a sufficiently powerfi
spring. These brakes are ordinarily designed to apply on the armatu
shaft of the motor at the commutator end. The series-wound brake (in coi
nection with direct-current motors) is by all means the safest and tl
most reliable. Shunt-wound brakes of course are necessary in connectic
with alternating-current hoisting motors, because a series-wound bral
would act as a choke coil and materially reduce the voltage at the mot<
terminals.
80. Types of brakes in common use, see I?ar. 532 to 536.
81. Brake lining. In present practice the friction members in a
the types of brakes mentioned above are lined or faced with a compositio
of asbestos, woven together with bronze wire. This material affords
very much higher and much more constant coefficient of friction than d
the leather, wood or metal brake facings used in the past.
82. The mechanical brake. After a load has been hoisted, it
usually necessary that it be lowered, at least a certain distance. If no moai
were provided for checking the lowering speed, the load might soon attai
almost the speed of a freely falling body, and in the case of a scries-wour
hoisting motor, might soon attain a speed which would destroy the moto
On electric overhead traveling cranes a so-called "mechanical brake" h:
been employed, this brake being so designed as to prevent the load fro
appreciably accelerating the hoist motor, when it is running in the lowcrir
direction, or from "overhauling" the motor, as this action is common
designated. Many ingenious designs of such brakes have been develope
All of them, however, act upon the common principle that if the load begi
to overhaul the motor, the brake is applied.
83. Dynamic braking. During recent years this method of retardii
the speed of the hoistihg motor when lowering a load has been quite general
adopted on electric cranes. The hoisting motor is driven as a generator 1
the lowering load, and is caused to generate energy which is either returni
to the line or dissipated through a resistance, or both. This gonerafii
of energy imposes a magnetic drag on the machine and thus retards
downward speed of the load. Dynamic braking with a series-wound ;

motor is accomplished by connecting the fiera winding in scries wn

resistance across the suppl.v mains, thus giving the machine the chai i

teristics of a separately-excited shunt-wound generator. In some Cii'^

the armature is connected in a local circuit containing a resistance win
may be varied at the will of the operator. In other cases the armatir
connected across the supply mains in series with a resistance which ni m
varied by the operator, this latter connection being the one most gen< i

used. See Par. 639.

84. Motor control in dynamic braking. Fig. 7 is a diagram
wiring connections of a face-plate typ(! of controller arranged for dynaiiJ
braking. When the load is traveling in the lowering direction, the re«i»
ances in series with both the armature and the field of the motor may i

varied by the operator by manipulation of the lever of this cimtroller..

hoisting, the motor is connected as an ordinary series-wound motor, tj
|

controlling resistance being in series with the motor circuit and varie« j

vary the hoisting speed. In lowering, however, it will be seen that t|

1246
 INDUSTRIAL MOTOR APPLICATIONS SeC. 15-85

irmature and the field are connected in separate circuits. On the first
Doint of the controller, in lowering, the field is excited through a resistance
A'hich allows practically full-load current to pass through the field winding;
ilso a considerable amount of resistance is included in the armature circuit.
it will be seen that on the first lowering point the armature is shunted by
',he field winding and the brake winding. This naturally produces an
'xtremely low speed. As the controller lever is moved from step to step,
the resistance in the field circuit is increased, while the resistance in the
irmature circuit is decreased. Increase in resistance in the field circuit
'naturally reduces the field excitation and counter e.m.f., thus allowing the
ipeed to increase. The resistance in the field circuit is ordinarily so pro-
>ortioned that the speed can increase as much as 100 per cent, to 150 per

Res. a
Lowering
First Point

Kote: When Uut-outB

not required connectj
St ends .Y & 1' of the
liiignelicawitcV, coila
'directly to positive

Fig. 7. — Face-plate type controller arranged for dynamic braking.

at. above normal full-load speed. be seen that at all times the
It will
dd is supplied with current from the mains, and at full speed this may
pount to only half of the full-load current. On the other hand, the
rmature is also connected to the supply mains, and as soon as the counter
ta.f. reaches a value sufficient to overcome line voltage, current is actually
[turned to the line, so that the net current required in lowering the load is
,6 difference between th^ current supplied to the field from the Hn« and the

irrent returned to the line by the armature. In lowering heavy loads the
irrent returned to the line is greater than the current drawn from the line
r the field, so that the lowering load is made
to do useful work.
i86. Slow-hoisting motor control. This type of control differs from
one illustrated in Fig. 7 only in the respect that a shunt is placed around
€ armature in order to reduce the speed, thus producing an extremely slow
>i8ting speed. This type of controller is frequently used in foundries
l9re extremely slow speeds are required in lifting patterns from flasks, etc.

r^ I"inait stops are now customarily provided in connection with

ihoisting motion of cranes and hoists. In the absence of a limit stop,
'hoisting block, perhaps carrying a load, might be carried upward into

1247
Sec. 15-87 INDUSTRIAL MOTOR APPLICATIONS
the mechanism of the trolley, provided the operator did not open his con,
troller at the proper time. Where the block of the hoist must be fre
quently run up to a point very close to the mechanism of the trolley, i
is advisable to use a limit stop which not only cuts off the current from thi
motor, but includes the motor in a dynamic braking circuit of such lov
resistance that the hoist is stopped almost instantly, irrespective of thi
condition of the brake.
87. Drive of the crane bridge. The designed speed of crane bridges
varies between very wide limits. In the case of cranes used in machine
shops, structural shops, and plants of like nature, it is advisable to hav(
the bridge of the crane driven at a speed of from 250 to 300 ft. per min
This corresponds to between 3 and 3i miles per hr. which is a speec
at which a man can walk while steadying long pieces of material carriec
by the crane, and passing through a busy shop. In other cases, such as
the handling of bulk material, where long runs are necessary, the bridg*
mechanism may be geared to operate at or above 1,000 ft. per min. The
power required to drive the bridge motion of cranes varies betweer
exceedingly wide limits, depending upon the span of the crane girders,
condition of the rails on which the bndge runs, and particularly upon the
rigidity with which the end trucks are fastened to the girders of the bridge
Unequal wear of driving wheels is also a factor to be taken into account
because, if the driving wheels on the opposite truck frames of the crane
become of unequal diameter, one end of the crane will tend to travel faster
than the other, thus producing a severe torsional strain on the driving shaft
and the bridge structure. Frequent starting and stopping are also factors
which should be carefully considered in designing the gearing of the bridge
drive. Where many starts and stops, and particularly short moves are to
be made, facility in starting and stopping is a prime requisite.
As an example, a certain crane with gearing designed for a bridge speed
of 500 ft. per min. performed a regular cycle of operations, making
short moves of approximately 24 in., 24 times in succession, and then re-
turning to the starting-point, this cycle being carried out substantially 24
hr. per day. At the outset the performance of this crane was extremely
unsatisfactory, as the operator would invariably run beyond the point
at which he was required to stop, would then reverse, and perhaps run too
far in the opposite direction, so that two or three attempts were required in-
each case to reach the proper position. The gear ratio between the bridge
motor and the driving shaft was altered in order to secure a gear reduction
of three times the original reduction. Theoretically, this should have
materially slowed down the operation of the crane, but through greater
facility in starting and stopping, the output of the crane was increased
more than 400 per cent.
88. Bridge drive with very long span. In this case two driving
motors are frequently provided, one being placed at each end of the bridge
and driving the truck wheels directly; the motors are coupled together by
a line shaft carried on the girder of the crane. In such cases it is preferable
to connect the two driving motors in parallel and to provide each of them
with a separate reversing switch, so that each will have its own connections
to the line.
89. Safety devices. Under this heading might be mentioned limit
stops, as described in Par. 86, and also what are known as crane switchboards.
These boards usually inclucle two solenoid-operated switches or contactors,
which connect all of the circuits of the crane to the main feed wires. When
these switches are open, all wiring on the crane is disconnected from the
line. These switches are controlled by a plug, which, when pushed in,
energizes the windings of the switch solenoids and causes the switches to
close; when pulled out, it opens the switches, thereby interrupting the energy
supply. The plug is also provided with attachments whereby it may be
positively locked in the open position by a padlock. When a motor in-
spector or repairman mounts the crane he pull.s open the plug and locks it
po.sitively in the open position, so that the crane cannot be operated until
he has finished his work and removed his padlock. In addition the two mag-
netic switches are usually arranged for overload protection, and are operated
by the action of overload relays in the circuit leads of each motor on the
crane. In case the overload is merely temporary, the operator is simply
required to reset the magnetic switches, which are conveniently at hand.

1248
 INDUSTRIAL MOTOR APPLICATIONS See. 15-90

If, however, the overload relays continue to act when energy is applied, the
operator must necessarily look for trouble in the mechanism of the crane.
90. Energy supply. In a plant in which a large number of cranes
are employed, it is by no means necessary to provide generator capacity
equal to the total rated horse power of all of the motors used. In a large
industrial plant in which 127 cranes were installed, generator capacity cor-
responding to 25 per cent, of the total rated horse power of motors used on
the cranes was found ample to care for the load. Where only a single crane
is installed it is wise to provide generator capacity sufficient to take care of
full-load on the hoist and bridge motions, leaving it to the overload capacity
of the generator to take care of the current required by the trolley, in case
all three motions of the crane should be operated at the same time. Naturally,
the larger the number of cranes installed in a given plant where a definite
* cycle of operations is not carried out, the smaller may be the proportion of
I generator capacity to the total horse power of the crane motors.

ELECTRIC HOISTS
BT WILFRED SYKES
Steel & Tube Co. of America; Fellow, America7i Institute of Electrical
Engineers
91. Drums. Hoists are generally classified according to the shape
of the drum. In general use are the cylindrical, the conical and the cylin-
dro-conical drums, the last mentioned being a com-
bination of the first two, part of the drum being a
, cylindrical and part conical (Fig. 9). The object
of the conical drum is to reduce the starting
torque, as the load is exerted on the drum at a
smaller radius when the cage is at the bottom of
, the shaft. The cylindro-conical drum is used with
i
the same object. All other things being equal,
> the roi)e wear is less with the cylindrical drums
than with other types of drums.
Flat ropes. The above types (Par. 91)
92.
'
use round ropes. Flat ropes, generally about 0.5
in. thick, are sometimes used, the rope being
wound upon itself on a reel, so that the radius at
which the load is suspended gradually increases,
•

-
the effect
drum.
being similar to that of the conical
Flat ropes on reels are used only to a very Fig. 8. — Unbalanced
small extent, on account of the excessive main- hoists.
tenance charges.
93. Balanced and unbalanced hoists. When running balanced the
1 empty cage descends as the loaded cage ascends, the cages and cars balancing
oaoh other. When working unbalanced only one cage is used, and the load.

Fig 9. — Balanced hoists.

1249
Sec. 16-94 INDUSTRIAL MOTOR APPLICATIONS ^.

due to the cage and the car, must be added to that due to the weight of tho
material hoisted in order to ascertain the load on the motor. See Figs. 8
and g.
94. Power reQuirements. In the case of small or medium-sized hoists,
it isusually difficult to determine a definite hoisting cycle, although the
maximum load to be hoisted can generally be assumed. In such cases
the rating of the motor required is usually determined from the following
formula:
, LXV^ _
^P'"" ^^>
33,000X0.8
Where L = total unbalanced load and y = speed of hoisting in ft. per min.
For large hoists, the cycle of operation is usually well defined, and the
required motor rating can be accurately determined. The calculation of
load diagrams will be found useful in such investigation.*
96. Mechanical efficiency. The over-all efficiency of the mechanical
parts of the equipment is assumed in general to be 80 per cent.
96. Service affecting motor rating. As the service is intermittent
and as the motors have an opportunity to cool during the intervals between
trips, it is not necessary that the motor should be capable of continuously
carrying the load as determined above (Par. 94). In order to preserve a
good balance between the maximum torque capacity of the motor and its
heating capacity, at the same time keeping down the cost, intermittent-
rated motors are used for such hoists. Experience has shown that if a motor
has sufficient capacity to carry the load, as determined above, for half an
hour continuously, it will operate the hoist under ordinary conditious.
In cases of very severe service, where the hoist operates a large portion of
the time, and where the peak loads due to acceleration may be high, such a
simple rule cannot be used.
97. Types of motors adaptable to hoists. Direct-current motors
for small hoists are usually series-wound, but occasionally compound-wound
motors are adopted, in order to simplify the control if dynamic braking is
required. With an alternating-current supply, slip;ring motors are used,
being designed for great momentary overload capacity. The high value of
maximum torque for which these motors are designed necessitates a large
magnetizing current, and usually such motors cannot be run continuously
even at light load. For small and moderate-size hoists, motors having
speeds from 300 to 500 rev. per min. are generally used, being connected
to the drum through single-reduction gearing. Large induction motors,
designed for direct-connection to hoists, have been built in a few cases
where the speed has been in the neighborhood of 100 rev. per min. Such
machines are very expensive and rather unsatisfactory from an operating
standpoint. The difficulty of controlling large machines by rheostat
practically confines the large motors to direct-current machines used in
conjunction with a fly-wheel motor-generator set, or a plain motor-generator
set (Par. 100 and 104).
In the case of hoists operating under severe conditions when the average
rotating speed of the motor over the whole cycle is low, and especially in the
case of direct-current hoist motors working with constant field excitation
which is not interrupted during periods of rest, it has been found desirable
to use forced ventilation. For this purpose, the back end of the motor is
enclosed and air forced through the machine by a constantly running fan.
In this way the cooling of the motor goes on continuously whether it is
rotating or not. Unless this is done the rate of cooling when the motor is at
rest is very slow and excessively large machines would be required to keep
the heating within permissible limits. Usually this is only necessary if the
hoist must run at full capacity for long periods and in the case of machines
of 500 h.p. and over.
98. Direct-connected and geared motors. Direct-current machines
can be built in all sizes for comparatively slow speeds, 60 to 75 rev. per
min. being quite common for machines of 500 h.p. and upward. The use of •

machine-cut double-helical gears has made possible the gearing of large hoist
motors in many cases, and the very satisfactory operation of this type of
• Sykes, Wilfred. "Large Electrically-driven Hoists," Transactions,
American Institute of Electrical Engineers, 1910.

1250
 .

INDUSTRIAL MOTOR APPLICATIONS SeC. 15-99

gearing when properly built is a strong argument in favor of using moderate-

speed motors instead of the extremely slow-speed motors necessary for
direct-connection
99. Balancing systems. The high peak loads, caused by hoists of
large capacity, especially during their periods of acceleration, make it
desirable in many cases to adopt some system of making the load on the
line more uniform. Practically all balancing systems utilize a fly-wheel,
the speed of which is varied, so that it gives up or absorbs energy according
to the demands of the hoist. The main requirements of a balancing system
are that it should be capable of preventing sudden excessive demands for
energy from the line, it should be automatic in operation, and that the
losses, due to it, should bo as low as possible.
100. Ilgner balancing system. The arrangement now most widely
used, was devised by Mr. Karl Ilgner. As arranged for alternating-current
supply, it consists of an induction motor with a wound rotor, coupled mechan-
ically to a direct-current generator, which in turn supplies energy to a direct-
current separately excited hoist motor. The motor-generator set is supplied
with a fly-wheel of sufficient capacity to care for the peak loads. The field

Flywheel Motor
Generator Set

Exciter Circuit
Fig. 10. — Ilgner balancing system.
of the direct-current generator is separately excited, and a controller ia
provided so that the excitation and the polarity of the generator can be
varied as desired. The field polarity of the hoist motor remains constant,
'30 that by reversing the armature current the direction of rotation can|;be
changed. By varying the excitation of the generator, the voltage applied
.to the armature of the hoist motor can be varied, and in turn the speed of
'the hoist.
'
101. Action of the automatic regulator. A regulator is provided
or automatically inserting resistance in the rotor circuit of the induction
notor, thereby reducing the speed of the motor-generator set, which causes
;he fly-wheel to give up part of the energy stored in it. The rate at which
he speed is changed depends upon the difference between the input that is
.0 be maintained on the induction motor and the power required to drive
he generator. When the load on the generator is reduced below the value
or which the automatic regulator is set, the fly-wheel speed is increased by
vatomatically removing resistance from the rotor circuit, energy being
'l.ored in the fly-wheel in order to enable it to carry the peak load, due to
he succeeding cycle.
102. Details of Ilgner balancing system. This system provides
lotonly for power equalization, but also for the control of the Roist motor

1251
 Sec. 15-103 INDUSTRIAL MOTOR APPLICATIONS
by the manipulation of the generator excitation, thereby eliminatinf
rheostatic losses, and the difficulty of controlling large machines. Th<
general arrangement of this scheme is shown by Fig. 10. In practice th«
speed of the fly-wheel set is varied from 15 to 20 per cent, during a hoistinf
cycle. High-speed fly-wheels with peripheral speeds reaching 25,00C
ft. per mm. are used in order to minimize the weight.

103. The losses with the Ilgner system are comparatively high
and it is seldom that an over-all efficiency of more than 50 per cent, if
realized from the combined electrical and mechanical equipment. Thif
efficiency decreases when the hoist is operated below its normal capacity
due to the constant no-load loss of the fly-wheel motor-generator set
However, for important hoists, the advantage of equalizing the input, and
the perfect control possible with this type of apparatus more than com-
pensates for the increased power consumption.
104. Converter balancing system. Another system has been devised
which provides for equalizing the input, but does not provide for the contro
of the hoist motor. This is shown in Fig. 1 1. In order to render the demand
on the line constant, the equalizing system is connected in parallel with tht
generating station. It consists of a synchronous converter and a direct-
current machine which is coupled to a suitable fly-wheel.

• Field Kheoatat
Fig. 11. — Converter balancing .system.
106. Operation of the converter balancing system. The synchronoui'
converter acts only a.s a connecting link between the alternating-current;'
system and the equalizing set, which consists of a compound-wound direct-
current machine coupled to the fly-wheel (Fig. 1 1). The field of this machint
is controlled by a regulator, operated by a series-wound solenoid connected
in the main-line. At the beginning of a trip the fly-wheel is running at fui
Speed, and when the load current exceeds the mean value, the regulatoi
automatically strengthens the field of the equalizing machine, so that il
acts as a generator driven by the fly-wheel. The amount of energy delivered
to the synchronous converter and thence to the line will depend on thf
excess of momentary load-current over the mean value of load current, foi
the regulator will continue to raise the excitation of the direct-current
machine as long as there is any tendency for the line current to increase
above the mean value.
When the current demand drops below the mean value, the regulator
will weaken the field, thereby causing the machine to run as a motor, which,
taking energy from the line through the synchronous converter, will ac-
celerate the fly-wheel. As before, the rate at which the resistance is intro-
duced in the field depends upon the excess of the mean current value over
the momentary current demand. In this way energy is stored in the fly-

1252
 INDUSTRIAL MOTOR APPLICATIONS See. 1&-106

wheel and the line load is kept approximately constant. The synchronous
converter changes either direct current to alternating current, or vice versa,
depending upon whether the fly-wheel is delivering or receiving energy.
106. Comparison of Ilgner system with converter system. It
will be seen that the fly-wheel speed variation in the converter method is
obtained by field regulation of the direct-current motor, so that the loss is
I
negligible. With the Ilgner system the loss is from 7.5 per cent, to 10 per
cent, of the input to the driving motor. This is a very important feature
; in equalizing systems using direct-current machines, as a much greater
fly-wheel speed variation, can be economically obtained with the converter
method, it being the usual practice to allow from 20 per cent to 25 per cent.,
, and consequently the fly-wheels can be comparatively light. The machines
of the converter equalizing equipment need be only large enough to deal
with the load variations from the mean value, and under ordinary circum-
; stances, the capacity need not be more than about one-half that of the
motor-generator set for the same duty. The equalizing equipment is quite
independent of the hoisting motor, so that it may be out of service without
'

cessation of hoisting. However, in this event the peak loads will be felt
:
on the line. With the Ilgner system the hoist is directly dependent upon
,
the motor-generator set.
107. Control for alternating-current motors. Magnetic-switch
controllers are used to a considerable extent. Liquid controllers for the
rotor circuit are also used, and these have the advantage of providing smoother
acceleration and of being simpler in construction.
108. Types of switches in use. For the control of the primary, both
oil and air-break magnetic switches are in use. For circuits of 550 volts and
under ordinary magnetic switches are quite satisfactory. For 2,200-volt
motors, special air-break switches are in use, and when properly designed
are preferable to other types on account of the accessibility of the contacts
and their ability to withstand hard service. Oil switches are used to a
con.siderable extent but for very severe service they must be very liberally
rated, otherwise there is danger of explosion, due to the heat generated
in the oil. Drum controllers can be used only for small hoists requiring
motors not larger than 75 h.p., and are not at all suitable for severe operating
conditions. Magnetic-switch controllers can be used for all sizes, but
iquid controllers are used only for motors of about 300 h.p. and above.
109. Control for direct-current hoist motors. Drum controllers
are satisfactory for direct-current motors under 100 h.p., providing the
service is not too severe. Magnetic switches should be used for motors
above this capacity. Liquid controllers are not satisfactory for direct cur-
rent. In cases of very large hoists with peak loads of 1,000 h.p. and above,
, rheostatic control, for either direct-current or alternating-current motors
I IS not very practicable. When power equalization is not required, a motor-
generator set is used without a fly-wheel. In every respect the operation
is the same as with the Ilgner system, except that the speed of the set is
not varied. The efficiency of such an arrangement is often greater than
that of the hoist with rheostatic control, and the maintenance is usually
,
leas than that of a large rheostatic controller, although the amount of
i
apparatus involved is greater.

j ;
ELEVATORS
BY DAVID L. LINDQUIST
[
I
Engineer Otis Elevator Company; Associate, American Institute of
'Chief
i Electrical Engineers
^ 110. Classification of electric elevators. There are two general classes
,

* i,of electric elevators, those employing grooved traction sheaves and those
D ;having spirally grooved drums. The cables of the former are frictionally
driven by suitably grooved sheaves, while those of the latter are wound up
:0n a drum to which they are positively attached. Traction type elevators
1
,are adapted to all kinds of elevator service, regardless of length of travel or
I
»i,ear speed. They are frequently operated at 700 feet per minute and speeds
9 M
1000 feet per minute are equally practical for high rise express service.
i iDrum type elevators are limited to travels of about 100 feet and to car speeds
> of about 200 feet per minute. The general superiority of the traction

1253
 I
Sec. 15-111 INDUSTRIAL MOTOR APPLICATIONS

type, particularly as to safety, has brought about the gradual elimination

of the drum type, so that comparatively few drum elevator machines are now
manufactured.
111. Orooving of drums and traction sheaves. Drums and traction
sheaves with double cable wraps usually have semi-circular grooves as
shown in Fig. 12(6). Traction sheaves with single-cable wrap usually have
grooves of the V-section (Fig. 12a) or of semi-circular, under-cut section
(Fig. 12c).

The circular groove gives the best support for the cable, i.e., minimum
pressure between sheave and rope, and consequently the least traction for a
given arc of contact. To obtain sufficient traction it is usually necessary to
resort to double wrap (Fig. 15) when round grooves are used. Sufficient
traction can usually be obtained with a single wrap when the V or under-cut
groove is used. In this case the secondary sheave shown in Fig. 15, is
omitted.
The latter type of grooves gives, however, greater unit pressure between
cable and sheave. This unit pressure is particularly high with a driving
sheave of small diameter and steep angle V groove, which has not been
worn. As excessive unit pressure will cause rapid wear of rope grooves as
well as cables this matter must be given careful consideration particularly
where plain V-grooves are used.
112. Roping and counterbalancing of elevators with winding drums.
Necessary connections arc usually made between drum and car and counter-
balance by means of two ropes for each connection, thereby decreasing size
of ropes required, the increased flexibility permitting the use of smaller
diameter drums and sheaves. Fig. 13 indicates the roping arrangement fol-
lowed when a single or back drum counterbalance only is used; wliile Fig.
14 portrays similarly the arrangement necessitated by the use of a double
counterbalance. With this Litter arrangement, one counterbalance con-
stitutes the back drum weight, while the other is attached directly to the car
The total counterbalancing should be proportioned to the average loads,
to be carried, which usually range from 30 to 40 per cent, of the rated maxi-
mum load. When only one counterbalance is used, therefore, its weight
should equal that of the car plus from 30 to 40 per cent, of the maximum load
in the car. With the double counterbalance, sum-total weight should also
be equal to the weight of the ear plus from 30 to 40 per cent, of the maximum
load in the car. In this event, the counterbalance attached to the car is
proportioned to approximately 70 per cent, of the actual weight of the car,
the weight of the back drum counterbalance being equal to the difference
between the total weight and that of the car counterbalance. Either method
of counterbalancing imposes on the motor a net maximum load of approxi-
mately two-thirds the rated capacity of the elevator.
For car travels in excess of 100 ft. it is advisable to compensate variation of
load on motor, produced by change in position of cables during run, by means
of a compensating chain attached from the car to the middle point of the
hatchway, as shown in Fig. 13, or attached from car to counter-balance as in-
dicated in Fig. 14. The following formulas derive total compensating weight
required, where 7i = weight of hoist ropes per ft.; dw = weight of drum coun-
terbalance ropes per ft.; «/' = weight of car counterbalance ropes per ft.;
c = weight of compensating chain (or ropes) per ft. With compensating
chain attached to_ car and middle point of hatch; C'=2{h+dw + cw). With
compensating chain attached to car and counterbalance: c= (,h + dw-\-2cu')/2.
For installations employing the single counterbalance only; cu' = 0.
1254
 INDUSTRIAL MOTOR APPLICATIONS ScC. 16-113

113. Roping and counterbalancing of elevators with traction

sheave. From Fig. 15, which clearly indicates roping required by what is
known as the 1 1 traction-sheave double-wrap type, it will be noted that
:

the single length of ropes used are directly connected to car and counter-
balance at either end. By the use of a secondary or idler sheave these ropes
are passed over the traction sheave a second time as a means for increasing

f^"%

13. —Roping arrangement

for use with single (back drum)
Fig. 14.
use
—with
^Roping arrangement
for double counter-
counter balance. balance.
rope contact, which, under the influence ofthe combined weight of car and
•counterbalance, provides the adhesion requisite to elevator service.
The foregoing arrangement corresponds to that used for the 2 : 1 traction-
Kheave type with the exception that the ropes, instead of being directly con-
nected to car and counterbalance, are passed under traveling sheaves located
at the upper end of both car and counterbalance; from this point they are
I'.xtended vertically to the top of the hatchway and there securely and per-
,manently anchored. Fig. 16 represents the 2 : 1 roping arrangement.
Sec. 15-113 INDUSTRIAL MOTOR APPLICATIONS
Both the 1:1 and 2 1 roping methods with double wrap, Fig. 15 and
:

Fig. 16 respectively, may be used with single wrap having driving sheaves
grooved as per Fig. 12a or Fig. 12c with the secondary sheave eliminated.
One of the striking advantages resulting from this arrangement of ropes
and method of driving them, is the total loss of traction obtained if either car
or counterbalance is obstructed in its descent or bottoms on its respective oil
,

! I

Idler Sheave
.
i.->

Fia. 15.- -Roping arrangement for use with Fio. 10. —

Two to one
traction sheave. roping arrangement.
buffer, causing complete cessation of all car motion even though the driving
member may continue to revolve. This property of the traction-sheave
elevator constitutes an extremely important and effective safeguard by ena-
bling the absolute fixing of the car travel between two given limits, inasmuch
as with proper roping the car will be brought to rest on its oil buffer before the
counterbalance comes into contact with the overhead work and vice versa.
A further advantage of the traction-sheave elevator lies in the fact that the
faces of the sheaves are entirely independent of the height of the building.

1256
 INDUSTRIAL MOTOR APPLICATIONS SeC. 15-114

Counterbalancing must in all cases be proportioned for an equal margin of

safety to counteract the tendency to slip on both up and down direction of
travel under maximum load conditions. Where there is a considerable sur-
plus of traction, however, the weight of the counterbalance should be made
dependent upon the average loads in the car, which, for this type of elevator,
usually range from approximately 33 to 45 per cent, of the maximum. Ordi-
narily, the total weight of the counterbalance should equal that of the car
plus from 33 to 45 per cent, of the maximum load in the car.
Elevators with traction sheaves should in all cases be provided with rope
compensation and with connections arranged in accordance with Fig. 14;
the weight per hatchway ft. of the compensating ropes should equal approxi-
mately the weight of the hoist ropes per hatchway ft. minus one-fourth the
weight per ft. of the electric control and lighting cables.
114. Electric elevator machines. The machines used for driving the
two types of electric elevators mentioned are distinguished by their methods
of power transmission between motor and winding drum or traction sheave,
namely, (a) worm gear; (b) worm and spur gear; (c) helical or herring-
bone gear; (d) 1:1 gearless traction; (e) 2:1 gearless-traction machines.
All of these machines should preferably be mounted over the hatchway
although they can be located below where conditions demand.
116. Worm-gear machines. These machines are used for both pas-
senger and freight service and may be arranged with either winding drum or
traction sheave. For the smaller sizes, known as dumbwaiter machines,
duties range from 500 lb. at 100 ft. per min. to 100 lb. at 500 ft. per min.,
while in the larger sizes the duties usually range from 500 lb. to 20,000 lb.
and the speeds from 100 ft. to 400 ft. per min.
In order to preserve alignment, all parts should be assembled on a ribbed
bedplate extending underneath, the entire machine. The armature shaft
of the motor is usually coupled direct to the worm shaft, the face of this
coupling being utilized as the brake pulley. The worm and shaft should be
solid and integral and of high-grade steel, the worm meshing with a bronze-
rim worm wheel attached to a cast-iron spider. This spider, being directly
and mechanically connected to the winding drum or traction sheave, renders
power transmission at this point entirely independent of keys. Self-align-
ing ball thrust bearings are provided on the worm shaft.
116.Worm and spur-gear machines. The two types may be classified
as safe lift machines and geared freight machines, the former being a special
adaptation of the worm-gear machine when it is desired occasionally to lift
loads greater than the normal and at considerably reduced speeds. This type
is generally installed in office buildings, where, with the special arrangement
applied to one or more of the ordinary passenger elevator machines, the
handling of safes averaging from 4,000 lb. to 9,000 lb. in weight at a slow rate
of speed, is greatly facilitated. To accomplish the increase in lifting capa-
city, a special provision is made for placing necessary gears in mesh between
the armature and worm shaft, thereby reducing the car speed and increasing
the lifting capacity in direct proportion to the ratio of tne gearing inserted.
By this method, therefore, and usually with a slight addition in counter-
balance, the safe-lift loads are carried without requiring more current from
the line than during normal operation. Geared freight machines differ from
the worm-gear type by the addition of a single spur-gear reduction between
the worm gear and the winding drum, thereby constituting them essentially
slow-speed machines with relatively large lifting capacities.
117. Helical gear or herringbone gear machines. These machines,
which can be arranged for use with either winding drums or traction sheaves,
are provided with a single gear reduction to the nnotor by means of the helical
or herringbone type of gear. Such gears permit a larger ratio of reduction
with greater efficiency than can be obtained with ordinary spur gears. The
;
motor speeds usually range from 300 to 600 r.p.m.
118. Gearless traction machines, 1 1 ratio. This machine represents a
:

combination of extreme simplicity, maximum economy and highest efiiciency.

,
Briefly, it is a two-bearing electric machine, the armature, traction sheave
jnd brake pulley being contained on the same shaft, all parts being compactly
i^rouped on a cast-iron bed. The motor is of the plain shunt-field, slow-speed
'O'pe of about 60 r.p.m. transmitting energy direct to the traction sheave.
Contrary to general belief, these motors have remarkably high §$^ieiicy

1257
Sec. 15-119 INDUSTRIAL MOTOR APPLICATIONS

and a distinctive procedure has been to arrange design with a view to realiz-
ing the highest efficiency (about 90 per cent.) at half rated capacity. This
figure corresponds with the average loads for this class of service, the full-
load efficiency being approximately 87 per cent. Frequently these machines
are provided with ball oearings as a means for further increasing the efficiency
and decreasing the space required.
Machines of this type should be located over the hatchway whenever it is
at all possible. They are used for car speeds of from 500 to 800 ft. per rain,
with loads ranging from 2,000 to 4,000 lb. inclusive. To date only machines
employing direct-current motors have been produced.
By means of a special arrangement, the regular machines can be converted
so as to enable the lifting of safes weighing from 5,000 to 8,000 lb. This
arrangement includes the placing of a second magnet brake in operation and
also the adding of extra weight to the regular counterbalance. When lift-
ing safes, maximum field strength of motor is utilized, producing a propor-
tionately slow car speed.
119. Qearless traction machines, 2:1 ratio. All mechanical features
of these machines correspond to those of the 1 1 gearless-traction type.
:

They have been designed for tr&ction sheave elevators requiring lower car
speeds than obtained with the 1 1 machine without the necessity of gear
:

reductions the car speed reduction being produced by the 2-1 roping arrange-
ment previously described. The machines have been designed for direct-
current service only, using shunt-field motors of from 80 to 140 rev. per min.,
with resultant car speeds of from 250 to 450 ft. per min., and they liave been
installed for capacities up to 12,000 lb. By an arrangement similar to that
with which the 1 : 1 gearless-traction machines are equipped, these machines
can also be used for safe lifting.
120. A common characteristic of all elevator motors is that they
must be specially constructed to withstand repeated stresses produced by
frequent starting and stopping. .In general, however, the performance of
alternating-current and direct-current motors differ to such an extent as to
necessitate their separate consideration.
121. Direct-current motors. This class of motors must iae designed for
sparkless commutation at starting, stopping and reversal of rotation under
all fluctuations of load within their rated capacity, and be capable of exerting
a heavy starting torque with minimum requirements as to starting current
especially where frequent starts and stops are made, in order to reduce the
energy consumption and the reaction on the generating plant. Because of
these requisite features, commercial motors are rendered generally unsuit-
able. As a means for reducing starting currents, those niotors used for
driving geared elevator machines, and usually operating at from 300 to 900
rev. per min., are arranged to start aa compound- wound motors having a
heavy series field which should be cut out, usually by a short-circuiting pr.
ess, as the motor speed increases. At full speed, therefore, the .mn
operates as a plain snunt-field tj^pc.
Because of the high self-induction of the field winding required by motors,
used for driving the 1 1 and 2 1 gearless-traction machines, which generally
: :

operate at from 60 to 140 rev. per min., when at full speed, the fields are
connected permanently across the supply lines, with retfuced current when
machine is at rest; this procedure shortens the length of time required to
bring the field to full strength on starting. 8uch a method of field connec-
tion materially reduces motor starting current. For direct-current elevator
motors the starting torque required is usually double full-load torque with
a starting current of about 125 per cent, of full-load current.
122. Single-speed polyphase slip-ring induction motor. This type
of motor has been extensively used in the past for elevator service and to a
certain extent is still used in the larger sizes.
123. Single-speed polyphase squirrel-cage induction motor. The
squirrel-cage motor has always appealed to the engineer for use in connec-
tion with elevator drives, because of its simpler construction due to the
absence of slip rings, brushes and external resistance with its necessary short
circuiting devices. Until recently motors of this type have been found more
or less unsatisfactory except in the smaller sizes because of their high star-
ing current and tendency to overheat where the service was at all severe.
The squirrel-cage motor has, however, lately been very materially ini-
1258
 INDUSTRIAL MOTOR APPLICATIONS Sec. 15-124

proved. The principal improvements are the welding of the end rings to
the rotor bars and the use of end rings of large radiating surfaces and very
well ventilated. Such a design permits using a sufficiently high internal
rotor resistance to reduce the starting current to about twice full-load run-
ning current and a smaller and consequently hghter rotor without objec-
tionable temperature rise in severe service. Due to the fact that the modern
squirrel-cage rotor has less momentum than a corresponding slip-ring rotor
the starting torque required to start the complete elevator in a given time
is less with the squirrel-cage motor. With less torque required and usually
higher starting torque efficiency the squirrel-cage motor takes about the
same starting current and power consumption as the slip-ring motor with
its external starting resistance properly proportioned and short circuited in
correct sequence and time.
With the poor attention that elevator controllers usually receive it is not
surprising to find that in service a slip-ring motor frequently takes a starting
current much greater than a corresponding size squirrel-cage motor and is
sometimes stalled and burned out because the starting resistance happens
to be left short-circuited or is short-circuited too rapidly.
For the purpose of preventing the starting current of the brake adding
to the full starting current of the squirrel-cage motor, and also to give a
smoother start, it is customary to insert momentarily at starting a certain
amount of external stator resistance. While the squirrel-cage motor usu-
ally has a greater speed variation than the slip-ring motor with the sUp rings
well short-circuited, this disadvantage is more than offset by the increased
reUability and safety. The squirrel-cage motor has a definite resistance,
not materially altered, even if several rotor connections should become open,
which is not likely to occur as these are welded.
With the slip-ring rotor there are several possibilities of getting excessive
rotor resistance and even open rotor circuits since the rotor connections are
usually soldered and connected in series. There also are possibilities of
resistance grids breaking and brushes and bolted connections failing to
make proper contact, as well as the failure of the starting device to short-
circuit the starting resistance. It is obvious that when the load is sufficient
to overhaul the motor, excessive or dangerous over-speed may occur
when
the rotor resistance is too high or the rotor circuits are open. Due to the
simphfication of both motor and control apparatus, increased reliability
and safety, lesser first cost and maintenance, the squirrel-cage motor is,
at
the present time, in most cases considered preferable.
12*. Two-speed polyphase induction motors. '
For car speeds of
150 ft. per mm. and upwards it is advisable to use two speed motors and
while it IS possible to use motors of slip-ring type, having double
windings
both in the stator and rotor, better results are obtained by using
here also
motors of the squirrel-cage type with double windings in the stator.
stator winding is arranged with a number of poles corresponding
One
to the high
.speed and the other winding for a larger number of poles
corresponding to
the slow speed. The high speed is usually three or more times the slow speed
1 he control is arranged in such a way that the operator can run
.
either on
Ingh or slow speed, but the motor will always start on slow
speed and when
practically full slow-speed is reached the slow-speed winding is
automatically
rendered inoperative and the high-speed winding is energized. In stopping
trom high speed, the high-speed winding is first rendered
inoperative and
the slow-speed winding is automatically energized and
as soon as slow speed
obtains the power is cut off and the brake applied. In changing from one
speed to the other there should be no instant where the motor
is without
power with the brake released. One way to accomplish this is to
the two windings in series and so arrange them that one
connect
or the other can be
short circuited. This arrangement together vidth the use of a squirrel-cage
.rotor has practically eliminated the arcing at the
controller contacts
5'^^ stator winding may be used by changing certain connections
•
to
?ive different numbers of poles but this requires a rather
complicated switch-
iig arrangement, particularly as
the power should not be interrupted while
changing from one speed to the other.
125. Single-phase motors. Up to the present a type known as the re-
lulsion-mduction motor alone has proven successful and in sizes
iicludmg 15 h.p
up to and
These motors, which start as one of the repulsion
-ype, are provided with a centrifugal governor,
usually located within the

1259
Sec. 15-126 INDUSTRIAL MOTOR APPLICATIONS ||

armature core, so designed and adjusted that at about 80 per cent, of full speed
the rotor winding is automatically short-circuited, and the motor operates
as if it were of the simple induction type. These motors cannot be reversed
while operating, as induction motors. Devices are required to prevent change
of connections until speed has dropped below that point at which the re-
Eulsion connections are re-established in order that reversal of rotation may
ecome effective. Although starting currents are comparatively high, this
condition is not objectionable in the smaller sizes, and in the larger sizes the
starting current may be appreciably reduced by an external resistance in the
stator circuit so connected that it is effective at the moment of starting and
during the first period of acceleration.
126. Brakes. All elevator machines are equipped with brakes for the
purpose of assisting in stopping and holding the car securely at a landing,
under any and all conditions of loads up to and including the maximum
specified. The brakes, which must be so designed as to be equally effective
for either direction of rotation, generally consist of two separate and inde-
pendent shoes, lined with leather or asbestos preparations, and actuated by
neavy helical steel springs. Brake release should be obtained by means
of an electromagnet, as this method enables the making of such connections
that the brake will be instantly and positively applied on failure or inter-
ruption of current supply.
127. Methods of control. The controlling apparatus of an elevator con-
stitutes one of its most important features, including devices for establishing
direction, for producing proper acceleration, retardation, and speed regulation,
and also including the necessary safety appliances. Usually slate panels
bolted to floor standards are provided, the switches being mounted on its
face with connections to these switches, and all resistances located on the rear.
All contacts of the various safety devices are usually connected in circuit
with the holding coil of what is known as a potential switch, and, since all
current to the controller and machine is carried through the contacts of this
switch, the operation of any one safety feature immediately interrupts all
current to the equipment. This switch also constitutes a no-voltage circuit
breaker and an excessive drop in voltage will cause the switch,contacts to
open. The motor circuits are completed by the reversing switches, two in
number, one for the "up" and one for the "down" direction, respectively.
The brake circuits are made simultaneously with the closing of either
direction switch. In order to prevent conflict, reversing switches are
generally electrically or meclrtinically interlocked.
128. Automatic starting:. It is advisable, with direct-current eleva-
tors, to arrange the stepping-out of the armature starting resistance en-
tirely indepjendent of the operator, and by this process eliminate the
damage which would result from a reduction of this resistance at too high
a rate. As a means for reducing energy consumption, however, starting
resistance should be stepped-out as rapidly as the load on the motor permits;
this is accomplished by means of either series relay magnets or magnets de-
pendent on the counter-electromotive force of the motor for operation. See
article on "Motor Control" elsewhere in this section.
129. Dynamic braking. Except with the small-capacity machines, the
wiring of direct-current controllers invariably includes a dynamic-brake
circuit which is obtained by introducing a resistance across the armature
terminals on stopping. The stopping field in some cases is obtained by
having the shunt field (permanently in series with a limiting resistance)
connected directly across the supply line. In other cases it is obtained by
providing an extra low-resistance shunt field; in the smaller machines the
residual magnetism of the field poles is sufficient. Although connecting the
field permanently across the supply lino slightly increases energy loss, an im-
portant safety feature is gained, for with such connections it becomes im-
possible to attain excessive car speeds either up or down should, for any
reason, the machine brake fail to apply. Ry various methods stopping
resistance is automatically stepped-out as the load on the motor permits,
thereby strengthening the dynamic-braking effect. With two-speed alter-
nating-current induction motors dynamic braking is obtained wiiile chang-
ing from high to the slow speed. Usually no dynamic braking is provided
in stopping from slow speed. As explained, single-speed alternating-cur-
rent motors cannot readily produce a dynamic stop and the machine brakes
must be relied upon entirely in bringing the car to rest.
1260
 INDUSTRIAL MOTOR APPLICATIONS See. 15-130

130. Eleyator speeds. Direct-current elevators are generally arranged

with one speed only for car speeds up to 150 ft. per min., except in the case
of automatic push-button-controlled elevators which are provided with two-
speed control for car speeds above 100 ft. per min. Witn car speeds above
150 ft. per min., two or more speeds, under control of the operator, are pro-
vided for convenience in making accurate landings. Alternating-current
elevators are generally arranged for one speed only up to 150 ft. per min.,
except for automatic push-button-controlled elevators where two speeds may
be used with car speeds exceeding 100 ft. per min. The foregoing applies
with eyual force to winding-drum and worm-gear traction-sheave macnines,
but where accurate stopping is essential two speeds may be provided with
car speeds lower than those specified above. The methods of operation from
the car are given in Par. 131 to 133.
131. Car switch —
magnet control. This method is suitable for all car
speeds and
consists of a master switch, located within the car, electrically
connected to the operating coils of the magnetically actuated switches on the
control panel. Connections are so arranged that after direction has been
.established the proper sequence of switches is obtained for the desired ac-
celeration and retardation. The car switch should be so designed that it will
iutomatically return to centre or stop position should the operator's hand, for
my cause, be momentarily removed.
132. Automatic push-button control. By means of a special type of
magnet controller, elevators can be operated by a selective arrangement con-
istmg of a call button located at each floor and a series of buttons, corre-
•ponding to the floors to be served, located within the car.
133. Hand-rope control. The contacts of the reversing switches are
iperated by the revolving of a small sheave, to which they are directly or
Qdirectly attached, the revolving of the sheave being accomplished by a p ull
n an endless rope connected to it and installed in the hatchway in order to be
I

ivailable from the car. For convenience this rope is occasionally connected
rO a hand wheel or revolving lever device located within the car. Hand rope
'ontrol becomes difficult to manage as the speed of car is increased and for
his reason is generally limited to car speeds below 150 ft. per min.

:
134. Automatic terminal stopping device. With machines of the
;vinding-drum type this consists of a series of contacts usually located above
ttie drum and positively operated either directly or indirectly by an ar-
•angement on the extended drum shaft at the gear-case end. These contacts
re so connected in the controller circuits that car speed is automatically
iiduced at predetermined distances from the terminal landings, and finally
brought to rest approximately near either terminal landing, provided the
perator, for any reason, has neglected to centre his controlling device.
Since with traction-sheave machines no fixed relation exists between the
Taction driving sheave and the position of the car in the hatchway, because
i the creeping action of the hoist ropes, a machine-driven automatic ter-

,iinal-stopping device cannot be used. With the worm-gear traction-sheave

'levators it has become the practice to locate a series of switches in the
atchway, properly spaced, operated by a cam mounted on the car, for pro-
ucing the necessary slow-down and stop at the terminal landings. Because
f the increased number of speed-reducing steps required with the higher-speed

earless traction-sheave elevators, the switch arrangement in the hatchway

ould present wiring complication's and increase the difficulty of adjustment,
nd for this reason it has become advisable to carry the switches on the car
impletely enclosed in a metal case for protection, operated by one cam located
t the top and one at the bottom of the hatchway.

136. Slack-cable switch. This device is used with winding-drum ele-

ators only for the purpose of stopping the machine and preventing the
awinding of hoist ropes in case the car is obstructed in its descent. The
Hitact of the slack-cable device is connected in series with the holding coil
. the potential switch or circuit-breaker which, on opening, interrupts all
irrent to the machine. Slack-cable switches are not required with traction-
leave elevators for, as previously described, the obstructing of either car or
;)unter-weight immediately causes sufficient loss of traction to prevent fur-
uir motion of the car and counterbalance.

' 136.Final hatchway-limit switches. To guard against the possibility

damage through disarrangement of the automatic terminal-stopping

1261
Sec. 15-137 INDUSTRIAL MOTOR APPLICATIONS

device, final limit switches are located, one each, beyond the terminalr
landings, and are operated by a cam on the car, in case the car overtravels to
a point at which these switches become operative. The contacts of these
switches are also placed in series with the holding coil of the circuit-breaker,
causing immediate interruption of current to the machine when opened.
137. Governor switches. With high-speed elevators, regulating devices
are usually provided, these being operated by a speed governor. These
devices control car speed by means of field regulation of the motor, and are
usually applied when the car speed exceeds normal by certain predetermined
amounts. One or more speed-regulating switches are used, the number
depending upon the average speed of the car, and, by their use, maximum speed
variation is retained within certain predetermined limits. Governors should
preferably be provided with a breaking contact adjusted to open at a cat
speed slightly lower than that at which the car safeties are set to operate
Therefore, connecting this contact in series with the holding coil of the
potential switch or circuit-breaker, usually stops the elevator by interrupting
all current to the motor, without the necessity of applying the car safeties
138. Car safet;^ switch. All electric elevators should be provided with a
small enclosed switch, located within the car and so connected in the con-
trolling circuits that current to the machine will be interrupted when it is
openedf. This switch is furnished for emergency purposes only.
139. Car-safety devices. The expression " car safety " is usually ajiplied ,

to that form of safety which is designed to bring the ear to rest by locking il
to the guide rails, in case excessive speed has been attained, irrespective of the
cause. All elevators should be equipped with a device of this nature. The
application of car safeties should be made dependent upon on a centrifugal or ;

inertia governor, adjusted with a definite and fixed relation to the speed of the '

car and arranged to operate at approximately from 30 to 50 per cent, above

normal car speed. The general practice is to support the safety device
within the lower member of the car frame, with the governor substantially :

supported at the top of the hatchway, although, in some cases, specially

designed governors are mounted on the car. With the governor located
over the hatchway, it is driven by an endless rope attached to the car and
safety mechanism in such a manner that, in case of excessive speed, thi;
governor holds or grips this rope and the safety is applied, usually by mean-
of a drum, sheave or lever arrangement.
Under certain building conditions, namely: where a room or vault is located
directly underneath the hatchway, it is advisable to furnish a guide grip saf et.>
for the counterbalance as well as for the car, in order to prevent damage suci'
as might otherwise occur through the breaking of the ropes. On all of th'
recent higher class installations counterbalance safeties have been furnishii
even where the foregoing condition has not existed.
140. Micro-leveling elevators. The micro-leveling elevator is oi
capable of giving automatically any desired accuracy of landing, irrespi
tive of the load and speed. It is intended for use wherever level landin
are desired and is particularly applicable where it is necessary not only i

make but also automatically maintain accurate landings during loading ai

unloading, independent of the stretch of the hoist ropes or leaking pisto
Where conditions necessitate that the car be brought to rest against a sol
abutment, as is usually the case with double cage elevators or inclined hoisi
a landing can be effected without shock or injury to any part of the apparat u
Micro-leveling elevators can be made for any load, any speed, any kiii'
of motive power and for any type of hoisting machine and method of control
Up to the present time only the electric and hydraulic types have been buili
141. Electric micro-leveling elevators. The electric micro-lcvelii
elevator embodies two essential parts, consisting of the main hoisting niachii
and the micro attachment. The main hoisting machine, with the exccpti^
of the magnet brake, may be of any type and involves no special featun
The main brake is usually of the regular shoe type except that the liousii
instead of being bolted to the bedplate is fastened to the worm gear of tl
micro and revolves with it. This main brake performs a double function
First, with the micro at rest it acts as a brake to stop the main machine and
second, when the micro operates it acts as a friction clutch driving the mail
machine. The micro is in itself a small elevator machine consisting of motor
brake and worm gear reduction.
1262
 INDUSTRIAL MOTOR APPLICATIONS See. 16-141

With the micro-leveling machine there are two controllers, one to control
the operation of the main motor and the other to control the operation of the
micro motor. The main controller is operated in the usual manner, either
by push button, car switch or mechanical control (hand rope, lever or wheel).
The micro controller is operated by a leveUng switch mounted on the car
frame. This leveling switch consists of two sets of contacts which control
the micro motor, one for up and the other for the down direction. These
_

contacts are operated by stationery cams in the hatchway, there being two
cams at each landing, one of which operates the up contacts and the other
the down contacts.
As the car approaches the landing at which it is intended it shall stop, the
circuit of the main motor is interrupted by either the floor controller, car
switch or mechanical operating mechanism, and the leveling switch engages
the hatchway cams thus operating the micro motor. If the main rnachine
brings the platform either above or below the landing, the micro will then
raise or lower it until it is level with the landing, when the leveling switch
will interrupt the circuit of the micro motor and stop the car. This posi-
tion of the platform will now be maintained under all conditions of loading.

Fig. 17. —A. C. micro-drive elevator machine.

ias the automatic control of the micro motor is independent of the door or
gate contacts; i.e., if the position of the platform be changed either by
increasing or decreasing the load, the micro will immediately return it to
its proper level.
There are two types of leveling switches. One for use where there are
top and bottom landings only and the other for use where there are inter-
, mediate landings. With the top and bottom landings only, the leveling
switch is so arranged that as the car approaches the upper landing it will
engage the cam at this landing and while the car approaches the lower
landing it will engage the cam at that landing. Where there are inter-
mediate landings it is necessary to prevent the leveling switch from engaging
the hatchway cams at these landings as the car passes them at full speed.
This is accomplished by means of a magnet mounted on the switch, which,
when the car is being operated from the main motor, prevents the leveling
switch from engaging the cams. When the power is cut off from the main
motor this magnet is de-energized and if the car is in the micro zone the
eveUng switch will engage the cam. The accuracy with which the platform
"stops relative to the landing depends upon the location of the leveling switch
dh the car and the setting of the hatchway leveling cams.
To obtain the greatest degree of accuracy the leveling switch should be
•coated in a vertical plane through the edge of the platform it is desired to
evel, thus ehminating any slight mislaignment caused by the deflection of
he car structure and lost motion between the car and guides. The maxi-
num micro zone is determined by the length of the leveling cams and varies
vith the speed, control system and service. The actual micro zone is the
pace in which the micro-drive operates.

1263
Sec. 16-142 INDUSTRIAL MQTOR APPLICATIONS
For push-button control the actual micro zone is determined by the set-
ting of the floor controller and the adjustment of the dynamic and mechan-
ical brake of the main machine. The floor controller should, therefore, be
set so that with the average load it will stop the main machine when the
platform is level with the landing. For car switch and mechanical control
the actual micro zone depends entirely upon the operator. It is, of course,
essential that the operator brings the car within the maximum micro zone;
otherwise no micro operation wiU be obtained. In all cases the actual micro
zone should be as snort as practicable in order to save time in leveling.
With a push-button machine where the actual micro zone is comparatively
large, it is preferable to use a two-speed micro which will permit of the car
being brought close to the landing at fairly high speed and the final leveUng
done at the slow speed required for an accurate landing. For the purpose
of saving time it is also preferable to use a two-speed micro for high-speed
car switch control machines and also on machines of moderate speed where
great accuracy of landing is required.
142. Safe lift operation. The micro-leveling elevator either of the
worm geared or gearless type is readily used for safe lifting and when so
used has several advantages over other types of machines arranged for
the same purpose. For the ordinary worm-geared machine it is necessary
to furnish back gearing with its shaft and bearings, a special motor shaft
and extra coupling. For the gearless machine a complete extra brake is
necessary.
To use the micro-leveling elevator for carrying safes, it is only necessary
to increase the main brake spring tension sufficiently to enable the micro to
lift the load, since the power is transmitted from the micro to the main
machine through the main brake acting as a friction clutch. As the car
usually rests on locking bars while loading or unloading a safe, it is evident
that should any attempt be made to lift the car before the proper spring
tension has been obtained, no injury could result as the brake shoes would
simply slide on the brake wheel and the car would not be lifted off the bars.
If, however, we consider the ordinary back-geared worm-gear machines
used for lifting safes, where the brake is mounted on the worm shaft, it is
evident that the motor acting through the back gearing could readily lift
the car containing the safe, although the brake might be unable to stop the
car in the down direction provided the brake springs had not been tightened
before the car was lifted off the locking bars. With the gearless machine,
should the safe lift brake, which is ordinarily blocked out of action, not be
thrown into service, it will be impossible to stop the car by the brake and it
will accelerate until stopped by the safety or the buffers.
143. Hydraulic micro-leveling elevators. The'* hydraulic micro-
leveling elevator with electrical micro control consists of two independent
operating devices which may be termed the main operating mechanism and
the micro-operating mechanism. The former is operated by push button,
hand rope or lever device, while the latter is operated in the micro zone after
the main valve has been centered. The main machine may be of any of
the recognized types of hydraulic machines.
The micro-operating mechanism consists of a micro valve which regulates
the supply ana discharge of water to the hydraulic cylinder through a by-
pass around the main operating valve and is controlled by two electro-
magnets. The control system for operating the micro valve is essentially
the same as for the electric micro-leveling machine, having a leveling switch
mounted on the car frame engaging the leveling switch cams at each landing.
This switch controls the magnets operating the micro-pilot valve, which
brings the car level with the landing and maintains it tnere.
144. Oeneral features common to both electric and hydraulic
micro-leveling elevators. Since the car is leveling at micro speed during
part of the time that the hatchway doors and car gates are being opened,
suitable precautions must be taken for the protection of passengers attempt-
ing to enter or leave the car during that period. The depth of the platform
at landing edge plus the depth of the landing sill must be greater than the '

length of the micro zone or it should be made impossible to open the hatch-
way door while either the upper edge of the car platform is below the lower i

edge of the landing sill as the car approaches the landing from below or th"
lower edge of the car platform is above the upper edge of the landing sill

1204
 INDUSTRIAL MOTOR APPLICATIONS SeC. 15-145

the car approaches the landing from above. In other words, it must be
made impossible for a person to get his foot between the landing sill and the
oar platform.
146. Micro-emergency operation. An emergency operation can be
furnished with any system of control. This consists of two extra push
buttons installed in the car, one for operating the car by the micro in the
up direction and one for the down direction.
146. The number of elevators required in a building depends on several
conditions, namely: height of building, relation of area of building to its
height, net rentable area in sq. ft. per floor, character of elevator service
required by prospective tenants and relative location of building. In
average office buildings it is not considered good practice to attempt to serve

Fig. 18. — D. C. micro-drive elevator machine.

uore than from 18,000 to 24,000 sq. ft. of rentable floor area per elevator.
ihe mileage of each elevator in a modern office buHding ranges from 15
•0 40 miles per day, depending on the character of service and type of ele-
ators used. These are general figures only, and complete service data must
eceive detailed consideration to accurately specify the most suitable elevator
equipment for a given installation.
147. Oeneral consideration of energry consumption. Usually, it is
'afe toassume that the loads distributed by an elevator to the different floors
f a building are the same, approximately, as those loads returned to the
•tarting point, and with such load conditions the work done consists merely of
!vercoming the friction. Of greater importance, therefore, in the energy
onsumption, is the power expended in imparting the kinetic energy required
o bring the masses up to speed, and the machine which will register the
owest power consumption must have a low moment of inertia together with a
)w value of friction.
The machine at present fulfilling the foregoing requirements to the most
itisfactory degree, is the 1 1 gearless traction-sheave machine and this
:

lot is clearly evidenced by the following comparison between a 1 1 traction

:

lichine with motor running at 74 rev. per min., and a herringbone-gear

action-sheave machine driven by a GOO-rev. per min. motor, both of

1265
 Sec. 15-148 INDUSTRIAL MOTOR APPLICATIONS
these machines being designed for a lifting capacity of 2,500 lb. at a speed
of 700 ft. per min. It was found that the kinetic energy required to bring
the 1 1 traction machine up to speed, without the car, counterbalance or
:

ropes, was 3,600 ft-lb., while, under the same conditions, the herringbone-
gear traction machine required the expenditure of 17,900 ft-lb. in attain-
ing full speed. The total number of starts and stops of an elevator,
constitute an important factor in the resultant power consumption per mile
of car travel, because of resistance losses which are greatly increased with
increased kinetic energy.
148. Multi-voltage system. This system, as applied to electric
elevators, usually results in a very considerable reduction of power con-
sumption as well as better and smoother operation. The voltage is divided
into equal steps successively applied to the motor without any external
armature resistance. Four voltage steps are usually sufficient for this
purpose. Where the primary source of power is direct current the four-
voltage steps are obtained by floating four direct-current armatures all
mechanically connected and in series across the line. Where the primary
source of power is alternating current the four armatures are driven by an
alternating-current motor. Usually two armatures are combined in one
armature having two separate windings and two commutators.
This Multi-Voltage Balancer has only a fraction of the capacity sum of the
elevator motors supplied by it during a part of their periods of acceleration
and retardation. The elevator motors are so connected to the balancer that
half of them start from each side of the line. During the periods that the ele-
vator motors are connected to the line, the balancer is relieved from their
loads, and only supplies at any time the unbalanced current required; the
balanced current coming directly from the line.
The smooth operation and practically constant rate of acceleration and
retardation with all loads, of the elevators suppHed with Multi-Voltage
Control, enables them to be accelerated and retarded more rapidly than with
single voltage control, so that higher elevator speeds are practical and
the service obtainable from a given number of elevators is generally increased.
The power consumption with Multi-Voltage Controlis lower than with any
other type, since external resistance losses are practically eliminated and the

Fro. 10. — Graph of recording wattmeter.

continuous running equipment is reduced in a minimum. It is decidedly
superior to the Ward-Leonard system in economy and in amount of special
generating equipment necessary. Multi-Voltage Control requires only a
single balancer having a small fraction of the capacity sura of the elevator
motors supplied. Ward-Leonard control requires an individual generator
of full capacity for each elevator motor. The Ward-Leonard etpiipment
roust also carry the full current of the elevator motors for a much larger
percentage of the running time than the multi-voltage balancer and, as
visually arranged, carries all the current suppUed to the elevator motor
armatures while thoy are running. Thus, both constant and variable
generating losses are higher for Ward-Leonard than for Multi Voltage Control.
Ward-Leonard control is also handicapped by requiring large field variation
in the special generators. It is not only difficult to design the apparatus to
allow the field to be changed with sufficient rapidity, but it is also neces.snr-
to provide special devices for commutation.
149. The line to load efficiency is determined by ascertaining the tut
electrical input, and the not work done on the load.
180. Required power is best determined by means of a recording !

wattineter writing a graph which shows the existent Telation between watts
and time, the energy consumption in kw-hr. beinif represented by the aren
surrounded by the graph and the axis of time. Fig. 19 is a reprodviction of
such a graph taken in one of the largest office buildings in New York City.

1266
INDUSTRIAL MOTOR APPLICATIONS See. 15-151
Sec. 16-152 INDUSTRIAL MOTOR APPLICATIONS

152. Influence of number of stops on energy consumption

(Tent data)

+S *^ i« a>

3^
Specification type of
machine and control ® » O
eS

Worm-gear drum machine

Direct-current motor 2.04
Magnet control 76 3.31
56.0 per
Duty 2,150 326
cent.
Maximum load
2,500 lb. 152 4.33
2,000 lb. at 300 ft. per min. 380 7.34
Rise, 69 ft. 6 in.
Overbalance 650 lb. 1.48
76 2.47
1,350 320
152 3.35
380 6.21

1 : 1 traction direct duty

motor 1.15
Magnet control
Duty 2,500 lb. at 600 ft. 1,500 600 50 2.45 68 per
per min. cent. _ I

Rise 537 ft. Oin. overbalance with maxi-j

1,125 1b. mum
load.

153. Testing of electric elevators. When an elevator is completed th

usual test consists of carrying the rated load at full speed, setting the ca
safety by overspeeding, and a trial operation of all electrical or mechanics-
safety features to determine their effectiveness. A more complicated tes
comprises determinations as to friction, line to load efiBciencies with differen,
loads in the car, the energy consumption with various net loads on the moto'
and number of stops, and the speed characteristics and the kinetic energy
154. Energry calculations. As previously explained the kinetic energ;
W required to accelerate the masses of the speed y has an important bearin
on the power requirements. Its determination is made accurate and com
paratively .simple by application of the formula:
/T rT
W= /t)3« = 0.7373
I
P. H (watt-sec.)

V
8
7
-8
 INDUSTRIAL MOTOR APPLICATIONS Sec. 15-155

counterbalance ropes, the watts input into the armature necessary to drive
the elevator at the speed v, minus the I^R losses, must equal the retarding
watts, if, at the speed v, the armature current be interrupted.
Under this method, a watt input-speed curve, Fig. 20, is first secured,
following which a retardation curve,
7(1
Fig. 21, is obtained; this latter curve is
a speed-time curve giving the relation
between speed and time if, at the speed
V, the armature circuit is interrupted
and the elevator system allowed to
 Sec. 15-157 INDUSTRIAL MOTOR APPLICATIONS
where O is the delivery in gal. per min.; L is the total length of the pipe in
ft.; d is the inside diameter of the pipe in in.; and hf is the friction hcad.l
expressed in ft., for the whole pipe length. The horse power required to
pump a certain quantity of water through a given length of pipe of knowni
diameter against a given head is expressed as follows: I

, GXH ,J
'^'
3,950 XEfBoiency "^
'j

where is the delivery in gal. per min., and H is the sum

of the static head;
and the friction head, both expressed in ft. ,'

In using these formulae it is well to note that 1 cu. ft. per sec. corresponds'
to 448.8 gal. per min.; also a pressure of 1 lb. per sq. in. corresponds to a'
head of 2.304 ft., for water weighing 62.5 lb. per cu. ft.
DISPLACEMENT PUMPS
167. Slip. In all displacement pumps, the volume of liquid pumped is
always than the piston displacement, or, in the case of the rotary pump
less
(Par. 163) the displacement of the rotating element. This difference is due,
partly, to leakage past the piston (in the case of the reciprocating piimp),
or the rotating element (in tne case of the rotary pump), and partly due to
leakage through the valves. The difference between the displacement of the
moving part (piston or rotating element) and the volume of water discharged,
is called the slip, and is usually expressed in per cent, of the total displace-
ment. This slip may vary from 2 per cent, in a new pump to 50 per cent, in
a badly worn pump. Generally speaking, anything under 5 per cent, may
be considered fairly good performance for pumps that have been in service ;

any length of time. i

168. E£Fect of speed on capacity of displacement pumps. Neglect-

ing slip, the capacity of all types of displacement pumps varies directly
with the speed, regardless of the head pumped against. For constant head,
the horse power required varies almost directly as the speed and, therefore,
as the capacity. This, of course, is not strictly true, for the pump efficiency
will be slightly greater and the slip in per cent, slightly less as the pump
approaches rated capacity. These characteristics and the service to be
performed will determine the type of motor to be installed.
169. Displacement pumps under constant head require practically
constant driving torque at all speeds and, therefore, at all capacities.'
This characteristic has a very direct bearing on the type of motor to be se-
lected in cases where it is required to operate the pump at variable capacity
and, therefore, at variable speed. From this, it is evident that no saving
of power will result if variable speed of the pump is obtained by inserting
resistance in the armature circuit of a direct-current motor, or in the rotor
circuit of an induction motor. To effect a saving of power, it is necessary
to use field control, in the case of the direct-current motor, or a pole-changing
device for an alternating-current motor, or any similar device in which the
torque of the motor remains constant, for reduced power consumption at
the motor service switch. In considering the question of head, it should be
kept in mind that the total head on a pump includes both the static head
and the friction head in the pipe connections. Where this friction head
constitutes a large proportion of the total head, another factor must be taken
into consideration. The velocity in the discharge pipe varies directly with
the quantity discharged, while the friction head varies as the square of
velocity, consequently a pump under these conditions, running at rcduceds
capacity, will not be discharging against a constant head, even though thef
static head is constant, but instead, the head against which the pump operates'
will be less at partial loads.
160. Starting torque of displacement pumps. Displacemc
pumps operating at constant speed against a variable head will have a co
stant rate of discharge. The torque and horso-power input will vary (nogle'
ing minor losses) directly with the head. In starting these pumps again
the normal working pressure, the motor must exert fuU-load torque. .\

this requires very heavy starting currents, especially in the case of induction
motors, the expedient of by-passing the pump in starting is usually cniploycl
wherever this is practicable. Where the by-pass is installed, the head !it
starting, and therefore the starting torque, can be reduced to a negligible
quantity. After the pump is up to speed, the by-pass is closed.

1270
 INDUSTRIAL MOTOR APPLICATIONS See. 16-161

fz:-ht<s-n
Sec. 15-164 INDUSTRIAL MOTOR APPLICATIONS
two elements "mesh" in much the same manner as a pair of gears, bearini
on each other in line contacts. Consequently, any wear that occurs canno
be compensated for by packing or by adjustment of the moving parts. Th
slip in this type of pump is caused by the leakage through the line contac
of the impellers and through the clearance space between the ends of th
impellers and the pump casing. While these pumps do not require priming
they frequently have a small connection from the discharge pipe back inti
the pump casing to "seal" the joints between the impellers, as well as th
small clearance space between the impellers and the casing.
These pumps are primarily designed for low-head work and show theii
greatest efficiency at low heads. When used for high-head work, it is gen
erally for intermittent service, such as fire-pump service. They probabl;
find their greatest field, however, in pumping heavy oils, liquid tar, syru]
and liquid food products of various kinds. The speeds are usually so lo\
that motors of ordinary speed must be geared or belted to the pump shaft.
164. Kfflciency of rotary pumps. Typical efficiency curves of thi
type of pump are shown in Fig. 23. These curves, like the curves in Fig. 23
do not represent the performance of a single pump, but rather the effi
ciencies of a series of pumps, designed for definite conditions of capacity ani
load, plotted in a single curve.

CENTRIFUaAL PUMPS \

166. Mechanical construction. Centrifugal pumps for low heads aH

almost always of volute type, but manufacturers and designing engineer^
apparently differ as to the best practice to be followed for pumps dischargin
against higher heads. The turbine and the volute types of pump use sub
stantially the same type of impeller. The difference between the two type
lies in the design of the water passages of the casing. The volute pump, as it
name implies, has these water passages built in the form of a volute, increasin
in size toward the discharge opening. For the lower heads, the velocity o
the water is comparatively slow and there is little or no "churning" an^
"eddying." Moreover, as this type of pump is cheaper to build than a tur
bine pump, the reason for its popularity for low heads is evident. For highe
heads, however, the velocity in the pump casing is necessarily great, and thi
increases the tendency to form eddies with resultant loss of efficiency. T
meet this situation, some builders resort to diffusion vanes. These vanes ar
a part of the pump casing and simply act as guides to direct the flow of th
water and prevent eddies. To be effective and not cause loss of head, the-
must be of a design which will provide water passages with long easy curve
and wilj change the velocity head of the water leaving the impeller, to pressur
head without shock. When these vanes are added, the casing is no longe
built of volute shape and the pump is then called a turbine pump.
166. The importance of suction lift in the selection of a pump
One of the fundamental factors in the relative performance of displacenien
pumps and centrifugal pumps is that the former are capable of creating '

partial vacuum in the suction connection without priming (Par. 167), whil
the latter are not. This one characteristic at once eliminates the centrifi:
gal pump from consideration in all cases where the pump must necessaril
be located above the level of the water, and where it is not practicable t'
prime the pump at starting. Where, for other reasons, it appears desirabl'
to install a centrifugal pump under conditions where it must "lift" it
supply, some provision must be made to prime the pump and its suctio!
connections, i.e., to fill them with water and expel all of the air that mat
have accumulated. • -i

167, Priming. In large centrifugal pumps, this priming is usually aq I

oomplished by actually "lifting" the water through the suction pipe and th;
pump from the source of supply by some auxiliary device. Where steam i
available, a steam syphon is a very satisfactory means of accomplishin
this result. Where condensing apparatus is used, the water may be "lifted
into the pump by means of a connection from the vacuum chamber of f
condenser to the pump casing. Where no such auxiliary devices are a\
able or their installation impracticable, a hand pump may be installed.
the case of small pumps, this result is usually accomplished by installiIl^;
check valve in the suction line or, better still, a foot valve at the bottom '

the suction line. In addition, a "priming" connection is made to soin

available supply so that by opening the valve or connection, the pump an

1272
 INDUSTRIAL MOTOH APPLICATIONS SeC. 16-168

suction line are filled with water, a vent cock being usually provided in the
top of the casing to allow the escape of air while the pump and suction line
are being filled. The pump is then started, but not until the suction line
and pump casing are entirely filled with water. Once the pump is in opera-
tion, it will continue to pump with practically no danger of losing its priming,
unless the suction lift becomes abnormally high or air leaks into the suction
pipe or pump casing.
168. Attainable suction lift. With all air leaks eliminated, almost any
good centrifugal pump may be depended on for a suction lift of 15 ft. (after
it has been primed and started). Under favorable conditions, this may be
increased to 20 ft. suction lift. While there are centrifugal pumps operating
under greater than 20 ft. suction lifts, this requires the best of conditions,
both as to pump and connections, and even then it must be understood
that these same pumps would be much more reliable and dependable if the
suction lift were reduced to 20 ft., or less. This sanie characteristic makes a
centrifugal pump much more sensitive to air leaks in the suction connection
. than a displacement pump. An air leak in the suction line of a centrifugal
pump which is not even sufficient to cause a displacement pump to "knock"
may cause a centrifugal pump to "lose its suction" or "priming."
J

169. Multi-stagre pumps. A pump designed to deliver 100 gal. per min.,
against a head of 75 ft., will require exactly the same h.p. to deliver 100 gal.
ger min., against 80 ft. head, with the supply flowing to the pump under a
ead of 5 ft., or to deliver 100 gal. per min., against 125 ft. nead, with the
supply flowing to the pump under a head of 50 ft. This characteristic is
taken advantage of in designing pumps for heads higher than can be satis-
factorily met by single-stage pumps, by using two or more pumps in series.
.These may be entirely separate and distinct pumps, the discharge of one
jconnected into the suction of the other by pipe, or all of the pumps or stages
.may be housed in one casing. For ordinary motor speeds, centrifugal
pumps are usually built single-stage for heads up to 100-150 ft., depending
^3n the capacity of the pump and, therefore, the size of the impeller. As
the peripheral speed of the impeller increases, either on account of larger
diameter or of higher rotative speed, the allowable head per stage increases
correspondingly. When several centrifugal pumps are installed in the same
itation, they may be so connected that by the operation of a few valves,
I'.he pumps can be operated in series against a head aggregating the combined
fVorking heads of all the pumps, the capacity remaining the same as for one
ounip; or they may be operated in parallel, giving the total combined ca-
pacity, the limiting head in this case being the same as for a single pump.
170. The up-keep expense of centrifugal pumps is usually small
lor the reason that the only moving partsin contact are the shaft and bear-
Qgs. The clearance between the impeller and casing is almost always
;reater than the permissible wear of the bearings, so that there is little
Akelihood of the two coming into contact. Even if they did, this would
,irobablybe detected and the pump shut down before any damage was done.
High-head conditions require high impeller velocity, which gives high
elocity to the water leaving the impeller. In order to obtain good efficiency
hese conditions demand high velocities in the diffusion chamber (if there
e one) and in the volute. High velocity of water results in rapid corrosion
,fcast iron, the usual material used for volute pumps. This corrosion
ccurs wherever the water at high velocity comes in contact with the iron,
ad particularly so wherever a sudden change in direction of flow occurs
hich will cause shock and the formation of eddies. However, it is often
mnd that the efficiency of centrifugal pumps increases slightly after they
ive been in service for a time and this is due to the scouring action of the
ater on the surface of the water chambers.
171. Piping connections. From the principle of operation of centrifu"
il pumps and jespecially of turbine pumps, the velocity in the pump
ising is very likely to be higher than good practice would permit for velocity
water in pipes, consequently the size of the pipe connection should be
i.loulated on the basis of allowable velocity in the pipe rather than simply to
ake the connection of the size of the suction and discharge openings of the
imp. To avoid shock, due to sudden change of section of the pipe, this
:ange in size of pipe should be made by means of a standard "increaser"
"reducer," and this fitting should be installed at the pump opening. As
eady pointed out, the suction connections must be absolutely air tight if

1273
 Sec. 15-172 INDUSTRIAL MOTOR APPLICATIONS

satisfactory operation is to be obtained. Incidentally, also, the packing

glands must be drawn up tight, but only tight enough to prevent leakage,
care being taken to avoid excessive friction on the shaft at this point. Some
pumps have a connection from the discharge chamber to the glands in order
to keep them under a " water seal " at all times. When this connection is
provided, the glands should be loose enough to permit constantly a .slight:
leakage.

3 S S 5 2
 INDUSTRIAL MOTOR APPLICATIONS SeC. 15-173

the pressure rises at first above the "shut-off pressure " and then falls as the
capacity is increased. While the shape of the curve depends primarily on
the shape of the impeller vanes, it will be found in general, although by no
means in every case, that volute pumps will show a curve similar to Fig. 26
and turbine pumps a curve similar to Fig. 27. With a capacity-head char-
acteristic curve similar to that in Fig. 26, the horse-power curve usually
reaches a maximum slightly above normal capacity and then drops off.
This feature is very important in the selection of a pump for service where
the head is likely to be materially reduced at times, as it will prevent the
motor from being overloaded. A pump with the characteristics shown in
Fig. 27 should be used only where there is no likelihood of its being operated
at heads greater than, equal to, or approaching the "shut-off pressure," or
where the head is likely to be reduced to a value considerably below the
normal working head. At heads equal to, or greater than the "shut-off
pressure," there are two capacities corresponding to each condition of head.
At these points, the operation becomes unstable with a probability that the
pump will discharge intermittently, the water surging up and down in the
discharge pipe. With heads below normal, the capacity and the horse .

power keep increasing with the result that the motor is likely to become
,
dangerously overloaded. In general, the characteristic curve of the volute
pump, and at least within the "working limits," the curve of the turbine
pump, show that for constant speed, the capacity incre^es as the head
decreases and vice versa, with but little change of power required.
Performance under vaxiable speed. Fig. 28 shows the effect
173.
of operating a given pump at variable speed. It will be noted tliat the
efficiency, the head and the capacity all fall off rapidly as the speed is de-
creased, so that there is little or nothing to be gained by the use of a vari-
able speed motor except, perhaps, in special cases. These curves also show
that the power required at starting is very low, permitting the pump to be
started even against normal head without the use of a by-pass and without
rfiquiring heavy starting currents in the motor —
a most desirable feature.
AIR COMPRESSORS
BY JOSEPH H. BROWN
Manager, SiiUivan Machinery Co.
174. Rating. The rating of air compressors is made on the basis of the
piston displacement of free air per min., and in designing a motor drive,
he first problem which arises is the determination of the power output
equired of the motor for the compressor operating under the desired
;onditions.
175. Measurement of discharge. The relation between the piston
lisplaceraent and the amount of air actually delivered has been taken, in
tie past, from indicator cards, but this method is extremely inaccurate,
ince slippage due to leakage past the piston rings and leakage back into the
:ylinder through discharge valves, cannot be detected. As a matter of
act, these leakages tend to make an apparently better card and to increase
he apparent volumetric efficiency. Recent tests have been made by dis-
harging the compressed air through orifices and calculating the quantity of
ree air delivered per min. by the following formula (Par. 176).
176. The dischargejormula may be stated as follows:
"
Q = S.MKd^VHT/Pm where Q = cu. ft. of air per min. at observed
einperature of upstream side of nozzle; d «= diameter of smallest part of
ozzle throat in inches; H = observed water column in inches; T = abso-
ite temperature of air entering nozzle, which is observed temperature
+ 460; Pm = absolute mean pressure between entering and leaving sides
f nozzle, lb. per sq. in.; K= coefficient of nozzle. With well-rounded
Iges the coefficient is between 0.98 and 0.99. The nozzle should be of such
size that the pressure on the upstream side will not be more than a
pound
er square inch above the atmosphere. The air delivered by the compressor
first passed into the regular discharge line receiver where the
pressure is
aintained constantly at the rated point by bleeding the air through a
live into a second receiver which is provided with the nozzle. The diame-
Jt of this second receiver must be at least two and a half times
the smallest
iameter of nozzle throat (preferably larger) and should be from 10 to 15
more feet long.
1275
 Sec. 15-177 INDUSTRIAL MOTOR APPLICATIONS
The quantity Q is reduced to Q\, its equivalent at the temperature of the
compressor intake, by the following formula Qi = Q X Ti/T, where Ti =
absolute temperature of air at compressor intake. The delivery of cu. ft. oj
air per minute then equals Qi.
177. Efficiency. In practice it is found that two-stage compressors
show volumetric efficiencies varying from 84 per cent, to 76 per cent, at
speeds of about 200 rev. per min. with a terminal pres.sure of 100 lb. gage.
Single-stage compressors under the same conditions show volumetric effi-
ciencies varying from 71 per cent, to 57 per cent.
The above figures may be used in determining the actual amount of air
delivered by the compressor. The power required per cu. ft. of air
depends upon the type of compressor, whether single-stage or multi-stage,
and upon the method of driving, whether direct-connected, belted or geared
(Par. 180 and 181).
178. Two-stage compression should be used for capacities over 200 or
300 cu. per min., where the pressure is between 40 and 200 lb. per sq. in
ft.
Not only there a saving in power of approximately 10 to 20 per cent., but
is
the reduced terminal temperature permits better lubrication.
179. Theoretical power required to compress air. For the ordinary
working pressure of 100 lb., the theoretical power required for isothermal
compression of l.cu. ft. of free air per min. is 0.131 h.p. To this must be
added the power lost in friction and that given off as heat, during compression
(Par. 182).
180. Test of a direct-connected compressor. In a test made in New
York City in January, 1912, the power input to the motor was 23.26 h.p.
per 100 cu. ft. of free air per min. compressed to 100 lb. per sq. in. gage
pressure and actually delivered through orifices. The compressor tested
was direct-connected to a 400-h.p., 188-rev. per min., self-starting synchron-
ous motor with belted exciter. The low-pressure cylinder was 26 in. in
diameter, the high-pressure cylinder 15.5 in. in diameter, stroke 18 in.,
and the displacement capacity 2,070 cu. ft. at 188 rev. per min. The
volumetric efficiency at this speed as shown by the orifice test was 88 per
cent. The horse-power input at full-load was 425, and the indicated horse
power of the air cylinders was 350. The overall mechanical efficiency
including motor, exciter and compressor was 82.3 per cent.
181. Comparison of direct-connected compressor with belted
compressor. For the purpose of comparison with a belted compressor
where the power is usually specified as that delivered at the compressor
pulley, the efficiency shown in Par. 180 may be divided into 91.5 per cent, for
motor and exciter and 90 per cent, for the compressor. This gives a motor
output of 389 h.p., or 21.4 h.p. per 100 cu. ft. of air delivered. Compared
with isothermal compression, the overall efficiency, exclusive of motor and
exciter, is 61 per cent., and with motor and exciter included, the overall
efficiency is 56 per cent. In a belt drive there will be a further loss of from
5 per cent, to 10 per cent., depending upon the efficiency of the belt drive.
182. Commutation of required horse power. The figures iri Par. 181
may be used in computing required horse powers from tables showing power
used in isothermal compression at other pressures, and will be found approxi-
mately correct for machines of over 100 h.p. rating. In the case of machines
of less than 100 h.p. rating, allowance should be made for reduced mechan-
ical efficiency of both compressor and motor. In comparing these figures
with those obtained from other sources, it should be noted that these results
are calculated from actual delivery, and not from piston displacement.
183. Advantages of direct connection. The ideal motor-drive for ^
air compressors is direct connection, and this should be used wherever
possible on machines of 100 h.p. and above. No power is wasted in the belt
transmission, the upkeep cost of the belt is eliminated and there is a great
saving in floor space. Compressors are now designed to give good volumetric
efficiency at speeds up to 225 or 260 rev. per min. by the use of plate valves,
un obstructed air passages, and ample discharge valve area. Self-starting
sy nchronous motors can be obtained which will operate at the desired speed,
and this type of motor is admirably adapted for such service. The exciter
is usually belt-driven from a pulley on the compressor shaft.

1270
 INDUSTRIAL MOTOR APPLICATIONS See. 1&-184

184. Use of fly-wheels with synchronous motor drive. Unless the

compressor is of a type that requires no fly-wheel effect (such as the angle
compound design) a fly-wheel must be provided, since the rotors of standard
synchronous motors do not give the necessary WR^.
186. Belt-drive is used on small compressors, also in the case of larger
installations of a temporary nature, where economy of pow.er and floor space
is not imperative, or where first cost and delivery must be considered.
In this connection, however, it is important to note that on the New
York
City tunnel of the Catskill Aqueduct, where the compressors were in service
only from 2 to 3 years, the great majority were of the direct-connected
type.
186. The short belt-drive has come into active use and makes a very
desirable arrangement for small installations. The motor and compressor
shafts are brought closely together and, by use of an idler pulley which rides
on the belt, sufficient arc of belt contact is secured on both driving and driven
pulleys, and the results are entirely satisfactory. For this purpose the belt
should be made endless, in order that no lacing will be required. The econ-
omy of floor space obtained by this arrangement has practically done away
with gear-drive for air compressors except in the case of very small machines
of the portable type. The only redeeming quality of the gear-drive was its
compactness, and it was always objectionable on account of noise and wear,
even when the drive was of the most improved type.
187. Regulation of air discharge. Since the demand for air is almost
always intermittent, and the compressor must operate at constant speed,
some method of regulating the amount of air compressed and delivered must
be employed. Various devices are used. With some types of mechanic-
ally operated inlet valves provision is made to hold them open during the
whole or part of the compression stroke, but any mechanism of this nature
has the objection of complicated moving parts, and furthermore the com-
pressor must be limited to comparatively slow speed to allow for proper
operation.
188. Regulation by clearance control. In this method clearance
spaces are provided which communicate with the cylinder through valves
controlled by the governor. The compressed air, instead of being delivered
to the line, passes into this clearance space and on the return stroke of the
piston, returns to the cylinder and expands again behind the piston. A part
of the work of compression is recovered in this re-expansion, but this method
of control is inefficient because a considerable amount of power is wasted in
'heat which cannot be regained, and there is also some leakage.
'.
189. Regulation by use of an unloading valve. The most satisfactory
|and economical method of regulation is the combination of an unloading
jvalve on the intake cylinder and an atmospheric relief valve on the dis-
fharge, or high-pressure cylinder. The unloading valve on the intake is con-
nected to the air receiver, and a rise in pressure causes it to close. All air
s then cut off, and as soon as the system is pumped out, the low-pressure
piston operates in a vacuum. But there will be a slight leakage past the
valve and around the piston-rod stufling box, and provision must be made for
lUowing this air to escape. If this is not done, a small amount of air will be
carried over into the high-pressure cylinder and compressed over and over
4gain, resulting in dangerously high temperatures and waste of power. An
itmospheric relief valve is therefore provided which is operated automatically
ifter the unloading valve is closed. This relief valve shuts off communica-
lon between the pressure line and the high-pressure cylinder, and at the
ame time opens a free exhaust from the high-pressure cylinder to the
tmosphere.
1
When the pressure in the receiver falls slightly, the intake unloader opens,
hen the relief valve closes, and the work of compression is again taken up.
;
his cycle is secured without shock, as the operation is comparatively gradual
ind as an appreciable space of time is taken to fully load or unload. With
iOis method of control the machine is either operating at its most efficient
'omt (full-load) or el.se no work is being done except that necessary to
vercome the friction of the moving parts.
' 190. A load factor of 60 per cent, may be taken as an average figure for
impressor operation. In the test referred to above (Par. 180), the com-
essor was equipped with combination .unloading valves and the power

1277
Sec. 15-191 INDUSTRIAL MOTOR APPLICATIONS

required at 60 per cent, load factor was 3.1 kw-hr. per 1,000 cu. ft. of free aii
actually delivered at 100 lb. pressure. A compressor of the same capacitj
and type, but fitted with clearance control, was also tested at the same time
and at 60 per cent, load factor the power required was 3.5 kw-hr. per l.OOC
cu. ft., or 12.9 per cent, greater.
191. Starting^. No special diflBculties are encountered in starting, sine*
the compressor is started without load and the load is not thrown on unti
the machine is up to normal speed.
192. Automatic starting and stopping is not recommended for largi
units or for installations where the starting and stopping is at all frequent
It is of value where the compressor is of small size and the demand for air verj
intermittent with long intervals where no air whatever is required. Th<
compressor should be arranged so as to start unloaded and not throw oi
the load until the motor is up to speed.

FANS AND BLOWERS

BT MERTON S. LEONARD
Chief Engineer, B. F. Sturicvant Co., Member American Society of Mechanica
Engineers
193. Definitions. Fans will here include only centrifugal fans havini
inlet at centre and discharging at the periphery, either directly or through s

casing which directs the air to the outlet; and propeller fans which mov(
the air in an axial direction by propulsive force, similar to the propeller of s

ship. Blowers will here include only positive rotary blowers, which, bj
the action of a rotating impeller or impellers in a very closely fitting casing
create pressure by direct compression.
194. Characteristics of fans and blowers. Fans and blowers, lik<
pumps and unlike most other machines, may operate with equal efficienc;
at any speed which their mechanical strength safely allows. They ma;
also discharge, in practice, through orifices varying in area from that of thei
full discharge, to a very small per cent, of the full outlet. The eflSciencj
varies with different orifice areas, but not according to any fixed law for a
designs.
The horse power for any fan or blower, if the area of the discharge orifie
remains unchanged, varies directly as the cube of the speed; also, if the are
of the discharge orifice remains unchanged and the speed is constant, th.
horse power varies directly with the density of the gas being handled.
196. The horse power of a centrifugal fan, if the speed remains ur
changed, generally decreases as the area of discharge orifice is decreasec
In some designs the horse power with rated orifice is not over one-third of th
horse power with orifice equal to area of fan outlet, and in other designs f

is very little less at rated orifice than with unrestricted orifice.

196. The horse power of a propeller fan, if the speed remains ur'
changed, increases as the area of the discharge orifice is decreased. In soni
designs the horse power with rated orifice is not over one-quarter of the horf|
power with complete restriction. '

197. The horse power of a positive blower, if the speed remains uij
changed, increases as the area of the discharge orifice is decreased. Owir
to the small clearances in these machines the horse power increases great,
with decrease of orifice, but blowers are provided with relief valves whic
can be set to limit this as desired.
198. Types of motors adapted to various fans. For driving centi,
fugal fans, with direct-current supply, shunt-wound motors should be use.
For driving propeller fans either shunt-wound or series-wound motors c!.'
be used, with direct-current. The series- wound motor is preferable,
readily obtainable. For driving positive blowers, with direct-current suppl
shunt-wound motors should be used. Induction motors are commonly use,
with alternating-current supply, for all types. |,

199. Starting torque. As the torque required to start any fan or blowj
is only that required to overcome the friction of the bearings, which^ai
usually two in number, and the inertia of a comparatively light rotatus
part, no special consideration need be paid to this feature.

1278
 INDUSTRIAL MOTOR APPLICATIONS See. 16-200

200. Method of control (direct-current). When a fan or blower is

required to operate at only one speed under all conditions of service, a start-
ing rheostat with no-voltage release should be used. If there is a possibility
of a condition arising in the system which will increase the horse power above
the capacity of the motor, as in the case of a centrifugal fan so arranged that
all air resistance may be removed by the changing of dampers or oTjening of
doors, or in the case of a propeller fan which may have its delivery entirely
blocked by a shutter, or in the case of a positive blower which may have its
delivery restricted by the closing of blast gates, an overload release should
also be provided.
A starting and regulating rheostat with no-voltage release should be used
where a fan or blower is required to operate under varying conditions at
speeds below normal, but operates the greater part of the time at normal
speed. Such equipment should also be used where speed varying below
normal is required, and the cost of energy is not important. See Par. 619.
When a fan or blower is required to operate at varying speeds, and operates
the greater part of the time at less than its maximum speed, or where varying
speed is required and economy of operation is more desired than low first
cost, a starting rheostat with no-voltage release should be used in combina-
tion tvith a field controller. The speed, with this arrangement, is adjusted
by variation of resistance in the field circuit. From 10 per cent, to 25 per
cent, speed increase by field control and 50 per cent, decrease by armature
regulation, are very common specifications for fan motors in high-grade
installations.
201. Kemote control. Any of these devices (Par. 200) may be arranged
for remote control, or for automatic speed control to maintain constant
volume or constant pressure of air from the fan or blower, or to maintain
constant steam pressure at the boilers in the case of rnechanical draft fans.
Automatic speed control of fan and blower motors is not recommended,
1 since it is very likely to give trouble on account of its complexity and
refinement.
202. Method of control (alternating-current) . Any method of con-
trol which is adaptable to alternating-current motors in general is suitable
'for alternating-current fan motors. However, such motors are usually
arranged to operate at only one speed, and are provided only with a start-
ing device. If it is necessary to vary the volume or pressure of the fan or
blower, it may be accomplished by throttling the air with a damper.
203. Methods of direct connection. Whenever feasible it is best to
mount the fan wheel directly upon the motor shaft. This can usually be
done with small centrifugal fans and with propeller fans up to about 60 in.
diameter; however, the deflection and the critical speed of the shaft should
be investigated to determine whether or not this is safe.
' When it is not feasible to mount the fan wheel upon the motor shaft, it is
best to provide the fan with two bearings and connect the motor by means of
1 flexible coupling. It is more common, however, on account of low cost and
jpace economy to provide the fan with one bearing and connect the motor
,3y means of a solid-flange coupling. If this is done, care must be taken
Koperly to align the bearings, and to maintain the alignment.
204. If a fan handles hot gases, means must be provided for the pro-
ection of the motor from the heat. This is accomplished by cooling the
haft or the bearings with water, or by separating the motor and the fan with
long shaft extension, or by driving the fan with a belt or chain.
.

206. Suppression of noise. If there is danger of noise being trans-

nitted through the air ducts, as in auditoriums, theatres, schools, churches
^nd hospitals, it is often better to drive the fan by belt from the motor,
'^his is particularly true of alternating-current motors.
206. Belt drive for fans. It is often possible to use a smaller and less
ostly motor by use of belt-drive, when the fan speed is lower than necessary
ir a motor of the same horse power. It is generally preferable to belt
Iternating-current motors, because the most desirable speed of a standard
m
for a given duty is seldom the same as the available motor speed, making
necessary to build a special fan, and thus increasing the cost, if direct-
onnected.
It is desirable to drive by belt, when the required fan speed or the fan
orse power is in doubt, as an inexpensive change in size of pulley will correct
16 error, if one is made.
1279
Sec. 15-207 industrial motor applications
207. Method of motor application to blowers. Blowers are essen-
tially slow-speed machines. It is, therefore, almost always desirable to belt
or gear the motor. If geared, the motor and the blower should be mounted
on the same base to assist in maintaining alignment.
208. Approximate horse power of centrifugal fans. The horse power
required to drive any centrifugal fan may be represented by the following
formula;

<^)
»^P-^(l^o)'^^((,l75)
Where K
(Par. 210) is a constant depending upon the design and upon
other conditions, T is the peripheral velocity or the tip speed of the blast
wheel in ft. per min.; D
is the mean diameter of the blast wheel in feet;
W is the mean width of the blast wheel in feet; to is the absolute density of
the gas handled, in lb. per ou. ft.; 0.075 is the weight of standard air at
65 deg. fahr. in lb. per cu. ft.
209. Approximate horse power of propeller fans. The horse power
required to drive any propeller fan may be represented by an expression of
the form.

Where Ki (Par. 211) is a constant depending upon the design and upon
other conditions, T is the peripheral velocity or the tip speed of the wheel in
ft.per min. A is the gross area of the wheel in sq. f t. to is the absolute density
; ;

of the gas handled in lb. per cu. ft.; 0.075 is the weight of standard air at OS
deg. fahr. in lb. per cu. ft.
210. Table of constants for centrifugal fans
(B. F. Sturtevant Company)

Values of K
Type of fan
Minimum Normal I
Maximum '

Paddle-wheel with 6 to 10 straight

blades and W
= 0A5D .0020 0.0060 0090
Steel pressure with 24 backward
curved blades and — 0.15D.W . . . .0020 0.0050 0142
Slow speed conveying with 18 for-
ward curved blades and — W
0.25Z> .0026 0.0100 0260
Single-inletmultiblade-drum with 60
narrow curved blades, inclined for-
ward and W = 0.50Z> .0065 0.0240 0390
Double-inlet multiblade-drum with
60 narrow curved blades, inclined
forward and W
= 0.60D .0091 0.0330 0550
Double-inlet multiblade-drum with
60 narrow curved blades, inclined
forward and W
= l.OOD 0. 0065 0.0250 0390
High speed with 16 backward in-
clined blades and = 0.8DW 0008 0.0017 0019

211. Table of constants for propeller fans

(B. F. Sturtevant Company)
 INDUSTRIAL MOTOR APPLICATIONS See. 16-212

212. Horse power of positive blowers. The horse power of a positive

blower at any speed varies over such a wide range, depending upon the pres-
sure, that any rule for the approximate horse power would have to take into
account the volume and the pressure of the air and the displacement of the
blower, all of which are so difficult of determination that it is thought beat
not to attempt to state a rule here. For estimating purposes, the efficiency
of such machines may be taken aa 60 per cent.

COAL AND ORE HANDLING MACHINERY

BT C. D. aiLPIN
Electrical Engineer
213. Definition. The term "coal and ore handling machinery" is in
tended to cover the apparatus used in re-handling coal and iron ore between
the mine and point of ultimate consumption. Such apparatus consists in

Gantry Crane or Ore Bridge for Stocking

Fia. 29.
ihe main of unloaders, bucket-handling gantry cranes, car dumpers, self-
iiropelled transfer cars and belt conveyors. Fig. 29 represents a stiff-leg
nloader, with a gantry crane for stocking such ore as is not to be immedi-
tely loaded into cars. Fig. 30 shows a gravity-type unloader and a gantry
rane.

Crane-Type Unloader Gantry Crane or Ore Bridge for Stocking

Fia. 30.

214. Motors for severe service are usually of the mill type with large
afts, fire-proof insulation, heavy frames, small moment of inertia of
mature and great commutating capacity. Shafts are generally tapered
the pinion end to allow for easy removal of the pinion, and axle bearings
! often used where a gear ratio of about five-to-one is desired. The
mes are generally entirely enclosed, although many of the larger sizes
constructed with part of the upper frame cut away in order to facilitate
dissipation of heat. It is possible that in the future, forced ventilation
y become common practice, as is already the case in electric locomotives

J18. Motors for light service where direct current is available, and of
"h.p. or under, are usually of the crane type. This construction is much
t^aper than the mill-type construction, yet is quite satisfactory for inter-
I'tent service where no severe overloads occur. The frames are entirely
closed, as heating is not a consideration.

1281
 1

Sec. 16-216 INDUSTRIAL MOTOR APPLICATIONS

216. Motors for car dumpers, where there is usually abundant space
available, and where the electrical apparatus is well protected from the
weather, are often of the open type with commutating poles. The speed oi
rotation is preferably lower than for the mill motor, owing to the greatei
radius of gyration of the armature.
217. Motors for transfer cars are commonly either of the railway oi
mine type, the latter often being preferable on account of their low speed
high torque and large gear reduction. Standard drum-type controller!
are ordinarily furnished with these motors.
218. Mill motors, where alternating current only is available, may b<
obtained for 3-phase, 25-cycle, 220-volt or 440-volt circuits. For a frequencj
of 60 cycles it is necessary to use an open type of frame, an outboard bearinf
being desirable for sizes above 25 h.p. Alternating-current motors shoulc
be of the slip-ring type, except for belt conveyors with light starting require
ments, where squirrel-cage motors may be used. They should be of sturdj
mechanical construction, and should be wound for high torque. Low
rotor speeds are desirable as tending to keep the acceleration load at )

minimum.
219. Controllers for heavy duty are always of the contactor or mag
netic-switch type with overload and automatic acceleration relays. Dy
namic braking for lowering buckets, etc., is practically universal; not only ii

the energy of the lowered mass dissipated in resistors instead of brake fric
tion, but the operator is given a very delicate control by means of his maste
controller instead of having to manipulate an air or hand brake. Wher
direct current is not available, dynamic braking is obtained by means of i

small low-voltage generator set, which provides direct current for excitin)
the stator winding of the motor lowering the load, thus allowing it to becouK
an alternating-current generator. Since only part of the winding can b
used for this purpose, and since an induction motor possesses inherently i

limited torque, this system of dynamic braking is not as reliable as wheri

direct-current motors are used. See article on "Motor Control" elsewhere ii
this section.
220. Distribution systems. The standard source of energy, especiall;
on the lower lake docks (Lake Michigan and Lake Erie) and in the grea
steel plants, is a 2oO-volt direct-current circuit, a metallic return circui
being generally used. In purchasing energy, part of the charge is usuall;
based on the peak loads, and where these peaks are figured on the basis o
five seconds or less, the cost of energy can often be substantially reduce(
by the introduction of a fly-wheel balancer set in connection with rotar;
converters.
221. A fly-wheel balancer set consists of a direct-current machine o
very high commutating capacity mounted on the same shaft with a fly-whee
and so arranged that when the station load exceeds a certain amount, th
field of the balancer machine will be automatically strengthened so tha
energy will be given out by the fly-wheel as it decreases in speed. Whe
t he demand ceases, the balancer field is weakened and the machine become
a motor, thus accelerating the wheel to normal speed. Such balancei
are commonly rated at from 200 kw. to 300 kw. of continuous capacity, wit
a commutating capacity for 200 per cent, overload; the fly-wheels vary froi
25,000 lb. (11,350 kg.) to 50,000 lb. (22,700 kg.) with rim speeds of aboi
16,000 ft. per min. (4,880 m. per min.} for cast steel wheels and 28,000 f
per min. (8,540 m. per min.) for laminated plate wheels. A very carefi
study of load conditions and the power contract is desirable before installin
one of these balancer sets.
222. The power requirements of coal and ore handling: apparatt
may be considered under two classes: (a) those in which a fixed force (

constant torque predominates, such as gravity or friction, and (b) those !

which acceleration or variable torque is the main feature. To the first cla
belong the hoist motions, where the speed is comparatively low and the r
quirement for acceleration is a small part of the total power. For this tyi
of motion a compound-wound motor has been commonly used, the compour'
winding being originally provided to facilitate dynamic braking. Lat
developments of control have made dynamic braking practicable for seri
motors, and the tendency now is toward the use of that type of winding. 1

control should include at least one "power point" in the lowering directic

1282
 INDUSTRIAL MOTOR APPLICATIONS SeC. 15-223

and should be so arranged as to provide dynamic braking or armature shunt-

ing at all times while lowering, so that it will be impossible for the load to
overhaul the mechanism at a dangerous speed. An emergency spring-closing
switch is often desirable; this should be so arranged as to connect the arma-
ture in series with the field and a small amount of resistance, in case of failure
of the line current. The motors should be provided with magnetic brakes,
the shunt type of winding being preferable in many cases.
223. The approximate motor loads may be obtained as follows:
The hoisting h.p. equals the hoisted load in lb. multiplied by the
hoisting speed in ft. per min., divided by 33,000 and again divided by the
efficiency expressed as a decimal. The nominal lowering h.p. equals
the lowered load in lb. multiplied by the hoisting speed in ft. per min.,
divided by 33,000 and multiplied by the efficiency. In this case the lowering
h.p. really represents current or torque as read on the characteristic
curve of the motor. Variations in lowering speed are obtained by changing
the dynamic braking resistance and thereby the motor voltage for the same
current value. The approximate heating of the motor can be determined
as shown in Par. 231
224. The power required by a belt conveyor is, normally, almost
constant. The size of motor is commonly obtained by referring to the manu-
facturer of the conveyor. The motor should have a continuous rating and
may be of the variable speed type. Electrical weighing devices are sorne-
times used to weigh the material as it passes a given point. Such a device
consists essentially of a magneto generator driven by the conveyor, connected
in series with a resistance which varies inversely with the instantaneous
weight of the material at that point on the conveyor. It is obvious that the
output of the generator depends both on the speed of the conveyor and on
the amount of material which it carries; an indicating wattmeter will there-
fore show the rate at which the material is being handled, and a watt-hour
meter will record the total amount of material handled during a given time.
226. Equipment for transfer cars and trolleys. In the case of trans-
fer cars and the trolleys of unloaders and bridges, acceleration is the pre-
dominant factor. For loads of this kind, two motors are used as a rule, in
order to obtain good traction; in such cases, series-parallel control is gener-
ally preferable. If the motors are permanently connected in parallel, it is
(Safer to provide a separate set of reversing contacts for each armature.
Armature-shunting points are occasionally employed to obtain very low
speeds, and dynamic braking is sometimes provided in the case of a gantry
crane or unloader trolley. To obtain dynamic braking for a series-wound
trolley motor, it is necessary to connect the field in series with a resistance
across the line, so that the characteristics of a shunt generator may be ob-
tained. An air brake is generally preferable for trolley service, except when
the operator is located at some distance from the mechanism, in which
;ase the motor should be provided with a magnetic brake, preferably of the
'disc type, and the controller should give dynamic braking on or near its
;entral position.
226. The
frictional resistance of the ordinary trolley may be taken
,it 25 lb. per ton; for a transfer car with standard trucks, 15 lb. per ton is
iraple. The horse power for the final assumed speed should first be figured
^s follows: h.p. == friction force at rim of wheel multiplied by the speed in ft.
)ei min. and divided by the efficiency (expressed as a decimal) and by 33,000.
^bout twice the result should be taken as the nominal horse power required,
his value being based on a rise of 75 deg. cent, in 1 hr. The per-
ormance of the trolley or car can then be easily worked out by means of the
actor curves, the step-by-step method being used as explained in Par. 233.
t will sometimes be found that the motor chosen is too small; where there
'f any doubt, the moment of inertia of the armature should be obtained
nd should be translated into its equivalent weight at the trolley speed. The
alculations should then be gone over more carefully; for slow trolley speeds,
le inertia of the armature becomes a very considerable part of the whole.
227. The longitudinal drive of an unloader or bucket-handling
antry partakes of the nature of a trolley drive, but owing to the much lower
seed and higher friction, inertia plays a smaller part, and dynamic braking
unnecessary. Friction may be taken at about 40 lb. per ton, although
lis figure is quite uncertain. The heating is not a factor in this class of
1283
 1

Sec. 16-228 INDUSTRIAL MOTOR APPLICATIONS

service, but suflScient commutating capacity should be allowed to take
oare of a wind-pressure equivalent to one and one-half times the friction;
this is merely a general rule, but is one which works well in practice. In
some cases long gantry cranes are driven by independent motors at each end;
this scheme is quite successful, even with series motors, although an auto-
matic device should be provided to prevent one end from leading the other.
With this type of drive, the motors should be provided with magnetic brakes,
the disc type being preferable because the shock when stopping is less than
with the post brake. For the ordinary gantry or unloader, one motor ia
generally connected by bevel gears to both trucks; a mechanical foot brake
which is held in the released position by the weight of the operator is prefer-
able to a magnetic brake in this case, since it can be applied more gently.
228. The gear efficiency of one reduction of cut spur gears in this class
of work may be generally taken as 95 per cent.; for cut bevel gears, 90 pei
cent. For important motions, the cut herringbone gear is becoming popular;
it should have an efficiency of at least 97 per cent, if properly erected. Tht
coefficient of friction for the ordinary bearing will average about 0.05
while for sheaves it is better to allow a value of 0.07. These figures may b«
safely followed except in special cases, such as in gearing for longitudina
drives where there is decided likelihood of poor alignment of shafts and gears
229. The calculation of power house or substation capacity for :
dock is a long and tedious process, since it is a matter of some conjecture as
to just how
the peak loads, which are usually violent, will coincide. A 10-toi
stiff-legore-unloader having a total capacity of 400 h.p. in five motors wil
show a momentary peak load of 1,200 amp. and an average load of 400 amp
Two such machines working together will occasionally take 1,800 amp
for 1 or 2 sec. One 15-ton stiff -leg ore-unloader with seven motors to
tailing 700 h.p. and requiring an average load of about 500 amp. will drav
a peak of 1,800 amp. The maximum current for four such machines, how-
ever, will not exceed 4,000 amp. Gravity-type unloaders are likely to shov
a higher proportional peak load because practically all the work is done bj
the hoist and the trolley; operators of this type of machine are generally
cautioned not to work too nearly in synchronism with the other unloaders i
the power house capacity is limited. If possible, it is much better to obtaii
data from an installation similar to the one contemplated. In any case thi
generators or converters should have a high commutating capacity and al
circuit-breakers should have time-limit relays. The tendency of late ii

distinctly toward the purchase of energy where possible; in many cases ai

excellent rate can be obtained owing to the fact that work is carried on bj
night as well as by day. A better rate is sometimes obtainable by reducinf
the demand during hours of normal central-station peak load.
230. Kxample of calculations for typical ore-handling gantry crane
The hoist-motion calculations are given in Par. 231, the trolley calculation
ip Par. 232, and the bridge calculations in Par. 233. The following calcula
tiona relate to the case of a typical 15-ton ore-handling gantry crane. Th
estimated average duty is to lift one bucket of ore 30 ft. every min., th
average distance to be trolleyed being 200 ft. Assuming that 10 per cent, o
the total time is lost in moving the crane longitudinally, etc., the speed'
must be such as to perforin the given cycle in 54 sec. Estimate th
time in which the trolley will not be working, as follows: Closing buckel*
6 sec; hoisting clear of ore pile, 2 sec; opening bucket, 4 sec; lowering buck^l
after trolley comes to a standstill, 2 sec; total, 14 sec. Time available fo^
trolley trip in one direction, 20 sec. Average speed of trolley, 000 ft. pe'i
min. Assume a maximum trolley speed of 900 ft. per inin. and a hdi-^i'Ti
speed of 180 ft. per min.; the latter speed is not required for the as-
cycle, but will be useful when making long hoists with a short trolley 1

231. Calculations for hoist motion (Par. 230). The hoist moti :>

assumed to be of the type in which each of two motors is geared through tw

reductions to its own drum, each of the two drums carrying one of the tw
sets of cables necessary for operating a clam-shell bucket. No. 1 nioti
closes the bucket; Nos. 1 and 2 hoist the bucket together; No. 1 opens tli^
bucket; and No. 2 lowers it, No. 1 running down with practically no-loacj
The efficiency may be assumed roughly as 90 per cent. The ore will weigii
33,600 lb.; assume the bucket weighs 30,000 lb., making a total of 03,600 111
The hoisting horse power per motor = (63,600 X 180)/(33,000X 0.90 X^
1284
 INDUSTRIAL MOTOR APPLICATIONS See. 15-232

= 193; or say 200 h.p. The lowering horse power for No. 2 motor
= (30,000 X 180/33,000) X 0.90 =147 h.p.; or say 150 h.p. Assume the
average closing load for No. 1 motor is 150 h.p., and for opening, 50 h.p.
The root-mean-square or effective horse power for No. 1 motor will then be
[C15Q2X6-f2002X10 + 502X4)/60]l =95 h.p. The mean effective horse
power for No. 2 motor = [(200:x 10-M50=X7)/60]i =96 h.p., assuming
that actual lowering takes place in 7 sec.
The smallest motor which suggests itself for this service is one having an
entirely enclosed frame and a mill rating of 150 h.p.; the mill rating is based
on the power the motor can develop for 1 hr. with a temperature rise not to
exceed 75 deg. cent. Investigation of the manufacturers' data shows that
the 1.50-h. p. mill-rated, fully enclosed motor will not have sufficient heat-
ing capacity if the crane is to be operated at full speed continuously, although
the commutating capacity is ample. This same motor, however, if built
with a semi-enclosed frame will have a mill rating of approximately 165 h.p.
and a root-mean-square rating of about 130 h.p., which is ample for the
service. Generally speaking, there is less trouble from heating than is indi-
cated by the calculations, owing to unavoidable interruptions to continu-
ous operation, and to good ventilation due to the movement of the trolley.
232. Calculations for trolley motion (Par. 230). Assume that the
trolley with bucket and ore weighs 170,000 lb., and is driven by two motors,
each geared through two reductions to one of the four axles. Take the
frictional resistance per motor at 25/2,000 X 170,000X J = 1,060 lb. Final
h.p. = (l,060X900)/(33,OOOX0.90)=32. Assume two 80-h.p. [temperature
rise of 7,5 deg. Cent, for 1 series-wound motors; from the characteris-
hr.]
tic curve it will be found that at 32 h.p. the motor speed equals 820 rev. per
min. and the torque equals 205 lb. at 1 ft. radius. Therefore the gear ratio
must be such that the desired trolley speed of 900 ft. per min. is equivalent to
a motor speed of 820 rev. per min. then ft. per min. = (900/820) X rev. per
;

min. = 1.1 X rev. per min.; also the force at the rim of the wheel willhave
the same ratio to the motor torque as the friction force has to the friction
torque; or, force = (1,060/205) Xtorque = 5. 17X torque. Assume effect of
armature weight equal to 1,500 lb. at 0.7 ft. radius; equivalent weight of
one armature at trolley speed = [1, 500 X 0.9 X (2irX 0.7 X rev. per min.)']/
(ft. per min.)2=([l,500X0.9X(2a-X0.7Xrev. per min.)2]/(l.l Xrev. per
niin.)2 = 2,160 lb.; or say 5,000 lb. including gearing. Total weight per
motor for acceleration = 85,000 + 5,000 = 90,000 lb. A.ssume that accelera-
tion while short-circuiting the resistance is 2.5 ft. per sec. per sec, which
is as high a value as the operator can endure with cotnfort; this initial rate
pf acceleration is determined by the rapidity with which the starting re-
sistance is cut out. Since the force of acceleration =ii'o= (wt. in lb. /fir)
,X acceleration in ft. per sec. per sec, then Fo= (90,000/32.2) X 2.5 = 7,000 lb.
Since the friction force is 1,060 lb., the total force = 7,000 + 1,060 = 8,060 lb.
Motor torque = J' = 8,060/5.17 = 1,560 ft-lb. From the characteristic curve,
^hen T= 1,560, h.p. =119; rev. per min. =402. Therefore ft. per min.
P"402X 1.1 =442, and ft. per sec. =7.4. This is the speed which is attained
it the instant the last section of resistance is cut out. The time = <i =
!peed/acceleration = 7.4/2.5 = 3.0 sec. The distance = di = average speed
\ time =(1/2)X7.4X3.0= 11 ft. After the starting resistance is cut out,
he trolley will continue to accelerate at a diminishing rate, as long as the
orce supplied by the motors exceeds the friction force. Assume that the
orse power has decreased to 60; then from the motor curve, rev. per min.
660. Since ft. per min. = 1.1 X rev. per min., the ft. per min. = 616, or
per sec. = 10.3, and the increase = 2.9 ft. per sec. The average speed
(10.3 + 7.4)/2 = 8.85 ft. per sec. Referring again to the curve, 7 = 560,
erefore F = 2,900 lb.; Fa=i*'-F/ = 2,900- 1,060 = 1,840 lb., acceleration =
-ffXFa/90,000 = 0.66, average A = (2.5 + 0. 66)/2 = 1.58, t2 = (increase in
peed) /(average acceleration) =2.9/1.58= 1.8 sec, d2 = 8.85X 1.8 = 16 ft.,
"ital time up to this point = < = 3 + 1.8 = 4.8 sec; total distance up to this
)int = (i = 11 + 16 = 27 ft. Assume the horse power has dropped to 35;
len rev. per min. = 760, ft. per min. = 836, ft. per sec. = 13.9, increase = 3.6,
iverage speed = 12.1 ft. per sec; 7" = 240, F= 1,240, Fo=180, A =0.06, aver-
»A = 0.36, U = 10.0 sec, da = 121 ft., t = 14.8 sec, d = 148 ft. Assume trolley
lasts for 1 sec. at 13.9 ft. per sec; U = \, d4 = 14 ft., < = 15.8 sec, d=162 ft.
Wttme retardation = 2.5 ft. per sec. per sec; <5 = 13.9/2.5 = 5.6 sec, dt = 39
iii^i'^f«*21.4 sec, d = 201 ft. The time originally allowed for a trip one way
1285
Sec. 15-233 INDUSTRIAL MOTOR APPLICATIONS

was 20 sec, but since the trolley will return light at a somewhat higher speec
the gear ratio originally assumed is close enough. If the heating is figure(
for the loaded trip and for one-half the cycle, the results will be on the safi
side. i + X
Mean effective h.p. = [(UO^ X3) (1 19^ 1/2 1.8) (60^ 1/2 X 1.8
X + X
+ (602Xl/2Xl0) + (352Xl/2X10)]/[60XJlli = 52. A fully enclosed mil
motor can keep up this cycle for about 3 hr., but not indefinitely. If tin
crane will not operate for over 3 hr. at any one time, 80-h.p. mill-rated en
tirely enclosed moto s should be used. For coritinuous operat on use thi
same motors with the semi-enclosed frames, which will have a mill ratini
of about 90 h.p. and root-mean-square rating of about 70 h.p.; or if nee
essary, forced ventilation may be used with the totally enclosed motors
In any case, the a ma.ure, fields, etc., will b^- the same, the diflerence in ratini
being due to thj different methods of cooling. The maximum loads to b
commutated should not exceed those shown on the motor curve.
233. Calculations for bridge drive (Par. 230). Ass me that the tota
crane weighs 1,200 tons, and that a 2-motor longitudinal travel drive i
desired. Friction force per motorat40 lb. per ton = 40X l,200Xi-=24,00(
lb. Assume that a speed of 75 ft. per min. is desire 1, and that each moto
has one spur-gear and two bevel-gear reductions. The efficiency would b
approximately 77 per cent. The friction load per motor = 71 h.p. I
80-h.p. mill-rated motors were used, the friction torque read from the curv
would be about 720 lb. at 1 ft. radius. Assuming the wind load = 36,000 lb
and acceleration at 0.25 ft. per sec. per sec. =9,300 lb., the total maximun
load =69,300 lb. and approximate maximum torque = (69,300/24,000
X 720 = 2,080 ft-lb., which is well within the commutating limit of an 80-h.p
mill motor. Note that the wind load to be resisted by the mechanism ma;
be greatly in excess of the above; hence rack drives are sometimes used fo
greater safety.

TELPHERAGE SYSTEMS
BY H. McL. HARDING
Consulting Engineer, Associate American Institute of Electric Engineers
234. Classification. There are two main divisions of telphers, autoniati
telphers and man-telphers. Automatic telphers are those which are drivei

Fia. 31. — Telpher train.

by electric motors, the control being apart or remote from the telijher. lli
original telphers were automatic, the telpher being placed in the middle (

the train. The chief use of the automatic telpher is for coal, ore and bul
material. Non-automatic or man-telphers are those which are cor'
trolled by an operator who travels with tlie load, and who operates both tb
telpher and the hoists from a cab or cage which is attached to the telphe

1286
 INDUSTRIAL MOTOR APPLICATIONS Sec. 15-235

or the carriage. It is employed for bulk material, like the automatic telpher,
and is also used for the hoisting and conveying of miscellaneous material,
boxes, cases and barrels, the package freight of railways and the mixed cargoes
of steamships, see Fig. 31.

Fig. 32. — Carriage hoist.

Suspension. A telpher is suspended from one or more wheels in

235.
tandem, of which one or all are driven by the electric motor or motors.
236. Clearances. In the minimum-headroom 2-ton (4,000 lb.) type
.designed for railway and steamship terminals (Fig. 32) the vertical space
'from the underside of the roof girders to the bottom of the hoist-hook is
i4 ft. 9 in. (144.8 cm.). The width of the hoist is 3 ft. 3 in. and 4 ft. Sin.
to the limit line for 10-deg. swing. From the centre of the rail to the inner
limit of the telpher and hoist is 16 in.
, 237. Energy supply, in the form
of either direct or alternating current
J.s communicated to the motors by conductors which lie parallel to the track,
the contact being made by shoes or wheels. Sometimes storage batteries,
juspended from the telpher or the carriage, are employed. On
steep grades
:he telpherage traction, in some installations, has been assisted by supple-
nentary cables, either fixed or movable.
238. Motors. The sizes of motors for telphers and hoists will depend
ipon the class of work to be done; the motors for telpher- tractors vary from
to 15 h.p., and for the hoists from 3 to 75 h.p., the loads being from
')

iOO lb. to 30,000 lb. The load factor for the tractor motor is 0.25 and
I
or the hoisting motor 0.16. The driving wheels and the motors may be
onnected by gears or by chain drive. The maximum service efficiency
f the motors is that corresponding to the efficiency obtained between one-

alf and three-quarters full-load. The motors are of slow or medium speed.
Direct-current, 250-volt or 500-volt, series-wound motors are preferable
tractors and hoists although alternating-current motors afford satisfactory
3r
: ,3sults. The motors should be dust and weather proof, and should have a
0 per cent, reserve in their rating. The average combined efficiency of the
lotors and gearing, for the tractor and hoist, is from 65 per cent, to 75 per
;nt.
239. Brakes. The telpher brake is of the mechanical type, and the hoist
rake is of either the electro-mechanical or electro-dynamic types. Spur
;ars and chain drive on the tractor transmit the power from motor to track
heels, and either spur or worm gear is used to transmit power to the
Msting drum.
240. Trackage. Telphers either run in one direction on a closed track
rcuit (Fig. 30), or to and fro over a single line. On the single line the
itomatic telphers reverse themselves on completing their trips. The spac-
g between the cars is automatically regulated by a block system, and the
rs are also automatically controlled at switches and crossings. The track
nsists of either a cable, or a T-rail supported on a wooden stringer, or upon
e top or lower flange of an I-beam. There are also track raUs of special
3tion The radii of the curves are from 8 ft. to 20 ft.
241. Track supports. The track is supported on brackets attached to
ildings, or is supported on "A" bents. Supports under straight track are
iced 20 ft. apart, and on curves the spacing is 8 ft. For long spans cables
trusses are used.

1287
Sec. 15-242 INDUSTRIAL MOTOR APPLICATIONS

242. Tracks may

be fixed or movable. In Fig. 33 the side tracks B.B'.
are fixed, but C is movable, being attached to a travelling bridge. The speed
of this bridge is from 300 ft. to 900 ft. per min. The motor driving this
bridge would have a load factor of 0.16.
The telpher train passes from the side track B by means of a gliding
switch, upon the movable track C. This track therefore may be placed any-
where over the area between the fixed side-tracks. The
D Dtelpher returns by means of the track B', to its start-
ing-point. By the operation of this movable track, all
the space can be served; this operation is called trans-
ferage. The minimum allowable radius of curves is 8 ft.

^ ^
243. Performance. The loads hoisted and con-
veyed on telpher hoists have be°n as high as fifteen
tons. The maximum speed of conveying on a straight
level track is about 1,000 ft. per min. The running
speed is reduced at curves, according to their radii.
244. For terminal work, the capacity of each hoisi
is 2 tons at 60 ft. per min. (18.288 m. per min.). Twc
hoists can be combined so .as to raise 4 tons. The
motors being series-wound, the speed of hoisting wil
increase as the load is diminished.
246. For freight handling, from two to four car
riage hoists constitute a train which has a total max
imum carrying capacity of 8 tons. Such trains an
used for assorting as well as for distributing, accordini
to consignments. Many telphers can be operated ii
one installation, the number being limited only by thi
FiQ. 33.— Typical design of the track layout. In freight or cargo handling
arrangement of tel- the fixed overhead tracks may be parallel or at righ
pherage tracks. angles to the surface railway tracks or to the waterfron
wall, but preferably at right angles.
246. Installation costs. The overhead trackage, made part of an<
attached to the building structure, costs the same in proportion as othe
structural steel. The weight, including the brackets, averages about .50 lb
per lineal foot. The steel is fabricated at the mill.

STEEL MILLS
BY WILFBED STKES
The Steel A Tube Co. of America, Fellow, American Institute of Electrii-(.
Engineers
847. Classification. Rolling mills are usually named after the materie
produced by them, although they are sometimes classified according to ih
layout of the mills. The principal types of mills are as follows:
(a) Blooming mills, rolling ingots, as cast, to blooms or billets. A
material rolled in a steel mill must pass through the blooming mill or it
equivalent, to be reduced to proper dimensions for handling in the finishiu
mills. The mills are built either two-high reversing, or three-high runnin
continuously in one direction.
(b) Slabbing mills (modification of the two-high blooming mill) produc:
slabs with finished edges, which are afterward rolled into plates. Vertiot,
rolls are provided for finishing the edges.
(e) Billet mills are usually of the continuous type, with rolls in tanden:
and roll material from the blooming mill to a suitable size of billet for th
finishing mills. Material passes directly from one stand to the other, tli
speed of the rolls being arranged to correspond to the reduction in area aftt
each pass.
(d) Plate mills may be either two-high reversing, or three-high runnia
continuously in one direction, and roll slabs to plates of various thicknessei
They are sometimes provided with vertical rolls for finishing the edges c
the plates and are then known as universal mills.
(e) Structural mills are usually three-high and are used for roUin
girders, heavy angles, channels, etc. In small plants such material may b
rolled by the reversing-bloomiug mill.

1288
 INDUSTRIAL MOTOR APPLICATIONS See. 15-248

(f) Merchant mills are used for rolling small angles, channels and all
types of profiles. They are usually three-high, with the finishing stand
sometimes two-high.
(g) Bar mills are usually three-high, and generally consist of roughing
stand and a separate finishing stand. These are used for rolling bars of
all sections and sizes.
(h) Eod mills are special types of bar mills, and are used for rolling small
sectiona at high speeds.
(i) Bail mills generally roll blooms or heavy billets to rails of various
sections, and are made two-high or three-high, according to the layout.
(j) Sheet mills roll 0.5-in. to 1-in. bars to sheets of all gages; they are
always two-high, and generally have separate roughing and finishing stands.
In addition to the foregoing types, there are several other forms of con-
struction, used for roiling certain sections of material, but their use is generally
confined to one particular installation.
Sec. 15-249 industrial motor applications

Occasionally the various stands are arranged on one axis, the finishing
stands being separately driven to give the proper speed adjustment. The
object of driving the finishing stands at different speeds than the roughing
stands is to increase the capacity of the mill, and to finish the material at
such a rate that it does not become too cool; this difference in speeds also
makes it possible to work without an exceedingly large loop from one pass
to the other.
249. Direct-connected drive. The best arrangement is to connect the
motor direct to the mill, if the mill speed is such that this is feasible. In
general, the lowest speeds possible for direct-connection at 25 cycles are as
follows: 250 to 500 h.p., 125 rev. per min.; 500 to 1,000 h.p., 100 rev. per min.;
1,000 to 2,000 h.p., 85 rev. per min.; 2,000 h.p. and upward, 70 rev. per mini
250. Geared drive. The first cost of slow-speed motors is high, and il
very large motors are not required, some speed-reducing arrangement it
generally used for slow-speed mills. The low power-factor of the slow-speed
motor is a serious objection. Gearing has been used extensively for con-
necting motors to mills, and the use of cut double-helical gears makes pos-
sible pitch-line speeds previously impracticable. Although the maintenance,
is increased, gears permit the installation of high-speed motor of gooej
performance at low cost. The use of gears introduces losses and off.sets th<
increased efficiency of high-speed motors, but the -advantage of high power-
factor is important. An important advantage of gear drive is that in thi
case of very slow-speed mills, the fly-wheel (Par. 254) can be located on thi;
pinion shaft and run at such a speed that comparatively small weight i<j

required. This is of particular importance in sheet mills, which run a'i

approximately 30 rev. per min., as sufficient fly-wheel effect cannot bi;
obtained to equalize the input properly if the fly-wheel is located on thij
mill shaft. j

When connecting the motor to the mill, the fly-wheel (Par. 264) shouU;
be so placed that the shocks from the rolls are not transmitted to the motori
The best location is on the mill shaft, but with very slow-speed mills, ij
may be necessary to place the fly-wheel on the pinion shaft for the reasoii
above mentioned.
When the fly-wheel is mounted on the pinion shaft, the gear must be proj
portionately larger, as it transmits the peak loads. When the fly-wheel ii
mounted on the mill shaft (Fig. 36), the gear need only be large enough ti
transmit the motor load. In practice, pitch-line speeds up to 1,500 ft. pe
min>are used with plain spur gearing, arid up to 2,500 ft. per min. wit:
double-helical gears. The best practice is to mount the gears in a substantis
case and to run them in oil, which decreases the noise and reduces in:iii:
tenance.

] CZJJ a [05 f^ ^QJ

Hi
ffl a

Fia. 36. — Gear drive, fly-wheel on mill shaft.

261. Rope drive is extensively used in steel mills where the mill-speed i

suitable. Rope speeds up to 6,000 ft. per min. are used, the rope wh&,;
acting as a fly-wheel for the mill. General practice does not differ from tht,
of rope drive in other industries. Large fly-wheels are generally require
to prevent rapid fluctuations in the amount of power transmitted fro
the motor ancf consequent whipping of the ropes. Belt drives are used on
to a small extent in steel mills, usually where a number of stands are arrangi
passf
in tandem to be driven from one source of power, the belt being

1290
 INDUSTRIAL MOTOR APPLICATIONS SeC. 16-225

around several pulleys. The present practice is to substitute gears for

type of mill.
belts in this
252. Reversing blooming mills cannot be driven directly by alternating.
current motors, due to the difficulty of control, and to the unsuitable char-
acteristics of such machines. Direct-current motors are used for driving
the rolls, and are supplied with power from fly-wheel motor-generator sets,
the field of the generator being varied and reversed to control the speed
and the direction of rotation of the roll motors. The roll motors are always
excited with the same polarity, and the reversal of the armature current of
the generator reverses the rotation of the roll motor. The fly-wheel is used
to equalize the input to the motor-generator set, and, in practice, limits
the load in the line to about one-fourth of the maximum output of the
generator.
253.Reversing rolling mills have been built with motors which exert
as much as 16,000 h.p. on the rolls for short periods.
254. Fly-wheels. The function of the fly-wheel is to give up energy
during the period when the load on the rolls is in excess of the capacity of
the motor, and to store energy when the rolls are idle between passes. In
rolling-mill practice, a speed variation of froni 15 to 20 per cent, is permissible.
The energy available from the fly-wheel is:
—^XT50" i^X>.f>^c.) (7)

where T7 = weight of fly-wheel in lb., Vi = maximum velocity of wheel at

radius of gyration in ft. per sec, Fj = minimum velocity of wheel at radius

110

100 ^__ ^
, 1

90

80
a
^70
I 60

~ 50

2 4 6 8 10 12 14 10 18 20 22 24 26 23 30 32 34
Times Original Length to which Material is Elongated
'iG. 37. — Curves showing average energy consumption of different types of.
mills.
Curve No. 1, rolling small billets of high-carbon steel to rods.
Curve No. 2, rolling billets to light rails.
Curve No. 3, rolling billets to flats and squares. '

Curve No. 4, rolling ingots to billets.

Curve No. 5, rolling slabs to plates.

f gyration in ft. per sec, ff = acceleration due to gravity = 32.2 ft. per sec.
y.properly arranging the control of the motor, the rate at which the energy
given up by the fly-wheel can be regulated, so as to limit the load on the
'otor to the average value, providing sufficient fly-wheel effect is available.
The majority of fly-wheels used on rolling mills are built of cast iron, and
H a general practice, the limit of peripheral speed in such cases is 6,000 ft.
Jr min., because higher speeds are not considered safe, owing to the un-
'^rtainty of the shrinkage stresses. By special construction to avoid such
1291
Sec. 15-255 INDUSTRIAL MOTOR APPLICATIONS
stresses, cast-iron wheels for a
peripheral speed of 10,000 ft. per o -ooooo
min. have been built with suc-
cess. For moderately high speeds,
cast-steel wheels are commonly
o ioc'o'o'o' O
used, the usual limit of peripheral
speed being 12,000 ft. per min.;
but in special cases cast-steel
wheels run at speeds up to 22,000
ft. per min. Such speeds are
dangerous if the material is not
homogenous and free from initial
80000
oooo
I
ggOOr-iOOiOCDiON
stresses, but with proper design
and annealing, they have proved
successful. For speeds up to
30,000 ft. per min. fly-wheels have
been built from discs cut from SB
single the plates being
plates,
riveted together to form a solid OOOCOOO'OOO
wheel.
256. Factors afifecting power
requirements. The power re- NO
quired by rolling mills depends mm
upon the following factors: (a) 4) o
it U
volume of metal displaced in a 05 oj
..*« tCt£
given time; (b) manner in which
the section is changed; (c) temper- -"--"^
T)<0'<J<"5 WIN
ature of metal during rolling; (d) otd.
class of material; (e) size of rolls.
The determination of the best
arrangement of motor and fly- MM
6!
wheel for any particular mill neces- M&D-
03 J2
sitates the analysis of the power 0"W-<t»-*<iOO St3
Z' ,

required for each pass. The aver-

age output required can be ob- .2t3 : XXXXXXoo^o
tained from Fig. 37, which shows
average energy consumption
for different classes of mate- $$2
rials. The figures given are h.p.
hr. per ton of metal rolled, plotted
against elongation. To these fig-
ures should be added the friction
of the mill, in order to obtain the XXXX^MXXo"'-
motor load. The size of the motor SglS-^xxooS-
may be determined from these .3^ CJ-

curves, provided that the tonnage O *

taken corresponds to the maximum
that the mill will roll if working
continuously, and that there is
sufficient fly-wheel effect available
to equalize the peak loads.

266. Motor rating and tem-

perature rise. Rolling-mill
motors 'are usually rated on a
temperature rise of 35 deg. cent,
and they have a continuous over-
load capacity of 25 per cent, with
.50 deg. cent, rise and a 1-hr. over-
load capacity of 50 per cent, with
60 deg. cent. rise. With the knowl-
edge now available of the power
requirements, a standard tempera- 611 MS 5 _: J .g .a _; _
ture rise of 40 deg. cent, with a 25
per cent, overload capacity for 2
hr. is satisfactory, if the conditions
are properly analyzed.

1292
 ,

INDUSTRIAL MOTOR APPLICATIONS Sec. 15-258

258. Energy consumption per ton of material

Original Finished Tons H.p.

Type of mill cross-section product hr.per
(in.) (in.) ton

Reversing blooming mill. 20X20 8X8 95 21

Reversing blooming mill 16X16 3X3 40 42
Plate mill 6X30 iX30 60 28
Plate mill 7X24 1X24 70 16.5
Sheet mill 7X30Xf 0.025 8 165
Sheet mill 7X30X1 0.04 10 128
Rail mill 4X4 40 Rail 75 20
Billet mill 4X4 HXli 50 20
Rod mill HXH i Round 20 60
Bar mill 4X4 1X1 15 48

259. Types of motors adaptable to rollingr-mill practice. Alternat-

ing-current motors are used almost exclusively for driving roiling mills,
lirect-current machines being adopted only in a few installations of com-
paratively small capacity, or where there are special speed requirements.
Special types of direct-current and alternating-current auxiliary motors
or steel-mill service have been developed, the principal characteristics of these
machines being high overload capacity without injury, and great mechanical
!trength. Accessibility is also an important factor in order to facilitate
apid repairs. Mill motors are built from 5 to 150 h.p., being usually rated
m a temperature rise of 75 deg. Cent, after 1 hr. operation. They are
equipped with heat-resisting insulation, because they are often located near
urnaces where the temperature of the motor even without load may be
'ery high. The maintenance cost of such motors is approximately one-
ourth that of the modified railway motors previously used. Full particulars
if these motors can be obtained from the publications of the manufacturers.

260. Control. It is becoming general practice to use hand-operated

ontroUers only for auxiliary motors up to about 30 h.p., larger machines
eing provided with magnetic-switch controllers. The principal charac-
eristics of steel-mill controllers are simplicity, reliability in operation and
bility to stand abuse. The special construction necessary to meet these
onditions increases appreciably the cost of steel-mill controllers as compared
ath controllers for ordinary industrial service.
For motors driving main rolls, magnetic-switch controllers are generally
sed, the resistance being so arranged that various running points up to
5 per cent, slip may be obtained, in order that the motor will slow down on
eavy loads and allow the Hy-wheel to give out a part of the energy stored
1 it. Automatic slip regulators are now being adopted, in order to regulate
16 rate at which energy is delivered by the fly-wheel, thereby obtaining better
iualization of the load on the motor. Liquid regulators are used on ac-
iunt of their simplicity and small maintenance, as well as quickness in
nion and sensitivity.
261.
—
Bibliography.
PuppE J. "Versuche Zur Ermittlung des Kraftbedarfa an Walzwerken."
—
Shover, B. R. "Industrial Application of Electrical Motors, Gary Plant,
Indiana Steel Company." A. I. E. E., Transactions, 1909.
—
Specht, H. C. "Functions of Fly-wheels in Connection with Electrically
perated Rolling Mills." A. I. E. E., Transactions, 1909.
Friedlander, E.— "Electrically Driven Rolling Mills." A. I. E. E., Trans-
tions, 1909.
Wiley, B.—"Power Requirements for Rolling High Carbon Steel, of Small
. actions." A. I. E. E. Transactions, 1909.
' fTEscHENTSCHEB, R.— "Electrical Power Problems in Steel Mills."
' I. E. E., Transactions, 1909.
Henderson, C. T.— "Electrical Control of Rolling-mill Motors." A. I. E.
, Transactions, 1909.
Gasche, F. G.— "Interaction of Fly-wheels and Motors when Driving Roll
•ains by Induction Motors." A. I. E. E. Transactions, 1910.

1293
lU
 . 1

Sec. 15-262 industrial motor applications

Sykes, Wilfred.— "Electrically Driven Reversing Rolling Mills." A. 1.
E., Transactions, 1911.
Sykes, Wilfred. —"Power Problems in Steel Mills." Iron & Steel Mil
Electrical Engineers' Association, Proceedings, 1912.
Sykes, Wilfred. — "Operation of Large Electrically Driven Reversini
Mill." A. E. E., Proceedings, April, 1912.
Meyer, F. W. and Sykes, Wilfred. — "Economical Speed Control of Indue
I.

tion Motors Driving Rolling Mills." A. E. E., Proceedings, November, 1912.

Sykes, Wilfred. — "Power Requirements of Rolling Mills." A.
I.
E: E. I.
Proceedings, November, 1912.

CEMENT MILLS
BY CHESTER W. DRAKE
General Engineer, Weslinghouse Electric and M anufacturing Co., Member
American Institute of Electrical Engineers

PORTLAND CEMENT MANUFACTURE

262. Materials. The necessary ingredients, lime, silica and alumina, an
generally obtained from two raw materials, in one of which the lime pre
dominates and in the other the silica and alumina. The materials used ii
this country are: (a) cement rock and limestone; (b) limestone and shal(
or clay; (c) marl and shale or clay; (d) blast-furnace slag and limestone
About 80 per cent, of all Portland cement is made by combinations (a) an(
(b). The process using combination (c) generally employs the wet or slurrj
system of grinding, since the marl is dredged from swamps or underwater.
263. Process. Briefly stated, the process of manufacture consists ii
reducing the raw materials to a fine powder, mixing the ingredients in tht
correct chemical proportions aa shown by analysis, burning to a clinker
and again reducing to a fine powder which is Portland cement. In a mil
using the dry process, the buildings, departments and machines are arrangec
in approximately the following order, although there are many different type
of machines in use to do the same work.

Departments Machines

Quarry.. . Hoists, air compressors, pumps.

Raw mill. Crushers, dryers, intermediate grinders, automatic
scales, fine grinders.
Coal mill Crushers, dryers, fine grinders.
Kiln building. . . Kilns, blowers or fuel feeding apparatus.
Clinker storage. Cranes, cableways, conveyers.
Finishing mill. . Intermediate grinders, fine grinders, or pulverizers
Packing house. Automatic sacking machines, conveyers.
Also numerous elevators and conveyors in all departments.
264. Power requirements. Extensive tests and investigations hav
shown that the average power demand per bbl. of cement per day depend
on many items, but is usually within the limits of from 0.75 h.p. to 1.5 h.i
at the switchboard. On this basis the energy consumption will be from 13.
to 27 kw-hr. per bbl. Even with energy at 1 cent per kw-hr. it will b
seen that the cost of energy is a very large part of the total value of th
cement, which, for the United States in 1917 averaged about $1.35 per bb
at the mill. In 1917 about 93 million barrels of cement were manufacture
in the United States, although the capacity of the kilns installed is aboi
50 per cent, greater. A total capacity of more than 400,000 h.p. of electr:
motors is installed in cement plants and the percentage of electric pow(
used is rapidly increasing and is now about 75 per cent. With the exceptio
of the quarry and the crushers, and sometimes the coal house, all of tl
machinery in a cement plant is in continuous operation and at a nearly coi
stant load; the load factor would be very nearly unity were it not for the;
portions of the plant, and is often from 80 to 85 per cent., based upon tl
ratio of average to maximum demand.

1294
 INDUSTRIAL MOTOR APPLICATIONS SeC. 16-265

26S. Waste heat boilers. One

most recent economies effected
of the
in cement production is the utilization of the exhaust gases from the kilns
for the generation of steam. Specially designed boilers are installed to
utilize the gases from one or more kilns according to their size and arrange-
ment. Experience has shown that in a mill using high efficiency prime
movers the waste heat will supply approximately enough steam for the entire
power equipments. A small steam boiler reserve is usually necessary to
take care of variations in kiln operation or power requirements. The instal-
ation of waste heat boilers eliminates practically all coal used for power
purposes with the result that the total coal used per barrel of cement is
•educed from 30 to 50 per cent.

S66. Motor characteristics. Induction motors either of the squirrel-

•,age or slip-ring type are used in practically all new installations, but syn-
;hronous motors in the larger sizes are used to a limited extent to give power
actor correction. The simplicity and ruggedness of the squirrel-cage motor
nakes it admirably adapted for the severe and dusty service of cement mills,
^he bearings should be made dust proof. Ball and tube mills and others
i similar characteristics are very diflncult to start, and motors for such
pplications should have a starting torque of not less than twice the value
f full-load torque. When synchronous motors are used for such drives
.•iction clutches are required, but other types of motors should be designed
{i meet the conditions. Slip-ring motors are often used for large gyratory
rushers, tube mills and other machines when the power required exceeds
pproximately 200 h.p., on account of the large starting current required by
juirrel-cage motors. Speed variation is often desirable on kilns and dryers
id such requirements are readily met by the use of slip ring motors with
isistance designed for 50 per cent, speed reduction.

, 267. Jaw crushers are often used for secondary crushing, or upon
uinker, and the following are typical ratings.

Jaw Crushers —Blake Type

Capacity per hr. Driving pulley
• ..• of according to size
jaw
Weight of Horse
)pening
crusher
Rev.
power
(lb.) Diam.i Face (aver.)
(in.) Tons In. Tons In (in.) (in.)
per
min.

'X 7 7,550 2i! 1 24 71 250 7i

' 30 250 10
15X 9 12,000 16 '

li 8i
20X10 21,500 38 19 36 13. 250 20
UX15 38,000 60 25 42 16i
I 250 25
i6X24 68,000 130 70 Pulleys to 250 75
t2X40 130,000 225 130 suit con- 250 100
iOX48 205,000 290 180 ditions 200 150
;4X60 400,000 450 11 280 100 200

Champion Crushers (American Road Machinery Co.)

Size of Tons per hr. Driving pulley

jaw Weight of
according to Horse
crusher Rev.
opening material and Diam. Face power
(lb.) per
(in.) I

feed (in.) (in.)

min.

7iX13 5,500 8 to 12 38 8 170 12

9 X15 8,800 12 to 18 48 9 155 15
10 X20 12,500 16 to 24 50 10 150 18
11 X22 12,000 18 to 26 48 9 160 20
11 X26 20,000 24 to 35 60 n 140 25

# 18 X50 60,900 70 to 100

1295
72 12i 105 50 to 60
Sec. 16-268 INDUSTRIAL MOTOR APPLICATIONS
268. Gyratory crushers. The following table gives the ratings of Gatei
crushers; other makes of similar size have approximately the same powe:
requirements.

Gates Gyratory Crusher — Style "K"

Capacity per Driving pulley

Size of Weight of hr. in tons
Size
openings breaker Horse
(2,000 lb.) Rev.
no.
(in.) (lb.)
,

varying with Diam. Face

power
per
material (in.) (in.)
min.

8X30 22,000 15 to 40 32 400 14 to 21

10X38 32,800 30 to 70 36 375 22 to 30
12X44 48,000 60 to 90 40 350 28 to 45
7i 14X52 68,000 80 to 120 44 350 50 to 75
18X68 103,000 130 to 150 48 350 70 to 1 10

21X76 155,000 250 to 300 56 300 100 to 150

Several larger sizes are manufactured

269. Rotary dryers. For the average size of dryer, 5 ft. diam. by 5(
or 60 ft. long, revolving at 2 to 5 rev. per min., from 10 to 20 h.p. is required
This varies with the construction of the dryer, the method of the drive an(
the speed of rotation.
270. Ball mills

Gates BaU Mills

Weight Cap. on Portland

Size without Weight of charge
cement clinker to
Horse
charge of of balls (lb.) power
20 mesh
balls (lb.)

7 ! 29,500 3,000 12 to 16 bbl. per hr. 30 to 40

8 j
41,100 4,500 18 to 24 bbl. per hr. 40 to 50
The F. L. Smidth Co. Kominuters are similar to ball mills, and the thre
sizes, No. 53j, 66, and 88 require approximately 30, 75 and 100 h.r
respectively.
271. Williams mills. These are of the swinging-hammer type, and ar
made in various modifications for pulverizing coal, clay, clinker, etc. Th
ratings of the coal and cement crushers are as follows:

Coal crushers

Pulley dimen.
Size no. Rev. per min. Horse power
(in.)

20X15 1,000 20
20X15 1,000 30
20X15 1,000 50-60
24X18 1,000 75
24X20 1.000 100
30X32 750 250

Cement grinders
 INDUSTRIAL MOTOR APPLICATIONS SeC. 15-272

272. Type of drive. For satisfactory service and long life, a motor
should not be subjected to severe vibration. Either belts or flexible coup-
lings are able to absorb the vibration of the grinding machinery, but the dust
causes rapid deterioration of belts and, therefore, the best practice is direct-
connection wherever possible. The countershafts of ball and tube mills
rotate at about 180 rev. per min. and, on 25-cycle circuits, motors at this
speed may be direct connected throught flexible couplings. Motors should,
whenever possible, be placed in a separate room, the shafting extending
through into the mill proper. For Fuller, Griffin, or other vertical-shaft
mills, special belted vertical motors can be obtained which are more satis-
factory than horizontal motors with quarter-turn belts.

273. Kent mills. This mill (made by the Kent Mill Co.) is in very
extensive use both a.s an intermediate and a fine grinder. Being of the
roll and ring type it can be started with comparative ease, and a 40-h.p.
motor is usually supplied to drive the mill with its elevator and screen.
The pulleys on the mill are 36 in. X8 in., and 64 in. between centres, running
at about 200 rev. per min. Motors with double-extended shafts make a
simple and satisfactory drive.
274. Tube mills of 5, 5.5, 6 and 7 ft. diam. by 22 ft. long are now in
common use in cement mills. The required power varies with the charge of
^pebbles and the feed, but with flint pebbles averages 100, 125, 150 and 200
h.p., respectively, for the above mills. The present day tendency however
is toward larger mills requiring 300 to 500 h.p. For belt drive, motors
from 480 to 690 rev. per min. are used, while for coupled drive 160 to 180 rev.
per min. is customary. The F. L. Smidth No. 16 and 18 tube mills are
usually driven by 100-h.p. and 150-h.p. motors, respectively. When
"cylpebs" (short cylindrical pieces of steel) are added to a tube mill the
power required is increased 20 to 30 per cent.
27B. Fuller mills. The Lehigh Car Wheel & Axle Works have on the
market three sizes of Fuller mills, known as the 33 in., 42 in. and 57 in. The
smaller mill is used principally for coal, while the two larger sizes are adapted
io pulverizing either raw material or clinker. The power requirements are
ijiven in the following table.

Pulley
Size of mill (in.) '
Horse
Diam. (in.) Rev. per power
max. Face (in.)
min.

33 45 12 210 25-40
42 54 18 160 7.5-90
57 75 23 130 150-200
ertical belted motors make the best drive for the.se mills.
276. Oriffin mills. These mills which are of the vertical type are manu-
ictured by the Bradley Pulverizer Company. Since the driven pulley is
bove the mill they are often driven in groups, but individual drive with
ertical belted motors is desirable especially for the larger sizes of mills.

Pulley
Type of mill Horse power
Diam. (in.) Rev. per min.

Junior Giant GriflSn I 30 190-200 30-35

Giant Griffin 42 160-170 75-85
Bradley 3 Roll 42 160 50-60
Bradley Hercules '

72 125 250- 300

277. Bonnotpulverizer. Although this is a vertical mill, it has a

nzontal pulley running at about 215 rev. per min. Only one size of mill
manufactured; this requires from 75 to 85 h.p. Either a belted or a
upled motor may be used.

1297
Sec. 16-278 INDUSTRIAL MOTOR APPLICATIONS
278. Aero pulverizers. These reduce crushed coal to an impalpabl
powder, and blow it into the kiln, mixed with the correct amount of air fc
combustion.

Aero pulverizers
 INDUSTRIAL MOTOR APPLICATIONS SeC. 15-284

:
mining machines are in use to-day, and many new types are being developed.
'The particular design of machine which should be used to meet a particular
set of conditions, can be determined only by experience.

884. For auxiliary power outside of the mine (Par. 296), such as
jower for shops, pumps, etc., steam engines have been largely used; and to
iubstitute an electric motor is usually a comparatively simple matter.
; 285. Safety specifications. Various countries and each of the mining
itates of this country have mining codes which deal with the manner of
nstalling electrical apparatus in mines and give general safety rules. The
lest reference for Rules for installation of electrical equipment in mines is in
1 ?echnical Paper No. 138 issued by the U. S. Bureau of Mines.

ENEBQT SUPPLY
286. The generators are generally of the direct-current, 250-volt or 500-
olt types. These generators should be compounded about 10 per cent., and
hould be capable of withstanding momentary overloads of from 50 to 100
'
er cent. Standard machines are built for 225-volt to 250-volt service, for 250-
olt to 275-volt service and from 500-volt to 550-volt service. The higher
oltage of 500 has an advantage over 250 volts in that very much less copper
needed and greater distance can be covered. The danger is, however,
'
msiderably greater, and many states are legislating against the use of over
"" vnlts underground. Compounding is desirable due to the long lines
tre required in reaching the workings. The type of load is such that
short-time peaks frequently occur.
287. Predetermination of generator capacity. When a mine is small
id electricpower is used for only one or two locomotives, the capacity of
le generator will be determined entirely by the peak loads. For instance,
the load were to consist of two 10-ton locomotives each having two 50-h.p.
otors, the conditions will be as follows: 1-hr. rating of motors, 200
p.; continuous rating of motors about 80 h.p.; maximum load with both
. comotives starting 300 h.p. To compensate for the line drop and efficiency,
I
kw. should be allowed at the switchboard for every horse-power at the
achine.
be seen from the above that on a heating basis, an 80-kw. generator
It will
n be used. This machine, however, could not take care of a load of 300
f. The generator should have a capacity of not less than 150 kw. If
1 second-hand generators and engines are installed, it will be necessary to
ovide for a capacity of from 200 to 250 kw., as there would be a lack of
erload capacity. The efficiency of power generation will not be very high,
.ce the unit will be carrying a small load a considerable portion of the time.
.:cellent examples of load diagrams showing the low average and the high
ik loads obtained at a coal mine power plant are shown in a paper presented
fore the A. I. E. E., April, 1913, by Wilfred Sykes and Graham Bright.
If we were to add to the above a third locomotive, a pump load of 50 h.p., a
I load of 50 h.p., and a cutting load of four 26-h.p. cutters, we would
ve the following conditions:
Dne-hour rating of motors 300 50 -f- 50 -f 100 = 500
-f-
Continuous rating of motors 120 50 -f- 50 -|- 40 = 260
-f-
Vlaximum load of 400 50 + 50 4- 100 = 600
-|-

'^or the maximum locomotive load, two locomotives can be considered as

irting, each developing 150 h.p., and one running taking 100 h.p. There
''1,no doubt, be a diversity among the machines, so that the actual peaks
'I not be over 550 h.p. The generator capacity should be 300 kw., pref-
tbly divided between two umts of 150 kw. each. From these figures it
V be seen that, for the larger plants, the generators can be operated more
i.rly at their continuous capacity.
U larger mines, or where one company operates a group of mines, a central
Sirnating-current generating system is frequently installed. Energy is
derated at 2,200 volts, 3 phase, 60 cycles, and is either transmitted to sub-
s ions at 2,200 volt.s, or stepped up to 6,600 volts or 11,000 volts. Motor-
aerator sets or rotarics are used at the substation to transform the alter-
Ding current to direct current. Motor generator sets can be readily over-
^ipounded if desirable while rotaries are best operated flat compound. In
dsrmining the capacity of the central plant, the machine and line losses
Dit be taken into account in determining the size of the main generating

1299
Sec. 15-288 industrial motor applications
units. These losses will average from 15 to 20 per cent. The capacity
the central plant will not be the sum of the individual substations, as thei
will be considerable diversity. The diversity factor will range from 1.2 ;

1.5 to 1.
288. Design and advantages of mines using purchased energi
When central-station power is used, the power application is very much sir
plified. For haulage, cutting and in.side pumping, a motor-generator a
or synchronous converter is used. The motor-generator sets are generally I

the synchronous type, owing to the power-factor correction which can )

obtained with the synchronous motor. This high power-factor will con
pensate for the lower power-factor obtained on the induction motors us<
for driving fans, pumps, and tipple or breaker machinery. The substati'
can be a very simple structure and, in a great many cases, the old generati)
room can be used. The care of a substation is an extremely simple matt
when compared with an isolated plant. For fans, compressors, outsi
pumps, tipple and breaker machinery and machine or blacksmith shop driv
the squirrel-cage motor is best adapted, as regards first cost and upkee
This apparatus can be operated at all times independent of the motor-genei
tor set which, in many cases, operates only 8 or 10 hr. per day.

MOTOR CIRCUITS
289. Permissible voltage drop for haulage, gathering and cutti,
(for good operation), should not exceed 20 to 25 per cent, at maximum lot.
290. Diversity in peak-load calculations. See Par. 287. Wh«
several locomotives and cutting machines are supplied from one feeder, t
maximum load is obtained by estimating the number of machines that m;
be running at one time. It is seldom that two locomotives will start at t
same time where only three or four are in use. In practice, a locomotive wj
not operate at full-load more than one-fifth of the time. The same is truei
mining machines, and the maximum load should be estimated from the to^
conditions that exist at each mine.
291. Construction methods and costs.* Trolley and feed wire slmi
be installed in a substantial- manner and protected from contact with mi
mules at cross-overs. The total cost, including labor and materi
erecting a 0000 trolley wire in an anthracite mine will range from $ I

11,400 per mile, and from $650, to $900, in a bituminous mine, depi huj
upon the nature of the roof. Outside of the mine, the cost per mile *i
range from $1,200 to $1,600. Number 0000 feed wire will cost, erected, fr<:
S900to $1,200 per mile inside of the mine, and from $1,100 to $1,500 outsii
of the mine for an anthracite mine. The cost of 0000 feed wire in a bitumint'
mine will be about the same as for the trolley wire. The rail return is g»
erally much neglected. The bonding should be frequently checked '"'fi
bond-testing instrument and cross bonds should be installed at aboii
200 or 300 ft. All switches, frogs, and cross-overs should be bonded
and cross-bonds should be placed on each side. Any water, or air ,,.
should be well bonded to the rail, especially near the main entrance, in om
to obtain the benefit of an extra return circuit and to prevent electrolyii
The total cost of bonding a track (rails varying from 30 to 50 lb. j
yd.) with No. 00 bonds including cross-bonding, will be about $.'550 ;'

mile, including labor and material. The total cost using No. 0000 hot
will be about $400 per mile. Electrically welded bonds are proving vi
superior to the compressed or soldered bond and in many cases are \\
expensive to instal. 1

The haulage and cutting circuits should be kept separate where pnsml
but should be arranged to connect together in order to help out one an'
•

emergency cases. In the larger mines, the feeders can be separated i

that local line trouble will not shut down the entire mine. However, i

large mines, it is the practice to connect everything solidly, and in

trouble the circuits are held closed and the source of trouble remo
literally burning it out.
292. Lighting circuits both inside and outside are generally tak'
the haulage or cutting feeders. Incandescent lamps for either 110
volts are used, with as many in series as necessary.

* Based on 1915 prices; add 50 per cent, to above figures for 1922.

1300
 INDUSTRIAL MOTOR APPLICATIONS See. 15-293

, MOTOR APPLICATIONS
t
893. Compressor motors. See Par. 174 to 192. Where compressed air
hs used, motor-driven compressors can be applied to advantage. For small com-
pressors, the best type is that used by street railways for suppljang compressed
air for brake systems. For larger compressors a synchronous-motor drive
'

smost used because of the high-power factor obtainable thereby. Com- _

.jressor motors are often operated at 80 per cent, leading power-factor in order
,0 compensate for the lower power-factor due to the induction motors which
ire used to drive fans, pumps and tipple or breaker equipment. With a syn-
;hronous motor drive, an unloading device must be used on the compressor;
his prevents the motor from being loaded untilit has reached synchronous speed.
S94. One great advantage of electrically driven air compressors i s
t'vt they can be installed at the most convenient location. Small auxiliary
ressors can be easily located inside of the mine at the end of long pipe
where it is difficult to maintain normal pressure.
235. Types of adaptable motors. For tipples, breakers and shops,
oiisiderable power is often required for crushers, screens, elevators, washers
ml machine tools. When direct current is employed, a compound-wound
r is best adapted, and is sometimes built totally enclosed in order to

the efTects of coal dust.

:
The motors should be continuously rated,
load is fairly constant. A shunt- wound motor is best adapted for shop
i>es, as its speed is more nearly constant under varying loads. When
is purchased, all outside motors can be of the alternating-current type,
at the motor-generator sets, or synchronous converters, need only eup-
V the haulage, cutting, inside lighting and pumping. Where very heavy
arting loads obtain, the wound-rotor induction motor with drum type
nrroller should be used. Where only moderately heavy starting torques
iiuired, the squirrel-cage motor is best adapted. The rotor characteris-
this motor will depend upon the character of the load.
: This is by far
luplest and most rugged motor built, the control also being very simple.
starting requires a low torque, alow resistance end-ring can be used;
•

high starting torques are required, a fairly high-resistance end-ring

•

!'l be used. The cast end-ring has solved all end-ring troubles which
>! once so prevalent.
296. Pumping. For inside pumping the reciprocating duplex or triplex
imp is most used for the smaller sizes. The centrifugal pump is not so
II adapted for moving about and for use under various heads. The capac-
.•
of the motor can be readily determined by the amount of work to be
't'.o, assuming an efficiency of 50 to 60 per cent, for centrifugal and 70 to

' per cent, for reciprocating pumps. See Par. 155 to 173.
297. Ventilation. Mine fans are inherently low-speed machines and are
ry well adapted for direct connection to a steam engine. For economy in
~t cost and operating cost an electric motor is inherently a high-speed,
irhine, usually requiring some speed-reducing device in such an application.
,
king seems to be the most popular method, although gearing, chain drive.
d even rope drive, are used occasionally. See Par. 193 to 212. A. C.
!uirrel cage motors for small fans and woundrotor motor for large fans
most popular. The synchronous motor is being proposed and will no
'

^ubt find many applications.

298. Machine mining. Pick mining is a rather slow and laborious proc-
of mining coal, although a large portion of the coal is still mined by this
thod. Machine mining has become a necessity owing to the increasing
nand for coal and the limited supply of labor. Punchers and chain
two types generally used. Punching machines were
chines are the
driven by compressed air, and most of the mach nes of this type are
t
•'
operated in this manner. The electric puncher consists of a motor-
1

<ven compressor attached to the cutting mechanism, so that compressed

f really is used to
operate the puncher. This machine has the advantage
< ilectric transmission, but is heavier and more expensive than the straight-
'nmcher.
e chain machine is the most, rapid of all mechanical cutters. The
cutter will require a motor having an intermittent rating of from 20 to
1

ii.p.^while the pneumq-electric machine will require a motor rated from

to 15 h.p.
i
As a rule direct-current compound-wound motors are used to
rate coal-cutting apparatus.
'
Alternating-current motors are being intro-

1301
 J!

Sec. 16-298a industrial motor applications

duced for both punching and cutting machines and have been very succes
ful. They, however, require a separate power circuit consisting of two fe«
wires with track return. They possess the advantages of simplicity of coi
struction and less danger of the workmen coming in contact with live part
298(a). Loading Machines. —On account of the high cost and scarcity
labor the Loading Machine is being rapidly developed.
(

These inachini
require about three men to operate and will load 100 to 400 mine cars pi
day. The power equipment is generally direct current consisting of 2 or
motors having a total horsepower rating of about 75 on the larger machine
LOCOMOTIVES
299. LocomotlTes for main haulage and gathering are of the direc
current type, designed to operate on 250- or 500-volt circuits. The serii
type of motor is invariably used as it has the best speed-torque cha;
acteristics for the service. The service is somewhat similar to street-rai
way conditions and the same general methods are used to determine th
weight and capacity of the equipment.
Mine locomotives are built in weights ranging from 4 tons to 35 tons an
gages ranging from 18 in. to the standard of 4 ft. 8.5 in. The wheels ma
be cast iron with chilled tread, steel tired, or rolled steel. Gathering locc
motives are built to replace mules; these weigh from 4 to 8 tons with equij
ment varying from two 10-h.p. motors to two 40-h.p. motors.
300. Locomotive-adhesion and weight calculations. The cast-ire
wheel will afford a running coefficient of adhesion of 20 per cent., and
starting coefficient of 25 to 30 per cent, when sand is used. The steel-tire
or rolled-steel wheel will have a running coefficient of 25 per cent, and
starting coefficient of 30 to 33.33 per cent, with sand. The above figxiu
are conservative and can be easily obtained with fair rail conditions. Tl
weight of locomotive is determined by the following formula:
T{30+20G)+20GW = 'iOOW. for cast-iron wheels,
= 500 IT. for steel wheels. i

Where T = weight of trailing load in tons. The item 30 is the friction in It!
per ton for the trailing load on the level and is the average value obtain^
by test for small mine cars. The expression 20O is the pull necessary i;

overcome gravity, G being the grade in per cent. W

= weight of locomoti^i
in tons. The item 400 '•

20 per cent, of 2,000 lb. f*

75 cast-iron wheels. The ite
600 is 25 per <:ent. of 2,0(;
lb. for steel wheels.
A margin over 20 and i
per cent, for starting wit
sand is available to take ca;
of the extra tractive effo
necessary for acceleratiti
the load and locomotiii
when starting. See Sec. Ij
301. The track-cun
resistance can, as a rul
be neglected, since tl'
length of the average mil
trip is many times that •,

any the curves.

of Ft'
gathering, the curves mi
have a vital influenci
general, each 1 deyi
curvature adds i lb. per
'

tlie friction. The ability of a locomotive to negotiate a curve depends upt

the wheel base and size of wheel. The curves of Fig. 38 show a minimu
radius of curve that any locomotive with a certain wheel base and size
wheel can negotiate. These values are conservative and are based on stam
ard wheel flange and track play. With a liberal spread, the value of whe
base can be safely increased from 25 to 50 per cent.
302. Braking. In some cases the problem of braking becomes mo'
important and the weight of the locomotive is determined by its ability 'i

1302 j
 INDUSTRIAL MOTOR APPLICATIONS See. 15-303

bold back a loaded trip on a certain grade. If a runaway would result in

ierious damage, then a smaller coefficient should be assumed than would be
ippropriate for pulling a load up a grade. With cast-iron wheels the coeffi-
jient for braking should not be over a value from 15 to 18 per cent, and for
iteel wheels 18 to 20 per cent. Care should be taken that wheels do not be-
;ome too hot; this may break a cast-iron wheel, or cause a steel tire to slip,
i^or retarding a trip down a grade, the formula of Par. 300 will be changed to:

fTC20G - 20) + 20G W = (300 to 360) W. for cast-iron wheels,

= (360 to 400) W. for steel wheels. •
803. The friction of the average mine car is about 30 lb. per ton. New
ars in good condition may have a resistance very much less than 30 lb., but
he friction increases with the age of the car, and may reach 40 to 50 lb. per
"n Roller bearings when kept in good condition will have a fairly low
iuce, but unless good care is taken of them, their frictional resistance
we rapidly.
304. Selection of proper rail weight. For each given weight of rail
Mil' is a corresponding maximum weignt of locomotive which should not be
'iceeded for satisfactory operation. The following table has been prepared
y the Baldwin Locomotive Works and represents the best modern practice.

If a heavier locomotive is desired than is shown in this table, taudem units

e often applied.

305. Bating of locomotive motors. Although the niotors of a mine loco-

otive are given a 1-hr. rating, it is the average heating that determines
e capacity for all-day service. This heating is proportional to the square of
e current. The average of the square of the current will give a squared
lue, the square-root of which is really the capacity of the motor for all-day
ryice. This value is known as the square-root of the mean-squared current.
is obtained by finding the different values of the current for one motor
roughout a round trip. These current values can be obtained from the char-
iteristic motor curve of the particular motor used. After the weight of the
•omotive has been determined, one of the standard motors for this weight is
fed and calculations made to determine if it is of the proper capacity.
ital tractive effort per motor is determined for each grade, allowing 20
• I

!ier ton for the friction of the locomotive. For each total tractive effort
; current and speed are obtained from the curve, and the time is calculated.

squaring each current value and multiplying by the time, we have the
•

in of the products of various squared values of the current, multiplied by

time.
! This summation should be increased by from 5 to 10 per cent, to
ke allowance for acceleration and switching movements at each end.
'
e final value is then divided by the total time, and the square-root ex-
Ipted. The characteristic curve gives the continuous current capacity,
'ich can be compared with the final result obtained. t Where the exact
editions are not known, as is generally the case, the common accepted
1 ctice is to allow 10 H.P. per ton weight of locomotive. This question
s uld however be checked since the real capacity of a locomotive is the
otinuous rating of the motor and a motor of poor design may have a high
c> hour rating and a low continuous rating.

The car friction should be taken at 20 lb. for descending trips.

For a more detailed explanation of the determination of weight and
•'
ipment of a mine locomotive see article. Electric Journal of March,
1:^, entitled "The Determination of Weight and Equipment of a Mine
Lomotive," by Graham Bright. (This article gives an example with com-
Pe set of calculations.) Also see Coal Age, issues of March 6 and March
2 1915.

13(»
AWM
 1

Sec. 15-306 industrial motor applications

306. An electric reel is sometimes applied to a Rathering locomotive i

that it can be taken into rooms where no trolley wire is erected. This re
may be chain driven from one of the axles or motor driven from a smj
independent special motor which maintains a constant pull on the cabi
This cable may be single-conductor or double-conductor, depending up<
the track conditions. A No. 4 A. W.G. cable is generally used.
307. A traction reel can also be .supplied on a gathering locomotive,
consists of a small motor-driven crab with from 300 to 400 ft. of steel cabl
This type of reel is used where the room grades are very steep, and arc drive
to the dip.* I

308. The storage battery locomotive is used extensively in gatherii

^ service. There are three types of storage batteries available which a
satisfactory for application to locomotives. These types are the EdisC
alkaline, the ordinary lead acid battery and Iron-Clad ll)xide type MV let
acid. The overall efficiency of conversion of the electrical output at tl
battery terminals to the mechanical output at the wheels will vary fro
60 to 72 per cent. Assuming the overall efficiency to be 67 per cent,, tl
watthours per train-mile is equal to the product of the total tractive effo.
times three (.w.h.p.t.m. = TE X 3). The tractive effort can be calculatf]
by assuming the frictional resistance of the cars to be 30 lb. per ton, and
the locomotive, 20 lb. per ton, making a further allowance of 20 lb. per ttj
|

for each per cent, grade, if any grades are involved. To estimate the liuf te;
capacity required for a given service, the entire haulage should be subdividi
into as many sections as there are different characteristics. By calculatii
the tractive effort and distance for each section, the watthours for each se.
tion can be obtained from the formula mentioned before. The summati('
of the watthours of all the sections will give the watthours of total batte:'
capacity required for the service. The proper battery may be selectij
from the storage battery manufacturer's tabulated data. If the man'
facturer's data specify the rated capacity in ampere hours, the ampere-ho'
service capacity may be obtained by dividing the calculated watthoj
capacity by the average voltage of the battery, assuming the average servi'
discharge voltage of an Edison battery to be 1.1-volts per cell and of a lei
battery 1.95 volts per cell. The Edison battery is rated on a 5-houi d
charge basis and the Philadelphia and Iron-Clad Exide batteries on a (i Im.
discharge basis. Where the total elapsed time of discharge is not lef<> 1

six hours, the rated capacity of a lead battery will be available for !-'

Great care should be taken in making Storage Battery Locoi

applications and itwill be found that many storage batteryapplicatious
have been trolley type. (Refer to Article on Storage Battery appUrin
to be printed in Coal Age in near future by M. F. Packard).

BIBLIOGRAPHY
309. Selected list of reference literature.
—
Bright, Graham. "Does it Pay the Average Coal Mine to Pui
Central Station Power?" Proceedings, American Institute of EUm rri>
Engineers, April, 1012, p. 737.
—
Bright, Graham and Stkes, Wilfred. '* Mining Loads for Central Si
tions." Proceedings, American Institute of Electrical Engineers, April '."
—
Eddy, H. C. "Purchased Power in Coal Mines." Proceedings, An,
—
Institute of Electrical Engineers, April, 1913.
Warren, H. M. and Bieseckeb, H. S. " Characteristics of Sul)>
Loads at the Anthracite Mines of the Lackawanna R. R. Co." Proci
American Institute of Electrical Engineers, April, 1913.
Beerb, C. W.— "Central Station Power for Coal Mines." Procev
American Institute Electrical Engineers, April, 1913.
—
Bright, Graham. "Determination of Weight and Equipment of a Mi
—
Locomotive." Electric Journal, Vol. VIII, p. 986.
Eaton, G. M. "Weight Equalization on Locomotive Wheels." /

Eaton, G. M. — "Weight Transfer in Electric Cars and Locom-

Journal, Vol. VII, 943.
p.

Electric Journal, Vol. VIII, p. 257.

* Additional information regarding gathering locomotives can be obt:

from articles printed in the Electric Journal, Vols. VIII and IX, by G.
Hamilton.

1304
 INDUSTRIAL MOTOR APPLICATIONS SeC.15-310

Hamilton, G. W. — "Electric Mine Haulage." EUclric Journal, Vol.

Ill, p.
Hamilton, G. W.
939.
—"Gathering by Electric Mine Locomotives." Electric
ournal. Vol. IX, p. 756.
Hamilton, G. W.-—•"Locomotives for Electric Mine Haulage." Electric
IX,
ournal. Vol.
Bright, Graham.— "Determination of the Weight of Mine Locomotives,"
p. 706.

Age, March
Bbight, Graham. — "Determination of the Equipment for MineLocomo-
oal 1915, 407. 6, p.

ves". Coal Age, March 20, 1915, 490. p.

Brioht, Graham. — "Designing An Electric Hoist to Meet the needs of a
Dng Mine Slope." Coal Age, May
Bright, Graham. —-"Determination 1920. 6,
of Electrical Equipment for a Mine
oipt." Transactions, A. I. M. & M. E., Sept., 1921.
REFRIGERATING PLANTS
BY AUGUSTUS C. SMITH
[ Member A. I. E. E.
Sales Engineer, Buffido General Electric Co.,
^310. Motors adaptable to refrigerating service. Ammonia compress
and auxiliary apparatus in refrigeration plants may be driven either
3
direct-current motors or by alternating-current motors. The flexibility
'
speed control of the direct-current motor offers an advantage, but the
issibilities of speed control of the induction motor together with the char-
teristic advantages of this type are sufficient reasons to justify its selection
'lere alternating current is available. If variable speed is not required,
^achronous motors may be used.
Sll. Motor speeds and speed controL Motors for the operation of
" 'lia compressors should be of the variable-speed type, so that where the
"

ng conditions require it, suitable speed control can be secured. Com-

^ of 50 tons capacity, and over, are operated usually at about 70 rev.

i.iiu., so that a belted motor of 500 rev. per min. or less, is desirable.
leii the compressor is of high speed type the motor can be direct connected .

112. Multispeed motors. With the two-speed motor, the compressor

operated at full speed and at half speed; while with the three-speed
it can be operated at full speed, two-thirds speed and one-third speed.
(thod of speed control, however, provides for changes in the com-
~>nr at fixed and predetermined steps only, and does not, therefore, pro-
I

e for the flexibility in speed control necessary to meet the usual require-
"

ints in the operation of refrigeration machines.

13. With the
slip-ring type of motor and resistance speed control,
1 operation equivalent to that of the steam compressor is attain-
ibility of
' The power-factor of this motor remains practically constant at all
>.

'-
hut the efficiency falls off with the reduction in speed; operating the
-sor continuously, at reduced output, with this type of motor, is there-
I'conomical from a power-consuming standpoint.
Plant duplication. In plants where it is necessary materially to
he output, during certain periods of the year, it is desirable to employ
t

wian one compressor unit. This is especially true in large refrigeration

pits, where the total compressor capacity should be divided among indi-
vual units, properly proportioned according to the required operating
C'litions.
16. The
standard rating for ammonia compressors is based on
I'b. suction pressure, 185lb. condensing pressure, and condensing water
BO deg. Fahr. (21 deg. Cent.). The power necessary to drive a compressor
Vies directly with the operating pressure, the horse-power being determined
b.ndicator card.
.-6. Power requirements per ton. Ammonia compressors operated
8.*5 lb. suction pressure and 185 lb. condensing pressure, having a rated
tficity oyer 5 tons of refrigeration per 24 hr., require about 1.5 h.p. per
tcof refrigeration; compressors having from 5-ton to 1-ton capacity, oper-
Jb under like conditions, require from 1.5 h.p. to 2 h.p. per ton. Increasing
tbibove pressures to 25 lb. suction, and 200 lb. condensing pressure, would
"I'ase the power necessary to operate the compressor about 16 per cent.
,7. Varying pressures and output requirements. In the daily
OEations of a refrigerating plant, it is frequently necessary to operate a
tsjressor at increased pressures. In some localities during warm weather

1305
Sec. 16-318 INDUSTRIAL MOTOR APPLICATIONS
the temperature of the condensing water will exceed 70 deg. Fahr. (21 deg!
Cent.), and during extremely warm weather it may be necessary to force the
compressor beyond its rated capacity in order to meet unusual requirements.,
all of which require increased power. For compressors of 50-ton rated capac-;
ity and smaller, about 25 per cent, additional motor capacity should be
provided for these possible excessive operating conditions; for larger com-;
pressors, from 16 to 25 per cent, additional motor capacity should be pro-
vided, depending upon the local and probable operating conditions of the
plant.

818. Classification of ice-making plants. Ice-making plants may be

divided into two classes: those making ice from distilled water, and those
making ice from raw, or natural water. The former method uses the can
system, while the latter may use either the can system, or the plate system.
The compressor-room equipment for an ice plant of equivalent capacity is
the same for all of these methods, except for the plate system, where about
15 to 20 per cent, more compressor capacity is required.
319. Operating data on 90-ton can-system ice plant using distilled
water

Month
 INDUSTRIAL MOTOR APPLICATIONS SeC. 16-321

321. Operating costs of plant using can system. The average con-
sumption of power in this plant (Par. 311) was 44 kw-hr. per ton of ice, while
the other items of expense were: engine and boiler room labor per ton,
31 cents; fuel per ton, 19.50 cents; tank-room labor per ton 25.10 cents.
322. Equipment of plant using plate system. While the compressor-
room equipment in both distilled-water plants and raw-water plants is
practically the same, the auxiliary equipment differs, depending upon the
type of plant, and the system used. The auxiliary and tank-room equipment
of a raw-water plate plant electrically operated, and having a rated capacity
of 100 tons of ice per 24 hr., may be taken as an example. In this plant all
the motors are of the 3-phase, 25-cycle, 220-volt, induction type. A centrifu-
gal condenser-water pump, direct-connected to a 6-h.p., l.SOO-rev. per min.,
constant-speed motor is used to supply excess water to the condenser in hot
weather, when the natural flow of city water supply is insufficient. A brine
pump, belted to a 2-h.p. 750-rev. per min., constant-speed motor is used to
circulate warm brine around the plates in order to loosen the ice. A rotary
blower, belted to a 7.5-h.p., 750-rev. per min., constant-sj)eed motor is used
Ho agitate the water in the tanks. The rest of the equipment consists of 3
cranes, each equipped with one 5-h.p. and one 3-h.p., 750-rev. per min.,
variable-speed motors; 2 tilting tables, each geared to a 2-h.p., 1,500-rey.
per min., constant-speed motor; 1 30-in. circular ice saw, operated by chain
'drive from a 3-h.p., 1,500-rev. per min. motor; 1 ice elevator, operated by
and geared to a 3-h.p., 1,500-rev. per min. motor.
323. Extracting the lifting rods, in the plate system. After the
plates of ice have been placed upon the tipping table, the ends of the lifting
rods (which extend about halfway through the plate) are connected to the
secondary terminals of a 1-kw. transformer, having a 220-volt primary and
i 4-volt, 250-amp. secondary. In about 4 min. after the current has been
;urned on, the rods will be melted loose, and can be readily withdrawn.
324. Centre-freeze system. The can-system raw-water plant, fre-
luently referred to as the "centre-freeze" or "core" system, undoubtedly
presents the ideal of an electrically operated ice-making plant, as it has all
,he advantages of the can system, together with the productive economy
)btained through the use of raw water. In brief, this type of plant consists
)f stationary cans, fed from the bottom, with raw water supplied through a

pooling tank. During the period of freezing, the water in the cans is con-
tantly agitated by a jet of air under a pressure of about 3 lb. per sq. in. The
vater freezes in the cans from the sides toward the centre, so that the space
ontaining free water and all the impurities is gradually diminished. When
his space has reached a very small area, all the water remaining, with the
mpurities contained therein, is drawn off, and the core is filled with distilled
vater; this, when frozen solid, gives a cake of very clean pure ice.
325. Auxiliary equipment of a 60-ton plant using the centre-
reeze system. A 1 5-h.p. motor is belted to the line shaft, which in turn
rives the following: 1 fan having a capacity of 500 cu. ft. per min., which is
sed for agitating the water in the freezing cans; 1 centrifugal pump having
capacity of 200 gal. per min., which is used in pumping the brine through
he cooling or supply tank; 1 air compressor having a capacity of 40 cu. ft.
er min., used to operate overhead cranes which are employed in removing
he ice from the cans; 1 7.5-h.p. motor direct-connected to brine agitator,
'he distilled water used is furnished from a 10-h.p. boiler operated at from
to 15 lb. steam pressure.
326. Operating data on plant using centre-freeze system. The
rst complete month's operation of the above plant showed a total maximum
emand of 125.8 kw., with an energy consumption of 91,056 kw-hr., and a
roduction of 1,599 tons of ice. This is equivalent to a resultant maximum
emand of 2.42 kw., or 3.24 h.p. per ton of ice, and 57 kw-hr. per ton of ice.
387. Domestic refrigerating equipments in their completed form, as
laced on the market are in reality a self-contained refrigerating plant,
specially adapted for use in homes, restaurants, butcher shops, clubs and
jartment houses, or where the average requirements may run from 10 to
)0 lb. of ice per hr., or the refrigeration effect equivalent to the melting of
om 15 to 100 lb. of ice per hr. The universal method of drive is the elec-
ic motor which may be of any type, either belted, geared or direct con-
,;cted, depending on the type and speed of the compressor used.

1307
Sec. 15-328 industrial motor applications

These equipments are operated on the compression system using sulphur-'

dioxide (SOs) as the refrigerant which condenses at a relatively low pressure.
The complete equipment consists of a compressor, condenser, brine tank'
and automatic temperature control, the principal element being the com-*
pressor which is either of a reciprocating or rotary type; in the case of the
latter it consists of a pair of herringbone gears running in oil which eliminates
i

the use of suction and discharge valves and permits of a direct connected,
motor.
The temperature is regulated by a thermostat, located in the refrigeratori
food compartment, which controls the motor switch. It is customary to-J
set the thermostat for about 45 deg. fahr. (7.2 deg. cent.) to be maintained!
in the food compartment, when the temperature rises above this, the motor)
switch is closed and the condenser set in operation, continuing to run until
the temperature is reduced to that of the thermostat setting when the motor-
switch is opened.
328. Hating and operating characteristics of domestic refriger-.
ating equipments, when operated under average conditions of brine at
27 deg. fahr. (—2.8 deg. cent.) and condensing water (at outlet) at 77 deg.
fahr. (2o deg. cent.). '
 INDUSTRIAL MOTOR APPLICATIONS SeC. 15-332

and as textile mills, owing to their liigh capital costs, require a high rate of
production, they should be provided with auxiliary steam plants capable of
carrying the whole load, even though the water power has a good record for
dependability.
332. Use of steam in textile processes. Nearly all textile mills must
use steam at some point in the manufacturing process, and for heating the
I
buildings in winter. A boiler plant is therefore essential and it generally
follows that one or more engines are employed to deliver their power to the
1 water-wheel shaft, the engine governor caring for the variations of load. In
such cases a portion of the steam power may be developed by simple engin*
operating against small back pressure, the exhaust instead of live steam
'
being used for certain processes; or steam may be taken from the receiver, if
1
a compound engine is used. If turbines are the prime movers, the bleeder
type may be used to furnish the necessary amount of low-pressure steam.
In cotton mills the most common use for steam (aside from heating buildings)
. is in the slashers, which require a small amount steadily through the day.
Woolen and worsted mills use steam for scouring, drying, back washing and
•
combing. Finishing mills, which may form a part of either cotton or woolen
mills, use steam for numerous purpcses such as heating water, rolls, plates,
etc.
333. Application of electric drive. Existing water wheels and steam
engines can be made to drive generators, and even though the units are
scattered, the control may be from a central point. In general the loada
in textile mills are steady, and there should be close speed regulation. Elec-
tric drive is in general superior from the standpoint of .speed regulation,
aside from the advantages of flexibility and cleanliness.
334. Group and individual drives. In all kinds of textile mills anything
that scatters dirt, lint, flecks, etc., becomes more of a nuisance as the goods
produced become finer, for the finer textures reveal the foreign substance
more plainly, and, being imperfect, are less valuable. In determining,
therefore, whether to use individual drives or group drives, the presence of a
belt becomes a deciding factor.
336. Type of motor adapted to textile mills. While for many reasons
the direct-current motor meets the demands of the textile mill, the presence of
more or less lint in the air makes the induction motor preferable. At the end
Df a day's run individual machines are disconnected from the drive, so that
their motors will have but small starting loads; usually the totally enclosed
iquirrel-cage type is well adapted to the work. To eliminate a possible varia-
tion of speed dependent upon variable slip, a group arrang 'ment may be
.employed where the constituent machines are either little affected by smajl
changes in speed, or have constant loads. It is well to use only enclosed oil
iwitches. Inasmuch as starting conditions are favorable there is often oppor-
unity to u.se synchronous motors, if the power-factor is low, either on the
ame line-shaft with squirrel-cage motors, or in separate units.
336. Cotton-mill cards may be run in groups, belted from above or below.
337. Cotton-mill fly frames arc driven from one end and may be so
r.rranged that by means of extended shafts and two pulleys on each end of the
;notor, four frames may be driven by one motor. As these machines can be
topped individually, doffing and empty bobbin replacing may be accom-
lished without stopping more than one frame at a time. Ring spinning and
wisting may well be treated similarly to fly frames, although here again
adividual motors may be used.
338. Looms are perhaps the most susceptible to power variations
f any textile machinery. The power to drive a loom varies with the
peed of the loom, usually expressed as so many picks per min., a
ick being one strand of filling left in the warp by a traverse of the shuttle,
i^hile there are so-called positive shuttle looms, most shuttles are thrown
ioross the lay of the loom by a blow of the picking stick. As the shuttle
Iters the box at the end of its traverse, it pushes out one side of the box,
iUed the swell, which operates a stop motion; when the shuttle does not
Toperly enter the box, the swell is not displaced and this is called "banging
3. The speed of the shuttle must therefore be suflScient to accomplish
us, yet not so much as to cause rebound. The adjustments vary with the
)eed. The power to drive a loom also varies with the weight of goods, the
;at-up, the number of harnesses and boxes in use.

1309
 .. . ;

Sec. 15-339 INDUSTRIAL MOTOR APPLICATIONS

339. Advantage of motor drive for looms. Overhead shafting a;
belts are objectionable on account of the damage likely to occur from flyi
slugs, oil, etc. As looms must be stopped and started continually, and
they start under full-load immediately, belts in weaving rooms require mu
attention if high efficiency is to be maintained. The shafting can be p
below the fJoor, and long lines reduced by group drives, but the belt frc
shaft to loom remains. The individual motor obviates practically all
these troubles. It may be arranged to drive through a cluoch or be gear
directly to the loom. In the first case the motor is kept running all the tin
tvhile in the second case it is started and stopped with the loom. The shipp
handle of the loom is connected with the control switch of the motor, so thi
the operative has nothing new to learn. A
direct-connected motor mui
start instantly with full-load torque. The induction motor with small si'
has, then, an advantage over belted drives in cleanliness and in consta
speed. Variations in angular velocity are undoubtedly less in the ca
of direct electric drives than with belted drives, as shown by tachoiuet
readings.
340. Power requirements for cotton-mill machinery.
Spindles per li.

Gins saw 10 saws per 1 h.p Intermediate

Gins roller 40 in 1 25 to 3 h.p . Fine (roving)
Bale opener 2.0 to 3 h.p Jack (fine) 1
Hopper feeder 1 50 to 3 h.p .

Thread extractor. ... 2.0 to 4 h.p Spinning-frame warp, IC's and

Single cylinder beater 3.0 to 4 h.p coarser spindles per h.p
Two cylinder beater. 6.0 to 8 h.p 22
Top flat card. 0.20 to 0.33 h.p
. . 40
Revolving flat card, 40 in. 60
Production per hr. 80 11

7 lb 0.75 h.p.
9 lb 1.0 h.p. Filling
12 lb : . . 1.25 h.p. Spindles 8,500 rev. per min. ,.

Sliver lapper 1.0 h.p. Spindles 9,700 rev. per min. ^

Ribbon lapper 1.0 h.p.
Comber, 6 heads 0.50 h.p. Twister sp. per h.p. 6,500 r.p.m.
Comber, 8 heads 0.75 h.p. Filling winder sp. h.p 3
Railway head 0.33 h.p. Spooler 200 to 3J
Drawing frame, 1 head. . . 0.25 h.p. Mule 100 to i:
Drawing frame, 5-head Warper h.p .

metal rolls 1.0 h.p. Denn warper 1 . (

Drawing frame, 6-head Bailer h.p O.J

plain rolls 1.0 h.p. Slasher (drum) h.p 1 .'.

Plain loom narrow light 0.1

Speeders, Spindles per h.p. Fancy loom wide heavy 1 .(
Coarse 30 Reel 50 sp l.(
Intermediate 42 Brush and shear 3 .
i

Fine 48 Folder O.i

Slubber fly-frame; spindles per
h.p 50
341. Automatic loom economies. It should be remarked that
the increase of automatic looms the necessity for frequent stopping and
ing decreases. Automatic looms have increased production from, pa-
per cent, to 95 per cent., or even 98 per cent., but as yet they are not genera'
used except by plain-goods mills. However, their use in fancy-goods mil
is increasing.
342. Woolen and worsted mill drives. Scouring bowls, which cv
to considerable length, are satisfactorily driven by several overhead ni<
These rooms are damp and the air is vapor laden. Pickers and card.-s i:-
be driven in groups. Mules are usually set in pairs, and one motor may driv
each pair. Combs, gill boxes and roving machinery, whether for Bradfor
or French systems, may be driven in groups. Cap, ring or flyer spinniu
frames may be arranged as for cotton ring frames, that is, four frames ma
be driven by one motor. '

343. Manufacture of woolen and worsted yarns. Both woolen an

worsted yarns are supposedly made of wool, but other fibres are often mixe;.

1310
 INDUSTRIAL MOTOR APPLICATIONS SeC. 15-344

with the wool. In general, woolen yarn is made of short fibre and worsted
of long fiber. Furthermore, in woolen yarn the fibres are made to lie in a
variety of angles with reference to the axis of the yarn, for ultimately the
fabric is fulled or felted. The finisher card doffs narrow strips of the carded
fibre, passing them between rub rolls or aprons (or tape condenser), which,
while carrying the roping along, rub it into cylindrical shape. Forty or
more of these ends are wound on jack spools and are made into yarn by the
mule. The tendency of the mule is to throw one end of each fibre to the out-
i
side of the yarn, while holding the other end in the centre, that is, the shap>e
'
of the fibre is helical.
» With worsted, the fibre is combed after carding, to remove the short
' fibres or noil. Then follow the processes of gilling and drawing, each of
I which makes the fibres more and more parallel, just the reverse of the woolen
^ process. The Bradford worsted system converts the roving into yarn by
* means of the spinning frame, either cap, ring or flyer. The French worsted
= system starts with the "top," essentially the sliver, carded, combed and
gilled, wound into about 8-lb. balls. There is no twist in the sliver, and
by the French process no twist is put in until the final or spinning process.
;5 In this case a mule is used which is much like the cotton mule, which keeps
If the fibres smooth and parallel.
'' 344. Power requirements of woolen-mill machinery.
! Cone duster, h.p 7.0 Cards 48-in. h.p 5 to 8.0
Wool and waste box duster Back washer h.p 3.0
h.p 3 to 5.0 Double bailer gill box 2.0
'^ Scouring bowls per bowl 3 to 5.0 Weigh box 2.0
*
Apron dryer 10.0 Noble comb 2.0
"Stone dryer, 15 ft 14.0 Intersecting gill box per head 1.0
; 18 ft 15.0 Etirage, 10 porcupines 3.0
'''i-
21ft 17.0 Reunion, 12 porcupines 3.0
j
48-in. mixing picker 10.0 Chute, 24 porcupines 3.0
!^48-in., 3-cyl. set cards to Bobinier intermediate,
_
40
start 4.0 porcupines 2.5
Running on light work. .. 2.5 . Avant finisseurs, 50 pore. 2.5
Heavy work 8.0 Finisseurs. 2.5
''60-in., 3-cyl. set cards. 10 to 15.0
. French mule spindles per h.p. 50.0
'Mule 300 sp. 2-in. gage to Cap and flyer spinning (Brad-
! start 5.0 ford system) spindles per h.p. 50
Running
\
2.5 Shoddy pickers 7 J to 10 h.p.
I'jarge mules 7.5
S46. Power requirements of finishing' machinery.
, >6-in. double shear 3.5 Raw stock dyeing machine.
Measuring, doubling and 1,000 lb. batch _. . . 3.0
winding 0.75 Raw stock dyeing machine,
:'wo-cylinder gig 4.0 400 lb. batch 2.0
0-in. 36-roll napper 7.5 Hosiery dyeing, 200 lb., 400
2-in. 20-roll napper 6.5 lb 1.0
kein dyeing machine, 1501b. 2.0 Roll dyeing knit cloth, 4
batch strings. 1.0
kein dyeing machine, 400 lb. Roll dyeing knit cloth, 20
batch 3.0 strings 3.5
PAPER AND PULP MILLS
BY JOSEPHH. WALLACE
Industrial Engineer,Member, American Society of Mechanical Engineers
346. Qeneral application. Motors are generally well adapted for driv-
B,pulp- and paper-making machinery where the source of power is steady
id reliable and will insure continuous operation of the plant. The choice
the grouping method (group drive), or the assembling of several machines
be driven by one motor through shafting and belting, and the unit method
ulividual drive), or the driving of each machine by its individual motor,
11be determined by local conditions of layout and the probability of one or
ore machines in a group requiring operation while others in that group
"^""ut down. Where machines can be assembled in groups that are easily
by short lines of shafting, the grouping method is more often to be
•ed. The motor units then become larger, and being fewer in number,
1311
 '

Sec. 16-347 INDUSTRIAL MOTOR APPLICATIONS

installation and maintenance costs are reduced, and speed reductions ar

more easily secured without the use of countershafts or gears. The uni
method is preferable in case of large machines or where direct-connectei
apparatus can be used, and in places where points of power demand ar,
scattered and would involve long lines of shaft to group the machin*
together. It affords convenience in locating machines in places desirabl
from the operator's standpoint, and is preferable where individual control oj
machines is frequently required. j

347. Equipment adaptable to motor drive. In the equipment «^

paper and pulp mills specially suited to motor-drive can be included the foi
lowing; flat and centrifugal screens, stuff pumps, suction-box pumps, whit«j
water and effluent pumps, water-supply pumps, winders, rewinders, cutteri,
refining engines, elevators, exhaust fans, koUergangs, agitators, mixer^
slushers, concentrators, savealls, wet machines, rotary digesters, rotar^
boilers, conveyors, shredders, chippers, supercalenders and beaters. ^

348. Jordan engines. The application of motors for driving Jorda:

engines is very successfully accomplished by direct connection. The motc!
is mounted on an extension of the Jordan base, and mechanical arrangement
provided for the movement of the Jordan plug either by a coincident niov<i
ment of the motor, or by a special form of coupling connecting the mote.
with the Jordan shaft. In the refinement of paper stock much depends upo'
the pressure put upon the Jordan plug as it rotates within its shell or casinj
The power required is influenced by the pressure applied, and a good indict'
tion of what the refiner is doing is presented by the readings of a wattmet*.
placed in the feeder circuit to the motor. When power-factor correction
necessary or desirable, the direct-connected Jordan engine presents an exoe:
lent opportunity for attaching a synchronous motor large enough to proviC'
for the required condensing effect. Jordan engines are started without tl
working load applied, and the friction load is usually within the capacity <

self-starting synchronous motors.

349. Beaters. The question of driving beaters and other large uni
electrically will be largely affected by the elements entering into the generi
tion of energy. Beaters are usually grouped, and driving can be economicall
accomplished through main line shafting. Considerable quantities of pow<|
are required within comparatively narrow limits, and conditions are ofte:
in favor of steam engine cirive instead of motor drive, where the power can b:
developed in eflScient slow-speed compound condensing steam engines loca*e^
in close proximity to the beater room. This method is especially favoraM
where electric power is generated with steam-driven equipment. Mil
deriving electric power from hydroelectric plants can usually adopt the m
'

drive for beaters with success.

360. Fourdrinier and cylinder paper machines that require v:i
speed, and steam for drying purposes, are driven best by variable
steam engines, using the exhaust steam for drying the paper. Pulp gi i

are seldom driven by electric motors; the power requirements are s^

that the method almost invariably accepted as the best is to attaili t!
grinders direct to a water-wheel shaft.
361. Types of motor suitable. In general polyphase alternaiin
current (induction) motors give the best satisfaction in pulp and paper ni
service where constant speed is desired. In ca.ses where variable speo<ls n
required from the same motor, or where smooth and even acceleration
desired in starting, as in the operation of supercalenders, direct-curni
motors can be employed to advantage. In other cases the alteriKitin
current motors will be lower in first cost, more reliable for continue
operation, and lower in cost of maintenance. It is possible to use raoi
higher voltage with alternating current than with direct, resultinj;
reduction in cost of transmission and distribution circuits. Indj
motors wound for 2,200 volts a'.% frequently used in units of 75 h.p. and
For smaller size motors. 440 volts is usual and for lighting 110 volts
generally accepted standard; 5.50 volts is quite as common and is cons
more desirable than 440 by the author. Step-down transformers are c
ient for lowering the voltage, and require a minimum amount of atti
^

Three-phase alternating-current has been found to be most adaptable t^

era! uses in paper-mill work. With unity power-factor, the amount of c<n'V
required for distribution of energy will bo about 25 per cent, less than
th

1312
 INDUSTRIAL MOTOR APPLICATIONS SeC. 15-352

required by direct-current of equal voltage. The absence of commutatora

on inductiou motors is a decided advantage from an operating standpoint;
and where slip-ring induction motors are provided with brush-lifting and
short-circuiting devices, the element of fire hazard due to arcing disappears.
A frequency of 60 cycles per sec. has been generally adopted as standard
'

in the United States and Canada for paper- and pulp;mill practice, although
'
25 cycles is sometimes used where considerations outside the influence of the
pulp- or paper-mill proper demand attention; 50 cycles is the accepted stand-
[ard in Great Britain, and in some of the European countries.
) 362. Motor characteristics. Induction motors with short-circuited
irotors of the squirrel-cage type can be well recommended for most applica-
itions to paper-mill machinery where the units require a small amount of
power, ordinarily under 50 h.p., or in larger sizes when the motor can be
started and brought up to full speed under a light load. The starting of
large squirrel-cage motors draws heavily on the supply lines, and the selection
of large units of this type of motor should be influenced by the size of the
power-plant supplying energy to such motors. Unless the generating plant
capacity compared with the size of the motor units to be started,
.has large
.the heavy draft of energy will lower the voltage sufBciently to affect other
inutiirs that may
be in operation. In order to overcome the limitations of
MiuiTel-cage motors in tne larger sizes, motors of the wound-rotor or slip-
ins type may be
used. These are desirable when motors require starting
inilur full-load,when the units are large, or when automatic or remote control
.1 motors necessary.
is Synchronous motors are desirable in cases where the
uciuired starting torque is low, for the beneficial effect that they have
II the power-factor; when of larger capacity than the actual require-
iients for power, they can be used to raise a low power-factor. They are
iiitable for direct-connection to Jordan engines, and for motor-generators,
lit full consideration must be given to the available generator capacity

upplying them, as their starting characteristics are similar to those of the

(uirrel-cage induction motors.
353. Switching equipment should be selected with great care, and
luturs should be provided with some form of automatic protection against
verload. Fuses are often found to be unsatisfactory, and in large sizes
re expensive for renewals. Oil-immersed switches fitted with overload and
>w-voltage release are much preferred for pulp- and paper-mill installations.
354. Specifications for motors to be used in pulp and paper mills should
111 for heavy-duty machines. Form windings are to be preferred and in
I'iirrel-cage motors special attention should be given to the method of
itaching the rotor bars to the short-circuiting rings. Moisture-proof
isulation in windings is important. Motors should be rated for a tempera-
iie rise not exceeding 40 deg. Cent. (104 deg. Fahr.) for continuous opera-
,on and be capable of carrying 25 per cent, overload continuously without
ijurious heating.
395. Standardization of sizes, speeds and types is to be recommended
n a considerable number of motors are required in the same mill. Stand-
' ttion will result in reduced number of repair parts and will often facili-
the interchange of motors in case of repairs.
356. Power required by paper- and pulp-mill machinery will vary
irough wide limits, oftentimes on the same machine. This is especially
ue in the case of beaters and Jordans, when a variety of product is made in
-ame mill. Loads will frequently vary 100 per cent, in the treatment of
imt stocks, and the most careful judgment is required in the selection
jtors that will meet the maximum demand, as this condition may exist
much longer periods than the overload capacity of a motor for the average
id would allow.
357. Power required by the constant line, operating in connection
th a 104-in. Fourdrinier machine (Fig. 39). Power input was derived
im wattmeter in feeder line to motor.

B.h.p. (motor
'Tiput
Amp. per
Power-factor efficiency,
phase [

90 per cent.)

0.87 78.4 h.p.

1313
Sec. 16-358 industrial motor applications

Fig. 39.
—
A 100-h.p. three-phase induction
motor, 330 rev. per min.
F — Agitators machine sti''
chests.
B — 16-in. by 18-in. vacuum (suc- G — Fourdrinier shake
tion box) pump.
C — 14-in. by 12-in. vacuum (suc- H— 6-in. centrifugal for baj
tion box) pump. water.
D— 8-in. fan pump (stock to screen). J— Three 12-plate screens.
E— 10-in. by 10-in. triplex stuff K— Rotary vacuum pump
pump. suction couch roll.

A — 50-h.p. three-phase induction D — Centrifugal pump.

motor 570 rev. per min.
—
B Three 72-in. wet machines. E — Two 10-plate screens.
—
C 14-in. by 12-in. vacuum pump.
368. Testong70upof wet machines (Fig. 40). Machines in operation .

one wet machine, two screens, vacuum and centrifugal pump.s and shaftii j

Power input derived from wattmeter readings in feeder line to motor.

Table of load variations

Kw. Amp. per

Volts
Power- B.h.p. (motor
input phase factor efiBciency, 90 per cent.

18.0 43.0 440 0.55 21.7 h.p.

27.0 45.0 440 0.79 32.5 h.p.
29.0 46.5 440 0.82 35.0 h.p.
33.5 51.2 440 0,86 40.4 h.p.
36.0 53.8 440 0.88 43.4 h.p.

1314
 INDUSTRIAL MOTOR APPLICATIONS SeC. 15-359

369. Test on Jordan engrine (Imperial size) direct-connected to 100-h.p.

induction niotor. Full-load speed 330 rev. per min.

Kw.
input
 Sec. 16-364 industrial motor applications

ELECTRIC DERRICKS AND EXCAVATING MACHINERY

BY GEO. B. MAgSET
Consulting Engineer, Member A. S. C. E., Member A. S. M. E., Member
Western Society of Engineers
ELECTRIC DERRICKS
364. Derricks. Electric winches for derricks usually are driven by onej
motor for hoisting the load, hoisting the boom and for swinging. Some-
times the swinging is done by a separate motor.
[

365. Derrick motor sizes. For this service, electric motors are used!
running at 1,200 r.p.ui. in the case of the small motors and as low as 450i
'j r.p.m. in the case of the largest mol'ors. Alternating-current motors are oft
the slip-ring induction type, the direct-current motors being either series orj
compound wound. The range of sizes is:

Derrick size, tons . . .

 INDUSTRIAL MOTOR APPLICATIONS SeC. 16-371

ELECTRIC DREDGES
371. Hydraulic dredges. A typical dredge has a centrifugal pump with
20-in. diameter single suction and 20-in. discharge. The diameter of shell
and runner is made to suit the maximum total head pumped against. The
velocity in the pipe line is 12 ft. per sec, for ea.sily transported material and
as high as 16 and 18 ft. per sec. for heavy material containing flat stones.
The percentage of solids pumped varies from 5 per cent, to 20 per cent.,
depending upon material and distance pumped. The pump is direct con-
nected to a 750 to 1,000 h.p. variable-speed induction motor; synchronous
speed 360 r.p.m., slow speed 270 r.p.m. The winch with five drums is
driven by a 25 to 50 h.p., 600-r.p.m. variable-speed induction motr with
75 per cent, speed reduction. The cutter head driven by a 75 to 150 h.p..
600 r.p.m. variable-speed reversible motor. The motors are supplied with
2,200-volt, 3-phase, 60-cycle energy transformed from higher voltage on board
the dredge.
372. Dipper dredges are very similar to shovels except that they have
30 thrusting action and the digging cycle is longer. Very few electrical
;ypes are in use. The motor and control equipment is similar to that used
)n shovels. The backing line to the dipper is operated by an independent
notor or by the hoist motor. Provision is made for raising spuds and
'pinning up" by power.
373. Clamshell dredges. There are very few electrically operated
lamshell dredges. The stresses can be calculated exactly as they are lim-
ted to hoisting and swinging the loaded bucket. One type, has the swing-
ng circle and hull equipped so that it can be pinned up on spuds, the other
vith wide enough hull to roll with the load, the hoisting line swinging the
'lOom to one side and the bucket-opening line swinging the boom to the other
Side. The motor equipment and control are similar to those for shovels.
374. Bucket ladder dredges are used mostly for placer gold, tin and
latinum mining. Electricity is the ideal drive. The energy consumed per
ubic yard, excavated, washed and stacked varies from 1 to 1.75 kw.h.
'he usual equipment is 440-volt slip-ring induction motors. The digging
lotor is connected to the bucket drive by two belts and a jackshaft to take
,ae digging shocks off the motor. All motors except pump motors are of
pe variable-speed type with secondary resistance for continuous operation
|om 50 per cent, to full speed.
375. Motor sizes for bucket ladder dredges
*^
Sec. 15-377 industrial motor applications
lessexpensive than the mill motors, are also successfully used, but the ave
age variable-speed motor has not the mechanical strength required by tl
severe service rnet in shovel work, and has too much fly-wheel effect to secu:
the rapid starting and stopping desired.
377. Shovel motor sizes
(Bucyrus Co.)

Type of shovel
 INDUSTRIAL MOTOR APPLICATIONS SeC. 15-381

Three systems are employed on the larger electric shovels, both railroad
type and revolving type (Par. 381 to 383).
381. Direct-current motors with rheostatic control. Direct-current
motor equipment is used with rheostatic control, low-voltage direct current
power being supplied to the shovel through flexible cables from an outside
source. This method of operation is well adapted to meet conditions where
the scope of operation is small and direct-current power is already available.
382. Direct-current motors with motor-generator set. Direct-
current motor equipment is used, low-voltage power being supplied by motor-
generator sets or synchronous converters located on the shovel, power being
supplied through flexible cables from a two-phase or three-phase alternating
current power system at 2,000 to 5,000 volts.
Where synchronous converters are used, control must be by rheostat
only. By the use of motor-generator sets these conditions are removed
and it is possible, by using a number of direct-current generators driven
by one alternating-current motor, to use Ward Leonard or field control,
thus eliminating rheostatic losses and securing several desirable operating
characteristics.
The motor-generator set consists of an alternating-current moror dri\'ing
one hoist, one swing and one thrust generator and one constant-voltage
generator for exciting the other generators and the alternating-current
driving motor if it should be a synchronous machine. The shunt fields of
the generators are regulated to vary the speed and torque of the shovel-
driving niotors. No resistance is used in connection with the motors for
reducing the voltage. Equipment of this kind may be operated at reduced
capacity, even with very poor supply, with either rheostatic or field control.
-By the use of the field control system, it is practicable to operate a large
shovel from a relatively small system without objectionable effect on the
!voltage regulation.
Where there
is any doubt as to the capacity or the quality of power serv-
should be investigated before purchasing electric shovels.
ice, this
383. Alternating-current motors with rheostatic control.
'
Two-
'phase or three-phase alternating-current motor equipment with rheostatic
leontrol is employed. Low-voltage alternating-current is supplied to the
'jhovel through flexible cables from an outside source.
'' This method is suitable where the scope of operation is small and Icw-
^ivoltage current is already available. It is also suitable for contractor's
HTork where the presence of high-voltage flexible cables might be objection-
ible. This same equipment may be used in connection with transformers
Bounted on the shovel, alternating-current pow'er being supplied at 2,000
'.o 5,000 volts through flexible cables.
This is undoubtedly the best solution of the problem on large operations
vith an adequate power supply. The
apparatus used is rugged and simple,
- )eing easily understood by the average
operating man. It has the minimum
lumber of rotating units and no commutators.
Another method is to use an alternating-current motor driving a single
;. lirect-current generator. Constant voltage is maintained at the generator
nd resistance is used in series with the hoist, the swing and the thrust
i

..yiiotors. This machine is less efficient than the others because it has both
jb»»QOtor-generator set and rheostatic losses. It has been given up largely in
iftavor of the field-control machine.
-I' 38i. Type of control. Regardless of which plan of electrification is
sed, the control is generally of the unit switch type except on very small
[

-? bovels. These unit switches niay be operated by compressed air or by

glenoids. The air-operated control is the most compact, rugged type and
'cupies less space than the magnetic type. The unit switches are controlled
y master controllers located conveniently for the operator. These may
arranged so that all operations are controlled by one operator or two
'

iirators, as desired.
385. Limitation of motor torque. A motor, being capable of sustain-
g large overloads, would cause an abnormally large amount of mechanical
pairs on the shovel if its torque were not limited. The safe overload
paoity of a motor large enough for the drive is beyond the overload capac-
')f the shovel consistent with good operation. This is due to the fact
' for continuous operation of the shovel the continuous rating and not
^overload rating, determines whether or not the motor is large enough.

1319

ii
Sec. 15-386 industrial motor applications

With rheostatic control, the motor torque is limited on the hoist, should
the dipper strike harder material, by "jamming" relays which open th«
accelerating switches, thus inserting resistance in the circuit aud holding
the torque below predetermined maximum at any speed. In this manner
the shovel operator retains control of the motor, and its torque is not inter
rupted, nor is time lost, as would result if a circuit breaker were dependec
upon. Accelerating relays are used to limit the accelerating peaks of all
motors.
With the direct-current field control shovel, where a separate generato|
supphes each shovel motion, the overload is Umited by using a differential
compound-wound field in the generator.
386. Special features. On the large electric machines, the dippers ar<
dumped by small torque motors instead of by hand, as on steam shoveb
With the exception of the smaller machines, the brakes for stopping an<
holding the various motions are air operated and automatically controlled
The smaller sizes of machines usually take the current aboard at less tha:
600 volts, and the larger sizes at the higher voltages, 2,300 and 4,000 voltf
With the higher voltages, the ground cable is usually of the armored three
conductor type. Cable reels are sometimes used on the machines.
387. Regenerative control is used on some of the 300-ton shovels whe
the dipper dumps at a height of 60 ft. above the surface upon which tli
shovel stands.
388. Choice of equipment. The proper equipment to use will depenj
almost wholly upon local conditions. Motors are usually geared to shov^
mechanisms in such manner that they will operate continuously over j
given cycle without overheating. When geared in this way, the motors a
'

usually operating at a very small percentage of their maximum torqB

usually under 50 per cent., due to their continuous rating. Either with ti
direct-current series motor or with the alternating-current phase-wourt
motor, a surplus of power is always available for exceptionally hard diggini
389. Reliability. Little consideration should be given to the relati\.
efficiencies of the various kinds of electrical equipment for shovels; first, bi
cause the difference is small, and second, it is negligible when compared to tl
expenses due to delays inherent in shovel operation, such as waiting for ca:
and mechanical repairs. Reliability is the most important consideration.
390. Power supply. In most cases, the power source is alternating cu
rent, and the choice of electrical equipment will depend on the size of tl;;
generating station, power factor and peak loads, especially where purchasti
power is to be considered.
Where a large shovel is to operate from a small generating station, ar
where consideration in the rate schedule is given for high power factor or
penalty for poor power factor, the field-control shovel should be used wit
a synchronous motor driving the motor-generator set, since the 'oad coia|
on gradually as compared to the resistance-controlled machine, thus pK
mitting better voltage regulation for lighting customers. This is due to ii
fact that the input to the motor builds up from practically zero at standrt
to full value with generator field control, whereas with resistance contaj
the input is at full value immediately when the motor is connected tot
line, even though the motor is initially at standstill and its power outp
nothing. The field-control equipment, being more expensive than resistail—
control, is for that reason limited to the larger machines which may cau
more disturbance on the power lines.
BRICK MANUFACTURE
BT C. W. PENDELL
Engineer, CotUract Dept., Public Service Company of Northern Illinois; Fell(^
American Institute of Electrical Engineers
391. General arrangements. Brick-making plants vary conside;
in their arrangements, depending largely upon the raw material used M
whether raw material is quarried upon the property adjacent to the mai^
facturing plant or is delivered by railway from a distant point. i

392. Raw materials. Various raw materials are used for various styl;
of bricks, as noted in Par. 393 to 396. Brick-making clays, shales, et
vary greatly in their natures and the individual raw material to be US'
should be carefully studied, analyzed and experimented with by an exp<i
U320
 INDUSTRIAL MOTOR APPLICATIONS Sec. 15-393

in ceramics to determine the proper working method of drying, temperature

and duration of burning, etc., before the manufacturing plant is designed.
393. Common clay is used mainly for common building brick. It comes
to the manufacturing plant in a semi-plastic condition and requires only to
be thoroughly mixed, tempered (moistened when too dry; dried by the addi-
tion of dry clay, when too moist), and have all stones removed before being
ready for the brick-making machine.
394. Shale is used for face brick and other high-grade building brick.
It comes to the plant in a lumpy, dry, medium hard condition that at times
I requires crushing, always requires grinding, moistening and thorough mixing.
396. Refractory rocks used for bricks for furnace linings. Manufac-
turing plants are seldom located at the point where raw material is quarried.
Rock is given a preliminary crushing at the quarry and is shipped to the
manufacturing plant, where the first operationis crushing to the size desired by
!
grinders. The method of grinding varies with the rock used and results
1 desired; some rocks are ground dry and others are ground wet. These
. bricks are usually molded into shape on account of the abrasive nature of the
material.
396. Silica sands used for bricks for furnace linings. They are given
thorough drying and mixed with some sort of a binder, molded into shape
and dried. The power demands are small in comparison to other classes
of brick.
397. Stripping and digging. Brick plants using a common clay as a raw
material are usually located adjacent to the pit from which clay i.s obtained.
In such plants the digging and handling of the clay furnishes a problem all
its own, being divided into "stripping the "over-burden" or black dirt
from off the top of the clay deposit, digging the clay and loading it upon cars,
and hauling the cars to the foot of the incline leading to the manufacturing
plant.
Stripping can be accomplished with the greatest ease and least cost by
means of a "drag line" type of excavator (Par. 369). Digging the clay
requires a shovel type excavator (Par. 376). Although both of these types
I
of machines have failures charged to them in attempted electrification, both
of them have been successfully motor-driven and there is no reason with
present-day developments for not using motor-driven machines; the troubles
of the past have been due mainly to lack of attention to details of control
apparatus and ventilation of motors.
Both of these loads are severe on the source of power and the source must
be able to stand the load fluctuations that will be imposed upon it. Both
ilternating-current and direct-current equipments have been built, one
maker favoring one and another the other. The simplicity and ruggedness
)f the alternating-current equipment, however, is somewhat in its favor.
Motor-driven excavators and shovels are more economical than steam-
Jriven machines on account of lessened amount of time out of ser^^ce for
•epairs and the high cost of getting coal and water to steam machines. The
vater around such a plant is usually very hard and boiler repairs are fre-
.{uent and eostly on that account, as well as on account of excessive vibration
>f the machine. It will be found to be false economy to purchase too small
* excavators and shovels, with consequent poor results due to machines too
mall for the work.
398. Clay haulage. The haulage of clay cars from the shovel to the
Manufacturing plant is done in places by means of electric locomotives, both
rolley and third rail types, but in small and moderate size plants a steam
linky locomotive usually works out to best advantage on account of the
hifting of tracks as tne cutting face changes, unevenness of ground, numer-
us spur tracks, etc. In larger size plants and in those where the clay pit
5 a half mile or more from the manufacturing plant, electric haulage works
ut advantageously. Local conditions must govern as to whether 250-volt
irect-current trolley, 250-volt direct-current third rail, or 440- volt alter-
ating-current three-phase trolley shall be used, considering carefully the
zard to workmen and mules, interference with digging shovels, initial
-t, cost of shifting, location of tracks, frequency of track changes, main-
lunce, etc.
399. Pit drainage. The average clay pit has a water problem, which
ariesfrom getting rid of small amount of seepage water, to the emergency
andling of flood water. This is a standard water-pumping problem in

1321

liik^
Sec. 16-400 INDUSTRIAL MOTOR APPLICATIONS
which high-speed centrifugal pumps direct-connected to squirrel-cage,
alternating-current motors with moisture-proof windings outclass all other
methods. A sUmp is located at a convenient point and a motor-driven
pump, or pumps, are installed so as to take water from this sump. Each
pump should have its own suction pipe equipped with a foot-valve. It isl
important to place a check valve adjacent to the pump, at the bottom of thei
discharge leading away from the pumps, to prevent water hammer bursting!
the pumps at time of stoppage.
400. Manufacturing plant. All brick-making machines are slow mov-|
ing and require relatively high torque on the clay-handling element. Ea
granulator, pug mill, battery of dry pans and augur brick machine requi]
an operator and the machines require frequent starting and stopping
account of uneven flow of clay through various units, so that it is commfl
practice to equip each of these machines with a friction clutch under contr
of the machine operator. , , .

The fact that as a general rule the main machines of a common-clay bn«
plant operate as a unit, wherein the stoppage of any machine for repairs
necessitates the stoppage of all other machines in the general line of manu-
facture, makes these plants almost ideal for driving from a main line shaft
driven by a synchronous motor.
In the past these plants have generally been driven by a single engine
unit, which has resulted in brick machines being designed so that, with
machines set properly for clay delivery to the next unit, their driving belts
lead off toward a main shaft location. Two lines of machines have been
developed, a single-reduction-gear line of machines for use with high-speed
main shafts, and a double-reduction-gear line of machines for use with slow-
speed main shafts.
401. Motor drives. If individual motor drive is used, double^reductioii
gear machines or jack-shafts are necessitated, with attendant higher first
cost and operating expenses. An individual motor drive does not eUminatc
the use of a friction clutch, on account of the desirability for quick starting
and stopping. The use of a main shaft, some 40 ft. long even in moder-
ately large plants, enables advantage to be taken of the use of single-reduc-
tion-gear machines and a single motor unit, with resultant low first cost and
operating expenses. With standard layouts it is always possible to extcnc-
the main shaft to the driving motor located in a small room outside the briol.
plant, thereby greatly improving the conditions under which the motoi
operates. If the plant consists of two or more brick-making sections oprr
ating independently, separate driving motors should be used on the differciK

While the above applies to the main plant, there are individual units that
require individual motors. Where dry pans are used for grinding shale or
refractory rock they will in all probability be so located that a separat« J
motor will be required for that unit. Individual slip-ring motors can be |
used for dry pans, or a single motor can be made to drive a group witb(
about equally satisfactory results. .
'

The main "off-bearing belt" (at times 150 ft. long, operating at nghi
angles to the drives of the rest of the plant and requiring to be driven V
its remote end) can be profitably driven by a separate motor. A slip^
ring motor should be used, as the starting load is heavy after any intwit
ruption has stopped the belt when loaded with brick. It is advantageowj
to equip this motor with a self-starter under control of the operator at th<
auger brick machine. . , , a '

Hot-air fans for driers should be equipped with individual motors. SotM
plant managers demand variable-speed control of fan motors. It is th^
author's opinion that perhaps some large plants are benefited by the UBJ
of two-speed motors, but that in the average plant all air regulation shoulc
be by means of a damper or gate in the fan discharge. It is advantageput
to equip fan motors with automatic starters having a phase-failure featUTf,
because they are operated without attendance.
'

Oil pumps for burning kilns, transfer cars, machine shop, etc., shoul(
have their separate motors, in accordance with standard practice in otnei
industries.
402. Voltage of electric drive. Unquestionably 440-volt, 3-phMe
alternating-current service provides the best motor voltage for a brick pl»nv
The larger motor units are too large for 220 volts and not large enough if.
1322
 INDUSTRIAL MOTOR APPLICATIONS SeC. 15-403

warrant 2,200 volts. All parts of the plant will be within the radius of
440-volt distribution, except perhaps the drag line excavator used for strip-
ping and the shovel used for digging clay.
403. Purchased power. If power is purchased from a central stationi
the voltage at which the central station company brings its wires to the brick
plant has a great deal to do with the design of the distribution system about
the brick plant.
If power is brought to the brick plant at a voltage higher than 6,600 volts,
it should come to a single transformer station where it is reduced to the work-
ing voltage. If no excavators or shovels are used, a single bank of trans-
formers reducing to 440 volts can be used. If large size excavators and
shovels are used, it will often be of advantage to purchase untransformed
current; install one bank of transformers for manufacturing plant and other
power within 440-volt radius; install a second bank of transformers reducing
to 2,200 volts, delta; extend an easily moved or semi-portable 2,200-volt
line to portable banks of transformers on trucks adjacent to and pulled by
the excavator and shovel; or if the excavator and shovel are operated by
direct current with a 2,200-volt motor-generator set, the 2,200-volt line can
be terminated on the excavator or shovel.
If the central station power is brought to the brick plant at 2,200 volts,
4,000 volts or 6,600 volts, it is sometimes of advantage to purchase untrans-
formed current and extend a line at that voltage to various parts of the
property, installing transformer banks adjacent to the main motor drive,
fan house, pump house, excavator and shovel.
404. Private generating plant. Although, as stated above, 440 volts
s the best niotor voltage for a brick plant, the generating voltage of an elec-
,ric plant installed to serve a brick plant will depend upon local conditions.

i.f no electric excavator or shovel is used, 440-volt generation will probably

)e the most satisfactory. If, however, an electric excavator or shovel is

ised, or contemplated in the future, 2,20C-volt generation, with a 2,200-volt
ine to the excavators and pump hou.se, 2,200-volt main motor drive and a
ank of transformers reducing to 440 volts for miscellaneous power, will be
ound most satisfactory.
406. Power requirements of individual machines. On account of
he widely varying nature of the raw materials used, difference in methods
sqiiired by different products, and great range in sizes of plants, it is possible
give only general figures for the horse-power requirements of the various
nits. A majority of brick plants, particularly those using common clay,
re seasonal in their operation and cease operation when the ground freezes
1 the winter. If such a plant operates during winter months, consideration
lust l3e given to this fact and an additional allowance of from 10 to 20 per
;nt. in power requirements made to cover the handling of partially frozen
1 aterial.
406. Excavators and shovels. Motor capacities will range from 50 to
i)0 h.p., depending upon the size of bucket, length of boom and speed of
)eration. In some machines the motor or motors run continuously and
ie load is applied by means of friction clutches; in other machines
the
'Otors are started and stopped at each operation.
407. Haulage locomotives require from 15 to 80 h.p., depending on
nnage hauled, grades, curves in tracks, and speed.
408. Incline hoist. This requires from 20 to 75 h.p. Some saving in
wer can be made by using a "double skip" hoist, but this is a doubtful
5nomy in a busy plant where a single hoisting track is not sufficient,
mg to lack of flexibility.
409. Oranulators and pug mills require from 15 to 150 h.p., depending
consistency of material, angle at which knives are set, speed of knives
i amount of material handled.
110. Dry pan grinders. A 9-ft. pan is about standard and requires
'"1 30to 45 h.p., depending on material.
momen-
owever,
,,
'tenal
.
, , ,.
and the amount handled.
,
—— -~„~ , consistency of

!U. Conveyors require from 3 to 15 h.p. Care should be taken that

'era supportingconveyor belts are placed close enough together so that

1323

mwk
Sec. 15-413 INDUSTRIAL MOTOR APPLICATIONS
the conveyor belt will not sag between rollers when loaded, as the power
reqmred to drive the belt increases very rapidly as the belt sags between
rollers.
413. Auger machine. This requires from 40 to 250 h.p. depending on
the work to be done.
414. Bepress machines demand from 3 to 5 h.p.
416. OS-bearing belt. This will require from 7.5 to 15 h.p.
416. Transfer cars require from 7.5 to 10 h.p.
417. Fans consume from 15 to 50 h.p., depending upon the si«e.
418. Machine shop. The power demand varies from 5 to 10 h.p.
419. Oil pumps require from 5 to 15 h.p.

PRINTING, BINDING AND LINOTYPE MACHINERY

BY CHARLES CARPENTEE E.
Engineer, Cutler- Hammer Manufacturing Co., Associate American Institute of
Electrical Engineers
420. Control. Modern practice requires that most machinery of this
class be equipped with self starters or self-starting speed regulators, oper-
ated from the line (service) switch or from one or more push-button stations.
On account of the great number of bearings, gears, cams, etc., the load is
largely frictional and the torque at starting is usually from 50 to 75 per cent.
m excess of the full-load running torque.

Fig.
controller
41.—^Starter-
with self-
Fio. 42.— Enclosed
service switch,
Fio. 43. —Starter-
controller,
contained line switch.

421. Job (platen) presses, with a heavy fly-wheel to accelerate, require

speed regulation in the ratio of one to two from minimum to maximum.
With direct current, about 40 per cent, speed reduction is obtaiiied with
resistance and about 20 per cent, increase by field control. With alternating
current, 50 per cent, reduction is obtained by resistance. The controller
(Fig. 41) is mounted on the wall and the enclosed service switch (Fig. 42)
on the press.
422. Power required by job or platen presses

Size: inside chase

 INDUSTRIAL MOTOR 'APPLICATIONS SeC. 16-423

423. Flat-bed (cylinder) presses require self-starting controllers

equipped with predeteriniued speed setting, for push-button operation and
wall mounting. With, direct current, speed reduction of 50 per cent, is
obtained with resistance and provision is made for 20 to 50 per cent, of shunt

Fig. 44. Fig. 45. Fig. 46.

field variation; dynamic braking is also provided. If alternating current
is used, 50 per cent, speed reductioi* is obtained with resistance, and if the
press is equipped with automatic feed a solenoid brake should be used on
the motor shaft for quick stopping. Accessories should be mounted directly
on the machine. See the table iu Par. 424.
424. Power required by flat bed presses
Single color —one cylinder
Size of bed
Maximum impressions
H.p.
per hr.

.X34 ia. 2,700 1.5

.X35 in. 2,600 2.0
.X41 in. 2,400 2.5
.X42 in. 2,400 2.5
.X44 in. 2,400 2 5
.X-18 in. 2,300 3.0
.X50 in. 2,200 3.5
. X 53 in. 2,200 4.0
. X 56 in. 2,000 4.5
. X62 in. 1,700 5.0
.X68in. 1,700 6.0
.X74 in. 1,600 7.5

Two color —two cylinder

43in.X56ltii' *"**t700
46 in. X 62 in.
'

1,600 10-
52 in.X65 in. 1,500 12
52 in.X67 in. 1,550 12.5

D
Sec. 16-425 industrial motor applications
iS6. Kotary lithographic presses require substantially the same equip-
ment as flat-bed (cylinder) presses, except that they should have one more
inching station for washing up and making ready, and the controller should
be reversible to assist in taking off blankets and forms. Offset presses under
this classification, where provided with Dexter automatic feeders, should
have a feeder-clutch switch for automatically slowing down when the feeder
clutch trips out.
426. Power required by rotary lithog^raphic presses

Zinc or aluminum

Size of sheet Normal impressions

per hr. H.p.

32 in. X 45 in. 2,000

42 in. X 53 in. 1,800
45 in. X 65 in. 1,500
50 in. X 65 in. 1,400

Offset

22 in. X 28 in. 4,000

26 in.X34 in. 3,000
30 in. X42 in. 2,800
34 in.X46 in. 2,500
38 in. X 52 in. 2,400
44 in. X 64 in. 2,000

Fig. 50. —
Reversing
master switch.
Fig. 51.—
Single button
—
Fig. 52. Two Fig. 53.— Two
button switch, button switch
switch. showing guard
flange.
427. Rotary typogrraphical presses (not newspaper or magazine
presses) require thesame equipment as rotary lithographic presses. Par. 428.
428. Embossing: presses require moderate-speed motors from 1 to 10
h.p. Direct-current motors should be compound wound with about 50
per cent, shunt field variation. Alternating-current motors should be of'
the sUp-ring type with 50 per cent, speed reduction by resistance. Dynamic
braking is not required.
429. Folders require motors of 0.5 to 3 h.p. Direct-current motors
should have 50 per cent, speed reduction by resistance and 20 per cent, shunt
field control; dynamic braking is not required. Alternating-current motors
should be of the slip-ring type, with 50 per cent, speed reduction by resis-
tance. No brake is required.
430. Paper cutters are started without load, except a heavy fly wheel,
and require constant-speed motors of 1 to 5 h.p. For direct current a com-
pound motor is required with self starter and enclosed service switch for
starting and stopping. For alternating current a squirrel-cage motor is
required, thrown directly on the line from the service switch.

1326
 INDUSTRIAL MOTOR APPLICATIONS SeC. 15-431

S.So2
3 fe'? o

udb
;a 2

^2
 .

Sec. 15-432 INDUSTRIAL MOTOR APPLICATIONS

432. Linotjrpe and monotype machines require 0.25-h.p. moton
started by throwing them direct on the line from the service switch. I,ino
type machines require back-geared motors of 400 r.p.m., with the machin
drive shaft operating at 72 r.p.m. maximum. Monotype machines ma;
have motors of 1,000 r.p.m., geared to machine drive shaft at 160 r.p.m
maximum. These machines on account of flying particles of type mets
should be provided with fine gauze screening.

FLOUR MILLS
BTA. E. HALL
Manager, Milling Machinery Depl., Allis-Chaltners Manufacturing Co. \

433. Drive. While a flour mill contains many separate machines, thed
machines must run as a unit, and it is not profitable from a commercial stand
point to drive each machine with a separate motor.
434. Machines included. A flour mill may be considered divisibP
as follows: (a) The roller mills or grinders; (b) bolting and purifyin
machinery, lofting elevators, conveyors and all the machinery in the mi
proper above the roller floor; (c) the wheat cleaning department, and in tb
larger mills the wheat receiving machinery; (d) on navigable water, th
marine leg. All the car pullers, passenger and freight elevators are opciatt
from separate motors.
435. Power requirements of individual machines
Mill proper

H.p. each H.p. tot

19 10X42 Style AA roller millis Corr.. . . . 17 324
20 10 X 36 Style AA roller mills smooth . . . 20 400
12 80 in. X 77 in. vibromotor universal bolters 3 36
20 8-ft. X32-in. centrifugal reels 4 80
4 8-ft. X32-in. round reels 3 12
22 7-ft. X30-in. purifiers 2.5 55
10 7-ft.X32-in. purifiers 2 20
5 aspirators for 7 X 40 purifiers 0.5 2.5
4 8-ft. X32-in. flour dressers 3 12
6 No. 7 bran and shorts dusters 8 48
2 70-in. double steel plate fan 27 54
2 65 -in. steel plate fan 15 30
1 40-in. single steel plate fan 8.5 8.5
53 elevators 1 53
25 dust collectors 0.33 9
Total 1144

Wheat-cleaning department
H.p. each H.p. total)
1 No. 4 comp shake Dbl receiving separator. 8
2 No. 5 comp shake Dbl receiving separator. 20
8 No. 90 milling separator 80
1 No. 7 automatic magnetic separator .125 0.126
1 No. 8 standard aut. magnetic separator. . .125 0.12SI
2 No. 10 standard aut. magnetic separator. .375 0.75
1 No. 8 2 high scourers 40
2 No. 9 2 high scourers 100
1 No. 31 dust collec. for grinder 0.33
3 No. 32 dust collec. for grinder 1
4 No. 33 dust collec. for grinder 1.33
1 No. 36 dust collec. for grinder 0.33 1

4 No. 46 dust collec. for grinder 2 ••!

2 32-in. X8-ft. round reels with drums I

1 30-in. attrition mill 60

1 45-in. double steel plate fan 14 .

16 conveyors , 6 ^ !

340

1328
 INDUSTRIAL MOTOR APPLICATIONS See. 15-4

436. Types of motors. For the main driving motor in a flour mill,
rhere as much as 700 h.p. is concentrated in a single motor, a wound-
otor slip-ring induction motor with a secondary resistance starter is recom-
aended. The equipment should also include a primary panel containing
in oil switch with overload and no-voltage trips, in order to protect the motor
rom excessive overloads or from failure of voltage on the supply Une.
The smaller motors throughout the mill may be of the squirrel-cage type
if induction motor, equipped with a potential starter or compensator.

437. Power requirements. The total power required to operate a

nill having a capacity of 3,500 bbl. in 24 hr. will be approximately
t.4 h.p. per bbl. or 1,400 h.p. for the complete plant. This can be increased
per cent, in mills making only 100 bbl. or less per day. The power required
or a flour mill varies considerably, depending on the condition of the wheat
,nd the fineness of the flour to be produced, as damp or tough wheat or close
oilling require increased horse power. The hard varieties of spring wheat
squire more power than the soft varieties of winter wheat.
For an entire mill requiring 1,400 h.p., the wheat-cleaning department
,.ould consume one-fourth of this amount, or 350 h.p.; the roller mills one-
[alf, or 700 h.p.; and the bolting machinery, which includes the sifters,
bran and shorts dusters, suction fans, elevators and conveyors,
jUrifiers,
ould require one-fourth, or 350 h.p.

BEET-SUGAR MILLS
BY WIRT S. SCOTT, M.E. IN E.E.,
(anager Industrial Heating Section, Westinghouse Elect, and Manufacluring
Co., Member, American Institute of Electrical Engineers
438. Power requirements. With electric motors properly applied, the
»tlJ power consumption should not be over one-half of that required for
eani-engine-driven factories. The machines of the types mentioned in
ar. 439 to 466 inclusive, vary in size according to the individual require-
ents, but the examples cited will serve as a guide as to the average,
actice.
489. Beet lift. Sixteen feet diameter by 2 ft. wide, with 33 buckets 12 in.
:ep, making 4 rev. per min., driven by pinion meshing with 8 ft. gear on
t;10 h.p. required, at constant speed, with high starting torque.
440. Beet washer. Six feet diameter by 18 ft. long, with thirty-two 24-in.
ms or paddles. Shaft makes 14 rev. per min.; 7.5 h.p. required, at constant-
eed and with a moderate starting torque.
441. Beet elevator. Thirty-four buckets, 22 in. wide by 17 in. deep,
shaped; 70 to 120 ft. per min.; 10 to 20 h.p. required, at constant speed,
th moderate starting torque.
442. Beet slicer. Capacity 50 tons per hr., 55 rev. per min.; 25 h.p.
luired, at constant speed, wath high starting torque.
443. Cossette conveyor. Capacity 60 tons per hr., belt 12 in. wide by
5 ft. long; belt speed, 250 ft. per min.; 5 h.p. required, at constant speed,
th light starting torque.
144. Sugar mixers. Shaft 50 ft. long, 12-in. paddles, speed 1.5 rev. per
u ; 10 h.p. required, at constant speed, with moderate starting torque.
145. Tube mill or granulator; 6 ft. diameter by 30 ft. long, 10 rev. per
n.; 10 h.p. required, at constant speed, with high starting torque.
146. Bagging machinery. Bag-sewing machine, requires 2 h.p.; bag
I cker, requires 3 h.p.
147. Pumps. Hydraulic gasket pump, for operating doors on bottom of
<:usion batteries, requires 5 h.p. Carbonation pump, 450 gal. per min.,
lb. pressure, requires 25 h.p. Thick juice pumps, 450 gal. per min., 30
I pressure, requires 10 h.p.
48. Crystallizers. Ten feet diameter by 16 ft. long; paddles 4.5 ft. long
furod to driving shaft which makes one revolution in 5 min. The
Iver required varies considerably during the cycle of operation, the amount
I uired at the completion of the operation being almost double that re-
tred at the start. For this reason the machines are best driven in groups-
ctrom four to eight, by one motor. For driving an individual machine,

1929
Sec. 15-449 industrial motor applications

from 2.5 to 3 h.p. is required at the beginning of the cycle, and 5 h.p. at the
end. Since the complete operation may require 60 hr., a motor must
have sufficientcapacity to operate at maximum capacity continuously,
with individual drive. Where crystaUizers are driven in groups of from
four to eight machines, 3 h.p. per crystallizer will be sufficient.
449. Centrifugals. The sugar centrifugal is one of the most important
machines in sugar making, the operating conditions of which are very severe
due to the inertia of the load and the cycle of operation. The time required
for the complete spinning process varies with the grade of sugar. Ordinarily
one man can operate two centrifugals on granulated sugar and up to four
centrifugals on white sugar. When these machines are to be individually
driven the cycle of operation must be known, as the rating of the motors
will depend upon the root-mean-square value of the power requirements,
and the torque required for accelerating in a given time.
450. Average cycle of operation of group-driven centrifugals with
fine grranulated sugar. The average time required is as follows: filling,
one-fourth speed, 30 sec; accelerating, one-fourth to full speed, 10 sec; full
speed, 120 sec. power off, retarding by braking, 20 sec revolving at about 25
; ;

rev. per min., 30 sec; total time, 3 min., 30 sec.

451. Average cycle of operations of individually driven cen-
trifugals with fine granulated sugar. Filling basket, revolving by
hand, 10 sec; accelerating, 100 sec; full speed, 30 sec; power off, retard-
ing by braking, 20 sec; stop, unloading by hand, 60 sec; total time, 3 min.
40 sec.
452. Average cycle of operations of individually driven cen-
trifugals with coarse granulated sugar. Filling basket, revolving
by hand, 10 sec; accelerating, 00 sec; power off, retarding by braking, 20
sec; stop, unloading by hand, 60 sec; total time, 2 min. 30 sec.
452(a). Average cycle of operations of individually driven centrifu-
gals with coarse white sugar. Filling basket, 25 sec; accelerating.
Too sec full speed, 15 min. power off, braking, 30 sec; stop, unloading by
; ;

hand, 145 sec; total time, 20 min.

453. Oroup-driven centrifugal machines furnish a very satisfactory
arrangement, whereas individual drive, although successful, has been used
to a much lesser extent. The character of the load is very similar to that of
a fly-wheel, so that with these machines arranged in a group and driven
by one motor, the centrifugals in operation will help to bring the idle machines
up to speed and maintain a uniform load on the motor. This can best be
shown by the following data. A group of ten 40-in. centrifugal machines,
driven by a 100-h.p. motor, with 1 machine starting, requires 20.5 h.p.; with
2 machines starting, and 1 at full speed, 40 h.p.; with 3 machines starting,
and 3 at full speed, 52.5 h.p.; with 4 machines starting, and 4 at full speed,
60 h.p.; with 1 machine at full speed 5.5 h.p.
454. When centrifugals are individually driven, the peak load is
about eight times the normal running load; for a 40-in. machine the peak i«
approximately 40 kw. input, corresponding to about 40 h.p. output. Since
at the very start the speed is zero, the horse power is zero, therefore the power
required at start should be stated in terms of pounds torque at 1 ft.
radius. The starting torque, together with the root-mean-square horse
power for the cycle, furnishes sufficient data for determining the motor
required.
455. The speed of a direct-connected centrifugal machine increases
very rapidly at the start and at a much lower rate as the motor approaches
synchronous speed. The motors are usually of the squirrel-cage type with
high-resistance end rings designed to give approximately 15 per cent, slip
at full-load; but, since full-load is never attained except at starting, the
maximum speed which can be attained by the centrifugal is almost,
synchronous speed, and in nearly every case the operation is completed be-
fore the machine has attained its highest possible speed. '

466. The torque necessary for starting a loaded centrifugal mk-i

chine, and accelerating it to a given speed in a certain length of time can be*
determined by the following formula: i

1330
 INDUSTRIAL MOTOR APPLICATIONS SeC. 16-457

= pounds torque at 1 ft. radius, TF = weight in lb. to be accelerated,

= radius of gyration of entire mass in ft., A'' = rev. per min. machine will
;tain in S seconds, iS = seconds required for accelerating.
The above expression does not take into consideration friction and windage,
id it will be necessary to increase the result thus obtained by 10 per cent.
Iorder to obtain the required starting torque.

LAUNDRY MACHINERY
BY FBITZ BALZER, M. E.
Manager, Troy Laundry Machinery Co., Ltd.; Member, Ameri-
ssistant Sales
can Society of Mechanical Engineers
457. Advantage of electric drive. The power laundry with its large
amber of different machines can employ electric drive to great advantage,
he elimination of belts reduces the friction load of the plant, premits the
mvenient location of the different machines to reduce handling expenses,
.sures cleanliness and light, reduces danger of accidents and finally decreases
.e operating cost. From a number of tests all over the country this saving
operating cost appears to be from 25 to 30 per cent. Alternating-current
ilyphase induction motors are recommended wherever possible.
'458. Use of steam in processes. When introducing electric drive in
y laundry it must be kept in mind that a laundry requires a large amount
; steam for drying and for the heating and boiling of water. This question
important in the controversy regarding the generation of electrical energy
rsus its purchase from a central station. In the latter event, steam must
produced independently of the source of power. In the majority of
368 it will pay the laundry to have its own power plant, therby having the
oduction of hot water as a by product of the generating plant. A careful
idy of conditions should be made, however, in order to determine which
^thod is the most economical.
169. Classification. Laundries may be divided into three groups: (a)
')se doing family work only; (6) institution laundries (hotels and hospitals)
laundries doing railroad or steamship work only.
I
Each of these groups
ji a different requirement for steam in amounts which can be expressed
iterms of the horse-power requirements. Thus, for group (a) the number
i.pounds of steam used per hour could be expressed 1.2 times the horse
I'ver for that group; for group (6) 1.4 times the noree power; and for group
(.1.8 times the horse power.
60. Method of drive. Group-drive of laundry machines is, generally
Baking, not desirable, for the reason that the groups must contain machines
Vich are not in constant use, and therefore the operating expense could
p be reduced as satisfactorily. The table below gives the machine groups
ii their proper sequence for the three classes of work done in the laundry.

-1'

Flat-work group Starched-work group Rough-dry group

"ashers Washers Washers

{tractors Extractors Extractors
imblers Starchers Dryroom-tumblers
at-work ironers Dryrooms
Dampeners
Ironers and finishing
machines

1machines enumerated above should be placed on one motor, unless a

•a dry makes a specialty of one particular class, and does work in the other
clfes only a part of the time. In the latter case it is advisable to place
all lachines, which are frequently used, on one motor, and to group the
ot -s as outlined above. The load factor is between 40 and 45 per cent,
la.-idual drive is recommended wherever possible, and the data in the
olldng paragraphs refer to this class, unless otherwise stated.
I, Washers consist of a stationary outside shell, inside of which re-

el cylinder. The goods are placed therein and subjected to the action
c wash solution. To prevent tangling of the wash it is necessary that

b 1331
Sec. 16-462 industrial motor applications

the cylinder alternate its direction of rotation. This reversing action i

obtained in various ways, which are described in Pars. 462 to 468. The loa«
characteristic is different with each application and each case will therefor
be treated separately. The cylinder sfiould make from seven to twelv
reversals per min., and in order to get the best results the surface speed
QJ
the cylinder should always be near 280 ft. per min. From a number o|
tests which have been made it appears that for every cubic foot of cylindei|
space the following power is required: 32 in., 0.04 h.p.; 36 in., 0.05 h.p.J
42 in., 0.06 h.p.
462. The power required by washers of standard size can be expressed
as follows: 32 in. X 46 in., or smaller, 1.5 h.p.; 36 in. X 54 in., or smalleri
2 h.p., 36 in. X 70 in., or 42 in. X 54 in., or smaller, 3 h.p., 42 in. X 70 in.'
or smaller 5 h.p. These figures check quite well with the empirical datj
given in Par. 461. The cylinders may have either of two kinds of perforai
tions, the plain round embossed hole or the turbine slots; of these the lattW
require about 20 per cent, more power than the former, but are frequentn
used on account of the attendant saving in time and supplies.
463. Washers with belt reverse require either enclosed direct-curren
motors, having a 25 per cent, compound winding, or alternating-curren;
polyphase motors with high-resistance rotors. The motors are mounted oil
a bracket on top of the washer, and the usual speed is 1,200 rev. per min
The use of a fly-wheel will add materially to the efficiency of the drive. Th^
load factor is 65 per cent. A disadvantage arises through the necessitv
-

using very short belts, with a consequent large loss of power. It isi

practice to fully enclose the motors to prevent the entrance of steai

spray water.
464. Washers with reversing motors. Reversing motors applied t

washers are probably the best for the purpose, but their success depeinl
upon the method of control u.sed. In these installations the motor is usuall
mounted on a bracket attached to the machine, for gear drive. On alter
nating current the use of wound rotor motors is recommended, and on (h
direct current the use of interpoles is imperative.
466. Timers for reversing washer motors. An auxiliary motor f'
timing is sometimes used to drive one or more controllers, which are constant I

rotating and making the proper connections with the individual motor
Individual and mechanically operated timers are also used, the timer boiti
actuated by the revolutions of the cylinder axle; or any other contiiniall
rotating part of the machine. The timer station operates a delay whicli i

turn controls the reversing contactors. The load factor of this group varii
between 55 and 60 per cent.
466. Extractors are machines employed to remove the water fron •'
goods after washing. This is done by placing the pieces in a perfoi
basket and revolving the basket at a very liigh speed, whereupon the v
is thrown out by centrifugal force.
467. Extractor speeds
 INDUSTRIAL MOTOR APPLICATIONS ScC. 16-469

Basket
diameter
Sec. 16-472 industrial motor applications
current motors should be compound-wound, with about 20 to 25 per cent
compounding. On alternating-current circuits plain squirrel-cage motonj
give good results. The load factor of motors driving tumblers is 60 per centi
472. fiaiupeners are machines used to moisten all starched goods aft
drying and prior to the ironing process. A large number of machines t
on the market, the table below (Par. 473) giving some of the more promin|
ones. No special features are required of the motors, and the load fa
varies between 45 and 55 oer cent.
473. Power requirements of dampeners
(o) Collar and cuff dampeners

Hagen 0.25 h.p. B. & E 0.75 h.p.

Wilson... 0.125hJ
Troy No. 1. 0.3 h.p. Troy No. 2.. 0.75 h.p.

(6) Shirt dampeners

& E... 0.375 h.p. Bishop con- t-^,, n k u .,«i

B.
vevor
veyor n
0.5 .-i hn
h.p
Troy..._. 0.5h.p3

474. Collar and cuflf finishing machines. A number of machine

comprise this class, of which only the ironers themselves are individual!;
driven, while the small finishing machines are belted from a line shaf
attached to the finishing table.
475. Collar and cuff ironers, for the most part, require no special motors
However, in the case of steam-heated ironers, it may be sometimes desirabl
to use variable-speed motors, in order to choose the speed best adapted t
the steam pressure, should the latter be changeable. The load factor i '

55 per cent.
476. Power requirements of collar and cuff finishing machines

Troy No. 5 Gas-heated, 3 rolls, 24-in 1.0 h.p.

Troy No. 5 Gas-heated, 3 rolls, 40-in 1.5 h.p. i

Troy No. 5 Gas-heated, 5 rolls, 24-in 1 75

. h.p. ]
Troy No. 5 Gas-heated, 5 rolls, 40-in 2.0 h.p. i

Troy No. 14 Gas-heated 1.0 h.p.

Troy Steam-heated, all sizes 0.75 h.p. '

B. & E. No. 22 Steam-heated 0.75 h.p..

477. Finishing table. The motor, which is of 0.5 h.p. capacity, is c

the non-reversing constant-speed type, and geared directly to the line shafli
from which the small finishing machines are belted. The load factor dof
not exceed 45 per cent.
478. Shirt finishing machines. These machines are used to iron c
press the neckband, bosom, sleeves and bodies of shirts. For each of thes
operations a special machine is used, in some cases there are several types i i.[

machine for each operation. See Par. 479 to 483. '

479. Bosom ironers.

j
Three distinct types of bosom ironers are in usf,,!]
first, the reciprocating type, where the bosom passes back and forth undt
a revolving drum; second, the one-way type, where the bosom travels ii
one direction only under one or more heated rolls; and third, the presses.
480. Keciprocating bosom ironers require a motor of 0.5 h.p. R(
versals may be obtained by means of reversing switches, in which case direct
current motors must be compound-wound and alternating-current motoi
must have high-resistance rotors. Reversals may also be accomplished b
means of mechanical-reverse devices, in which case non-reversing, constant
speed motors should be used. The reverse switch, as well as the mechanici;
device, is actuated by a foot treadle and lever connections. The load facte
for reversing motors is 75 per cent., and for the mechanical reversing typ
55 per cent.
481. One-way bosom machines require motors of 1 h.p. capacit}
without any special features. The load factor is 55 per cent.
482. Bosom presses are built in two types. In one case a reversin
motor operates a screw, and through it a toggle. This motor has a capacit
of 0.5 h.p. Should it be a direct-current motor, it ought to be conipounc

1334
 .

INDUSTRIAL MOTOR APPLICATIONS Sec. 15-483

wound; should it be an alternating-current motor, it ought to be equipped

with a high-resistance rotor. Single-phase motors cannot be used unless
some kind of mechanical reversing device is employed. The load factor
s 75 per cent. The other type of press is operated by a fluid (usually oil)
inder pressure. A
constant-speed, non-reversing motor of 0.5 h.p. capacity
jperates the pump. The load factor is 55 per cent.
483. Neckband ironers. For this service, small motors of from 0.125
;o 0.25 h.p. capacity are required. There are no special features, and the
oad factor is 55 per cent.
484. Sleeve and body ironers. These machines are almost identical,
their only difference being in respective size. All modern machines are
•eversing and, like bosom ironers, are reversed either electrically or mechanic-
lUy. The sleeve ironers require a motor of 0.25 h.p. capacity; the body
roners, 5 h.p. If the reverse switch is used the motors must be built for
eversing duty (compound-wound if for direct-current, or having high-re-
•istanre rotors if for alternating current). Single-phase motors cannot be
ised for this service. If the mechanical reversing device is employed,
standard motors without special features should be used. The load factor
)f reversing motors is 75 per cent., of the others 55 per cent.

485. Flat work ironers or mangles are used to dry and iron flat work
>y passing the goods under pressure over heated rolls or chests. With rolls,
me or more aprons may be used to insure perfect contact of the goods over
he heated surfaces, and while not essential, this may also be done where
hests are used. Nearly all machines of this class must be arranged to
I eliver goods at varying speeds, and the problem of motor selection must be
arefully worked out in detail. The data given below represent the average
esults of a large number of tests.
486. Power requirements of flatwork ironers

(a) Flatwork ironers, chest-type without aprons

i
Troy gas ironer v,. . 0.6 h.p., constant speed
iTroy handkerchief ironer. 0.5 h.p., constant speed
Troy addition 2, 3, 4 chest. 0.75 h.p., armature control
Troy addition 5.6 chest i
1.5 h.p., armature control
,Troy triplex No. 1 1.0 h.p., armature and field control
Troy triplex No. 2 1.5 h.p., armature and field control
Troy triplex No. 3 2.0 h.p., armature and field control
Troy five roll (8-in. rolls) 1.0 h.p., armature control
Troy five roll (12-in. rolls) 2 . h.p., armature or 3 to 1 field con-
trol

(6) Flatwork ironers, chest type with aprons

i'roy four roll 1

2 h.p., field control, 3 to 1 speed
range
{Iroy six roll 3 h.p., field control, 4 to 1 speed
range
Troy eight roll ; 7\ h.p., field control, 4 to 1 speed
I
range

(c) Flatwork ironers, cylinder type

ifroy Trojan, 1 cylinder, 48 in '

2 h.p , 1 speed range

field control, 3 to
Troy big two, 2 cylinder, 24 in ... |
2 h.p , mechanical regulation
^^roy big two, 2 cylinder, 30 in. . . 4 h.p , field control, 3 to 1 reg<ilation
|roy duplex, 1 cylinder, 24 in.. . . i 1 h.p , armature control
roy addition, cylinder only 36 in. 1 h.p , armature control

(d) Flatwork ironers, chest and cylinder type (aprons)

roy addition, 1 cylinder, 36 in. „ u c u . o ^ i ^

and 2, 3, 4 chests ''P' "®'" control, 3 to 1 speed range

1335
 >1

Sec. 15-493 industrial motor applications

487. Dry-cleaning plants. The underwriters do not allow the installa
tion of electric motors in the cleaning room proper; therefore it is necessar;
to mount the same outside and operate the plant by group drive. Th
power required may be calculated from the above data for the various ma
chines. The load factor, as in group drive, is 45 per cent.
SMALL MOTOR APPLICATIONS
BT BERNARD LESTER
Commercial Engineer, Westinahouse Electric and Manufacturing Co., Membeii
Am.erican InsHtiUe Electrical Engineers, National Electric Light Associa-
tion and Electric Power Club
488. Small motor types and chsiracteristics. There is a very broa
use for small motors for the operation of appliances principally in the homi
office, store, garage, and repair shop. Due to the extensive distribution <
alternating current for illumination, single-phase motors are mostly usee
Small motors may be classified as follows:
489. Single-phase types. The large majority of single-phase moto?
used in sizes of i-h.p. and below arc split-phase induction motors, whioj
are simple in construction, reliable in operation, and possess speod-tor^i
characteristics which are suited to the majority of driven machiiies. Tl|
principal limiting features in connection with the application of this type i

motor are starting torque and pull-out (maximum) torque. Occasional

these motors are designed with an internal centrifugal clutch which provid^
an overload protection for the "windings of the motor and tends to redut
the starting current and the length of time it is drawn from the ciro
during the period of acceleration.
The repulsion-induction motor is now extensively used principally i

sizes above i-h.p. upon applications where the starting torque required;
high and the lowest possible starting current is necessary. They are largd
used for pump.s, meat grinders, air compressors, etc. |

490. Polyphase type. The squirrel-cage polyphase motor is preferi^

to the single-phase motor on account of its simplicity. Its use is largej
limited to small motor applications in factories where polyphase current
available.
491. Direct-current types. Shunt, compound and series-wound direr
current motors are applied by following the same principles involved in 1

application of larger direct-current motors.

492. Universal types. The term "Universal" is applied to those mole
which will operate either upon alternating current or direct current, eitli ,

without any change whatever in adjustemnt of the brush rigging, or wi j

the addition of external resistance, or with both of these features. Su(

motors are necessarily series wound and possess speed-torque characteristi >

in general similar to a series-wound direct-current motor. Consequentl J

their application, except in very small sizes, is limited to the driving <

devices which are directly connected or geared to the motor. ObviousI i

applications must be such that a wide variation of speed with torque lo; f

is permissible. The application of universal motors is generally liiriited »

certain types of fans and blowers, electric tools, and domestic sewing ni
chines. The small portable vacuum cleaner which employs a blower
usually operated by this type of motor.
493. Service rating of motors. Obviously a motor which is requir.
operate under load for short intervals will not attain the temperature rt m
when operating at a similar load continuously. Consequently, for i

mittent service, smaller motors may be employed than for continuous sii
However, where the motor is frequently started and stopped, thoimi
aggregate running time is small compared to the idle time, the heating
become excessive due to the frequent inrush of currentincident to startii
The simplest method of arriving at the proper motor capacity is by acti
trial of a sample motor, subjecting it to a cycle of operations which will
equivalent to the most severe service conditions.
494. Split-phase motor characteristics. In analyzing the pi"
torque* characteristics and other features of split-phase mo tors for pur t>i
''
• Torque measured with brake-arm and scales at 1 ft. radius.
 INDUSTRIAL MOTOR APPLICATIONS SeC. 16-495

[lli Fig. 54. —Characteristics of split-phase motors.

pplication, Fig. 41, will prove of use in the calcuhition of approximate

e.

. Calculation of full-load torque, knowing the horse power and the

8.
<^-d, may be illustrated by the^following example: find the full-load torque
'>i 0.75 h.p.
motor running at 1,700 rev. per min. at full-load (1,800 rev. per
'»• synchronous speed). Find in Fig. 41 the intersection of the vertical hne
•"Ugh 1,700 rev. per min. with the curve marked 0.75 h.p. (560 watts), and
l»c;ontally opposite this intersection at the left is the torque 36.5 ounce-feet.

1337
Sec. 15-496 industrial Motor applications

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 ;.

INDUSTRIAL MOTOR APPLICATIONS Sec. 15-497

497. Starting torque. Since the starting torque and the pull-out or
maximum torque of a small split-phase induction motor are limiting features,
:are should be taken that the motor selected will start the driven machine
under the severest conditions of torque. The starting torque varies approxi-
mately as the square of the applied voltage, and any reduction in voltage
;aused by the inrush of currentiucident to starting, and possibly emphasized
by insufficient wiring or transformer. capacity in commercial circuits, reduces
very materially the starting torque delivered by the motor. It is customary
to select a motor which will start the driven machine at a voltage of approxi-
mately 80 per cent, of the normal circuit voltage.
The starting torque and the maximum running torque can be found by
Tiultiplying the full-load torque by the proper constants. For example,
f the starting torque of the particular motor considered in Par. 49S is 1.5
rimes the full-load torque, its value will be 1.5X36.5 = 55 oz-ft. Like-
vise if the maximum running torque of the motor is 2.5 times the full-load
orque, its value will be 2.5X36.5 = 91 oz-ft. These constants must
)e determined from the characteristic curves of the individual motor. Fig. 41

498. The horse i>ower at maximum torque can also be determined

rom the curve if the speed is known. For approximate results the slip of
|mall split-phase induction motors at maximum torque can be assumed to be
1 5 per cent. In the case of the motor discussed in Par. 496, the speed at
laximum torque will therefore be approximately 1,350 rev. per min. Find
1 Fig. 41 the intersection of the vertical line through 1,350 rev. per min. with
he horizontal line through 91 oz-ft. torque; this is near the line repre-
jjnting 1.5 h.p., which is the approximate power developed by the motor
list before pulling out, or stalling.
499. Input. The problem is to find input in watts, when given the horse
ower and the efficiency. Assume for example that the efficiency of a 0.75-
.p. motor is 75 per cent. Find in Fig. 41 the intersection of the vertical
Qe through 75 with the 0.75 h.p. curve, and horizontally across from this
tersection is the value 746 watts.
500. Current per phase. Knowing the watts input, the power-factor
id the voltage, the problem is to find the current per phase (or per terminal)
r example, assume that the power-factor of the foregoing motor is 70 per
nt. and the voltage is 220 volts. Locate in Fig. 41 the intersection of the
> per cent, vertical power-factor line with the diagonal representing 746
itts. The horizontal line passing approximately through this point, repre-
nts 1,050 apparent watts. Then from the intersection of the vertical line
presenting 220 volts with the diagonal representing 1,050 watts, the
•rizontal line representing amperes may be determined, namely, 4.8 amp.
igle-phase, or 2.8 amp. three-phase. The current per terminal in a two-
ase motor is one-half that for a single-phase motor, and in this case would
2.4 amp.
601. References to literature on small motor applications. There
practically no information available upon small motor applications,
•ference may profitably be made to the following articles by the writer.
"Small Motor Applications," Electric Journal, February, 1911; Vol.
II, No. 2.
Note on the "Application of Small InductionMotors," Electric Journal,

'..ESTER, Bernard. —
>vember, 1912; Vol. IX, No. 11.
"Fractional Horse-Power Motor," Load, Proc, A. I.
E., Vol. XXXIV, page 385.
.ESTER, Bernard.
-irnal, Feb.,
—
"Electric Drive in Domestic Engineering," £/ec<rtc
1917.
Oellen-badgh, F. S., Jr. —
"Split-Phase Motor Starting Switches," Electric
"irnal. May,
1917.
A'ebbr, C. a. M.
1, May, 1917.
—
"Winding Small Single-Phase Motors," Electric Jour-
Feeler, V. M. —
"Domestic Engineering," Electric Journal, June, 1917.
J
MiTH, H. B.
, 1918.
—
"Motor Drive in the Preparation of Food," £iec<ric /ourna/,

1339
 n 1 '

Sec. 15-502 industrial motor applications

MOTOR CONTROL
BY CLARK T. HENDERSON
Engineer, The Ctitler- Hammer Manufacturing Co., Fellow, American lhst,;ui
of Electrical Engineer
REVISED BY ARTHUR SIMON
Electrical Engineer, The CtUler- Hammer Manufacturing Co., Fellow, America
Institute of Electrical Engineers; Member American Society of Mechanical
Engineers '

STARTERS !

SOS. Necessity for starters. Standard direct-current motors of sm&

capacity and of any winding may be thrown directly on the line withou!
requiring an undue rush of current and without being injured. Specialll
designed motors as large as 10 h. li

can be started in the same niai

ner, but larger machines
shunt wound, compound wouik
wheth< —
or series wound— require
form of starting device noi
for restricting the current r,
at starting but also for the pn
tection of the motors themselvej
Also see Sec. 5.
Standard alternatlng-cui
squirrel-cage motors of mo.:
potential and of any cap
may be thrown directly on 1
without injury. High-\
motors are made only in >

capacities, and it is inadvisnD

to throw such motors directly c
the line because of the linesurgi.j
which are the invariable result (ji
such procedure. * Even in tljjj
case of machines of moderani
potential the current inrush is t
great as to cause serious hne di
any except sma
turbance.«>
if
machines are started in this raai
Lines
--
and
ner, most power compani
Fig. -
-Starter
-
for alternating current prohibit this practice with moto
•

polyphase motor. of capacity exceeding 5 h.p. Fii

55 snows a polyphase mote
starter, with fuses whichare cut out during starting. Generally speakini
the starting current required by standard squirrel-cage motors when thro\>
directly on the line is from five to eight times that required under fulMi'
conditions.

Fig Direct-current starter for large motors.

603. Direct-current starters in their .simplest form consist of a r^
tance of such value that only a proper current inrush is.allowed, tot;'
• Par. 641, No. 20.
1340
 INDUSTRIAL MOTOR APPLICATIONS SeC. 15-504

ith a switching device for removing this resistance in one or more steps.
1 and moderate capacities the switching device generally employed
small
ir short-circuiting the starting resistance, consists of a lever movable across

series of contacts which are connected to the starting resistance.

The no-voltage release which is usually a part of the direct-current
arter consists of the resistance-controlling lever normally held at the ex-
eme left or in the open-circuit position by means of a spring, and an elec-
omagnet in series with the shunt field of the motor, adapted to hold the
arting lever in the full-speed position as long as there is voltage on the
ae. In case of voltage failure this magnet will be de-energi zed, and the
arting lever will return to its open-circuit position. This no-voltage release
lagnet is sometimes placed in the shunt-field circuit, and is sometimes con-
joted across the line. The former arrangement is preferable because, the "
otor circuit will be opened in case of failure of the shunt-field circuit,' ,
In large capacities the use

osed
a series of successively
manually operated
t •

k KK
]
vitches seems to be preferred
/ most controller manufac-
irers. Interlocks are usually
ovided which prevent the
Dsure of such starting
/itches in any other than
eirregular order. Fig. 56
ows typical starters of this
iss.

;S04. Apportionment of
'sistance in direct-current
arters. Fig. 57 shows the
irtiug current required by a
eet-current motor, it being
3umed that a step of resis-
ice is cut out each time the
rrent falls to a predeter- Fig. 57. — Direct-current motor starting
ned value. For equal start- current.
: peaks the resistance must = Current peak.
^ divided unequally, the = Current just before a step of resistance
pper ratio between succes.sive is cut out.
sps being a geometrical pro- = Running current.
( ssion. The resistances of = Total resistance.
< steps, as well as the current = External or starting resistance.
uks which will obtain, may = Re.?i.-5tance of motor and its connec-
jdetermined graphically from tions,
^:.57, where Ji =initial in- ri, rj, . . . , rn =Resistance of starting steps.
•h; J2 =
current at which_ a
Sp of starting resistance is removed; /a = running current; ro = resistance
< motor and its connections; i? = external starting resistance. The ratios
cprogression with various numbers of starting steps, n, and for various
*ues of a (whic
Sec. 15-505 industrial motor applications
The above takes no account of motor impedance or armature accelcratii'
and, for this reason, practical results may be quite different from the
calculated. The current-carrying capacities of starter resistances a
proportioned for short-time duty; this determination of carrying capacity
more a matter of experience than calculation.
605. Star-delta switches for starting alternating-current motor
are used in connection with specially designed, three-phase, squirrel-oa
motors whose windings a
^*''" adapted for connection in st
during acceleration and .

delta for running. This foii

of starter is not often used
capacities exceeding 25 h.p. n
with potentials exceeding 5
volts. Fig. 58 shows the cc
nections for this form
Fig. 58.— Connections of delta-star starter. starter. Although not sho>
by the diagram (Fig. 58), sti
delta switches are almost invariably arranged either to short-circuit the fusl
entirely during starting or to transfer starting current through a seconds
of fuses which are of higher capacity than the running fuses. Some arranj
ment of this sort is almost essential, for if the starting current passes throui
the running fuses, they must be made so large as to afford practically •!
protection against overloads in normal operation. Star-delta switches e !

often equipped with no- voltage release, the magnet in such instances bei ;

connected directly across the line. j

606. Time-limit overload protection. A better protection is afford

by time-limit overloads, which permit the starting current to flow for
limited time and which when the overload continues de-energize the lo
voltage release and thereby disconnect the motor. A typical applicati
of these overloads is shown in Fig. 59.
607. Primary-resistance alternating-current starters are employ
to a limited extent in connection with two-phase and three-phase squirr
cage motors, and, to a considerable extent, in connection with single-phf i

motors which start as repulsion machines. They are of the same gene!^
form as those employed with direct-current motors, except, of course, tk *

where they are used in connection with two-phase or three-phase nioto' j

they must provide for the inclusion and removal of resistance from two lir^
instead of one. Since polyphase motors require greater starting currerj
when started by the primary-resistance method than when induction start* j
are employed, primary re.sistance is not often resorted to in any except t (|

small capacities. Its one advantage over the induction type of starter 1
j

in its lower first cost and its greater simplicity. The single-phase startij
are often equipped with no-voltage release, the no-voltage coil being cc j
nected across the line. Polyphase resistance starters are usually of 1 j
drum-controller type with one or two steps of resistance per motor phas*"]
508. Induction starters for alternating-current motors are mc j{

widely employed than any other form of alternating-current starting devi'-J

They consist of an auto-transformer together with a switching device j !

connecting the stator winding, first across reduced potential obtained fri j
the starting transformer, then directly to the line. In large capacities tb t
induction starters are often arranged to operate in three or more steps, tt',ii
reducing the current surges. For moderate-capacity machines they i

generally designed to connect the stator first across transformer taps whi:
deliver from 50 per cent, to 80 per cent, of line potential, and then to the m
Induction starters are almost invariably arranged to disconnect the startir
transformer windings from the line in all positions except the starting positio-*
Induction starters are also arranged to short-circuit the individual runni
fuses during starting. Sometimes the starting current is taken throu
auxiliary starting fu.ses of heavy capacity, but in most instances the nw>i.
are unprotected during starting. This class of starter is now almost ii
ably equipped with no-voltage release, and often with overload releasi .

replaces the fuses. The overload release generally takes the form of ovn
relays which are adapted to open the circuit containing the no-voli
release magnet; this allows the switching mechanism to open the mm'

1342
 INDUSTRIAL MOTOR APPLICATIONS SeC. 15-509

circuit. Where overload release is employed, the overload relays are indi-
vidually short-circuited during starting. Fig. 59o is a connection diagram
for a typical induction starter with no-voltage release and Jprotected with
fuses, while Fig. 596 shows the same device supplied with overload release.
In large plants one bank of starting transformers is sometimes employed
for starting all motors, and a five-wire system is installed. Where this
arrangement is employed the motors are first connected to a common line

For 2 phase i wire svatem L2 Is common line

and T2 Is common motor Inul

(a)

nd two starting lines, and then directly to the distributing mains, Fig. 60
'.

ihows the arrangement described.

609. Secondary -resistance starters for alternating-current motors
re used in connection with alternating-current slip-ring motors for the pur-
ose of increasing the secondary impedance during starting, and are of the
-ame general type as primary-resistance starters. Since slip-ring motors
[most invariably have their secondaries wound polyphase, it is quite impor-
.mt that the starters used with such motors be designed to keep the second-
ry circuit as nearly in electrical balance as possible, for any unbalancing of
'lis circuit reduces the
:arting torque which it ia Li .

osaible to obtain with a ^ |

'ven line current.
/>".
'
S e c o n d a ry-resistance
arters are sometimes en- Tranafon
rely separate from the
.vitching apparatus used
• open and close the
iimary circuit. In other
stances the primary
•itch is interlocked with
e device for controlling
e secondary resistance
such a manner as to
event the closure of the
mer unless the latter is

cuit.
iter
a position
3ondary resistance
Where
is
where
is
a slip-ring
started
)pped at frequent inter-
and
all
in

Fig. 60. —
ra
Five-wire system of starting
alternating-current motors.
Is, the primary switch
,d the secondary resistance commutating device are often connected to a
gle control lever, so that, as the latter is moved from the "off" position
jvard the full-speed position, the primary circuit is first closed and then
! secondary resistance is removed step by step.
The characteristics of motors with which secondary-resistance starters
employed have so much influence upon the design of the resistance that

1343
 .

xa S ,sa nNDUSTRIAL MOTOR APPLICATIONS

IB imposBjble to lay dpwn any rules governing the determination
of the*
ohmic value of the various steps; see Sec. 7. Non-inductive resistances!
should be used exclusively in the secondary circuit of slip-ring motors
610. Automatic or self-starters are used in connection with both alter-'
nating-current and direct-current motors when it is desired to have them
start and stop automatically in response to variations in pressure, water
'evel, etc.; or when it is desired to start the motor with greater convenience
•d with less demand upon the intelligence of the operator than is required
re hand-operated starting apparatus is installed; or when the motor is
so large that its control equipment becomes
cumbersome and difficult for the operator
to handle; or when the motor is frequently
reversed and is likely to be injured by taking
an excessive current when "plugged."*
Self-starters and automatic control would
be an utter impossibility without magnetic
switches (sometimes termed contactors)
and consequently a brief description of such
devices and their characteristics appears
necessary before entering into a discussion
of the various types of self starters (Par
6H to 518).
611. Direct-current magnetic switches
are generally of the single-pole type. The
most common form is operated by an electro-
magnet of the clapper form (Fig. 61). The
movable element or clapper carries a contact
mernber adapted to engage a corresponding
stationary contact, and a flexible connection
carries current to the contact mounted on
this moving clapper. Because an electro-
magnet adapted to long-pull work is inher-
ently inefficient and slow in operation, the
modern contactor is almost invariably ar-
ranged for a short break and in large capac-
ities must be provided with a magnetic
blow-out for disrupting the arc. In small
capacities the arcing contacts are often
used for carrying the current as well, but in
larger capacities the main or current-carry-
ing contacts generally consist of laminated
brushes which engage contact plates. Thi.'
laminated contact is protected against arcing
and burning, by auxiliary contacts located
in the magnetic blow-out field; these are
adapted to engage sooner than the laminated
Fia. 61. — Direct-current mag- contacts, and to open later. Fig. 61 shows a
typical direct=-current contactor with thf
netic switch.
blow-out pole pieces swung upward -so as tc
render the contacts easily accessible for repairs.
In order to be quick acting and positive in operation, direct-current con-
tactors should have coils which are capable of closing the switch with
potential equal to 75 per cent, of normal impressed at the coil terminals,
when the coils are at the operating temperature.
612. Alternating-current contactors are almost invariably called upoc
to handle two circuits simultaneously and are, therefore, almost invariably
of the double-pole type. They are generally of the clapper form, but the
magnetic circuit is necessarily laminated. Particular care should be taken tc
insure the holding of the laminations with sufficient rigidity to secure 8
permanent structure. The pull exerted by an alternating-current magnet if
proportional to the square of the voltage impressed at its terminals, conse
quently it is not practicable to make alternating-current contactors whi' I

have the same operating range as direct-current contactors.

* Par. 641, No. 8, 9, 13, 25.

1814
 INDUSTRIAL MOTOR APPLICATIONS SeC. 15-513

.It is practically impossible to obtain auflBcient sealing pressure with alter-

nating-current magnets to allow the use of laminated contacts, and, aa a
result, most alternating-current contactors depend upon butt contacts of
copper for opening the circuit and for carrying the current when closed.
Alternating-current contactors designed for voltages up to 550, are almost
invariably equipped with magnetic blow-outs, and those built for higher
potentials are generally arranged to open the circuit under oil. Air-break
contactors have been made, however, for potentials up to 2,200 volts. These
high-potential contactors are equipped with horn-
t,,,,,,,,,,,,, „,„„
type arc gaps, which permit the arc to increase in
length until it reaches the point of disruption.
^^^^^W
^ V//m///7////M//.

11
ill
111

Fig. 62. — Direct-current time-accele^Ja- Fio. 63. —

Series switch-
tion starter. operating magnet.
S13. Time-acceleration self-starters are designed to accomplish the
lecessary starting operations in a pre-determined and adjustable period.
Che timing may be accomplished in many ways, but a solenoid whose action
3 retarded by an adjustable dash-pot, is perhaps the most widely used device.
V.typical direct-current time-acceleration starter is shown diagrammatically
a Fig. 62.
•14. Ctirrent-limlt self-starters are devised to halt the starting opera-
'ion whenever the required starting current exceeds an adjustable predeter-
lined value, the starting operation being resumed when the current falls
elow this limit. There are several forms of current-limit acceleration self-
:arters, and only those which are most widely used will be described.

/inn-<0i-i
Fia. 64. — Starting device using the series switch of Fig. 63.

116. A
series switch operating: magrnet is shown in Fig. 63; this piece
< apparatus is designed to accomplish the current-limit acceleration of
'8ct-current motors. The .series switch is operated by an electromagnet,
'ich, as the name of the device indicates, may be connected in series with
> motor. The magnetic circuit enclosing this winding may be of jthe

1346
 !

Sec. 15-515 INDUSTRIAL MOTOR APPLICATIONS

solenoid or clapper form, but invariably includes a section of restricted!
area, "A," bridged by a movable element, "B," which gives a maximum|
shunting effect when the switch is
open, and a minimum shunting effect
when it is closed. An adjustable air
gap is included in the magnetic
bridging circuit. Whenever the cur-
rent passing through the winding is
in excess of a certain value, that
section of the magnetic circuit ("A")
which is of restricted area will be
saturated, and the excess flux lines
set up by the winding will, therefore,
seek the other path and tend to hold
the switch in an open-circuit posi-
tion. The switch remains open as
long as the current in the magnetiz-
ing winding is above the value for
which the switch is adjusted; below
this value the restricted area be-
comes capable of carrying a sufficient
proportion of the flux to set up a
counter force capable of overcoming
the restraining pull, and close the
switch.* The solenoid-type series
switch is quite fully illustrated and
described in the Transactions, of A.
I. E. E., Vol. XXX, page 1563, in a
contribution by A. C. Eastwood.
Fig. 64 is a typical connection
diagram for a self-starting device
made up of these switches. When
the line switch "K" is closed, cur-
rent passes from the positive line
through the shunt-field windings,
"/, " to the negative line; also from
the positive line through the arma-
ture, "A," the series field, "F,"
the resistance sections, "V»" "Vj"
"Vi," and the operating coil, "Ci"
of the first series accelerating switch,
to the negative line. If the initial
current inrush is in excess of the
—
Fig. 6.5. Magnetic lock-out switch.
value at which "Ci" locks open, no resistance will be cut out until th
accelerating current ha
fallen to the point which wil
permit "Ci" to lift it
plunger. When " Ci " lifts it
plunger, switch "Si"
closed, thereby short-circuit
ing resistance section "Vi
and including the windin:
"Ci." The operation
these series switches is pr?
gressive. When "Ci,"_tn
last of the accelerating wind
ings, closes its switch "iSi,
windings, "Ci," "Ct"
"Ci," are short-circuited •B)
the shunt winding, " Hi"'\
-Starter comprising three magnetic connected in circuit direetlj
~
lock-out switches. across the lines. Wind
"III" serves to hold '1
closed during running, thus guarding against the dropping out of the 61^
crating switches should the motor operate under light load.
'Par. 641, No. 29.

1346
 INDUSTRIAL MOTOR APPLICATIONS SeC. 16-516

616. The magnetic lock-out switch, illustrated in Fig. 65. is applicable

to direct-current motors. It is a clapper-type switch of conventional form,
operated by a series winding instead of shunt, and having a second series
winding, separately mounted, adapted to act on a downwardly projecting
extension of the switch clapper, and to hold the switch open as long as the
force exerted by this secondary winding exceeds that of the closing coil. An
adjustment is provided by which the air gap between the secondary or
locking-out coil and its armature can be varied; thus the current above
which the switch will be locked in an open position can be adjusted through
a wide range.

® — SO ^^ ^ S M^ n^

Fia. 67. —Alternating-current time-limit self starter.

^^
eferring to the diagram. Fig. 66, which covers a simple starter consisting
rthree magnetic lock-out switches, it will be noted that when the line circuit
closed, the motor current passes from the positive line through the two
ndings of the first magnetic lock-out switch, thence through three sec-
ins of starting resistance to the armature of the motor to be started. As
•ig as the current passing through these windings is in excess of a prede-
-mined and adjustable value, the restraining force exerted by the lower or
'^king-out magnet will exceed the attractive force exerted by the upper or
•sing magnet, and the switch will maintain an open-circuit position. When
^ current has fallen below this predetermined value, the upper or closing

1347
 ,

Sec. 16-517 INDUSTRIAL MOTOR APPLICATIONS

magnet will develop sufficient pull to overcome the lock-out winding. Ai
soon as the contacts of the switch engage, one section of the startini
resistance is removed, and, with this section, the lock-out coil, so that anj
tendency which this coil might have to hold the switch in an open-circui"
position is entirely removed. No. 1 accelerating switch, in closing, no'
only short-circuits a section of the resistance and its lock-out coil, but alsi
automatically includes both windings of the second accelerating switch'
which in turn locks open until the starting current has fallen below th:
value at which it is adjusted to operate. These switches will remain closei'
with 5 per cent, of their normal current; consequently no shunt winding i!
ordinarily required for the last switch. j

11 II ICie . /ii

Alternating-current current-limit self starter.

617. Tha counter-e.m.f. starter for direct-current motori is

reality a current-limit starter. In this device the starting resistance is r'
moved by a series of magnetic switches whose operating windings are coii
nected across the motor armature; these switches close successively as tij
counter e.m.f. of the motor increases with the speed.
618. Alternatiner-current induction self starters may also be of ettblj
the time-limit or current-limit type. In the former the primary windin]^'
are connected to the starting transformer for a predetermined length of tin'

1348
 INDUSTRIAL MOTOR APPLICATIONS Sec. 15-519

and are then thrown directly on the line. Fig. 67 shows a typical starter of
this class. A very similar starter is employed for the control of secondary
starting resistance, the removal of the starting resistance being accomplished
after a predetermined time interval. Both induction and primary-resistance
self staiters of the current-limit type are manufactured, but have not proven
as satisfactory as the time-acceleration type on account of the low starting
torque of squirrel-cage motors, and the possibility of their being so loaded
that they will not accelerate sufficiently to enable a cuirent-limit type of
starter to change from starting to running position. Fig. 68 shows a current-
limit acceleration controller for use in connection with an alternating-current
shp-ring motor. This controller consists of a primary contactor and two
secondary resistance contactors, all of which are double-pole type. The
opeiation of the primary contactor may be controlled by a pressure regulator,
a float switch, or a simple snap switch. The secondary resistance switches
are arranged for successive operation, and are governed by two 3-phase,
secondary series relays, which are arranged to halt acceleration whenever th«
motor current exceeds the value for which they are adjusted.
SPEED REOULATOBS
619. Direct-current speed regulators. The speed of direct-current
motors may be varied in two ways: first, by varying the potential impressed
at the armature terminals, the field strength remaining constant (the speed
of a direct-current rnotor operating at constant field will be directly propor-
tional to the voltage impressed on its armature terminals) second, by varying
;

the field strength, the voltage at the armature remaining constant. The
speed of a motor whose armature potential remains unchanged, will be in-
versely proportional to the field strength. Speed control can also be obtained
Dy a combination of the two methods just mentioned.
There are many ways in which the armature potential may be varied, the
•nost common being to insert a resistance in the armature circuit; the IR
Irop, across this resistance serves to reduce the voltage impressed upon the
vrmature. This method is open to the objections that it is inefficient and
hat the IR drop varies with the motor load; consequently the regulation is
lot good and only a limited range of regulation can be obtained. Assuming
a motor to be operating
under full-load torque,
about 125 per cent, of full-
load current will be re-
quired to start it, and the
amount of resistance which
will permit such a current
inrush will give 75 per
cent, reduction in arma-
ture e.m.f. and speed with
full-load torque and cur-
rent. It may therefore be
said that 4 to 1 is the
aWW\^ maximum speed range
which it is possible to ob-
tain satisfactorily by the ar-
Fig. 69. — Ward-Leonard system of direct- mature-resistance method,
and that in many cases
current control.
3 to 1 will be the maxi-
um range obtainable. The regulation with this method at reduced speed,
der variable loads, is so poor as to make armature-resistance speed regula-
m impracticable for any but constant-load work.
520. The Ward-Leonard system of direct-current control is well
apted for wide range, and has good regulation. Fig. 69 is a connection
'.gram for a typical system of this class. "G-1" and "G-2" are two
.lerators, one of which is self-exciting, and furnishes current for the fields of
:i-2|| and the niotor " M." By means of rheostat, " R," the voltage of
y2" can be varied, and the speed of "M" will be correspondingly varied.
;e regulation of such a system is very good, through a wide range of control,
U becomes unsatisfactory only when the comparatively small IR drop in
t armatures " G-2 " and " M" and the connections between them, becomes a
156 percentage of the total potential generated by "G-2" (Par. 641, No. 4).

1349
 1

Sec. 15-521 INDUSTRIAL MOTOR APPLICATIONS

By reversing the fields of "G-2," the direction of rotation of the motor

"M," can be changed (Par. 641, No. 19, 21 and 24). This system is extonJ
sively employed for reversing mill and mine hoist duty. !

621. The multiple-Toltage method of direct-current speed contro''

is generally used in connection with a certain amount of field control. Th<
older multiple voltage systems are almost invariably four-wire, as per Fig
68. A balancer set having three armatures is connected across a 250-vnl'
system and gives 60, 80
and 110 volts between the
three sets of mains. The
motor whose speed it is
desired to control, may
obviously be so connected
that it will have 60, 80,
110, 140, 190 or 250 volts
mpressed on its armature.
Field control is used to
smooth out the steps; the
motor field strength is re-
Fia. 70. — Multiple voltage system of direct-
current control.
duced while the armature
is connected to each potential, before ste{)ping to the next higher potentill
and is increased to normal strength as the change is made.
Later systems employ but three wires (Par. 641, No. 5) and provide fd
1 10 and 220, or 125 and 250 volts at the motor armature. To obtain reasOfl
ably small speed increments throughout the entire speed range, these threei
wire systems require a motor whose speed may be varied by field contrc
through a wider range than is required where a motor is operated on the foui'
wire system.
622. The field strength of a motor may be varied by electrical o
mechanical means. When this is accomplished electrically, the field stroiiKt
is generally varied by a field-regulating rheostat. Field regulation is effedc
mechanically by changing the air gap and consequently the reluctance of t!
field circuit. Either method produces the same results, the former haviii
the advantage that the regulating rheostat can be conveniently located ;

some distance from a motor, also that the field strength can easily be increase
to normal during starting.
The extent to which the speed of a motor can be <varied by field contri
depends upon its design. Generally speaking, a standard machine wi
seldom commutate well if its speed is increased in this manner more than L
per cent., while specially designed inter-pole motors have been built for spci
ranges as great as 10 to 1. On account of their good inherent regulation :ii
their high efficiency at all speeds, field-control motors are almost universal
employed where speed control of direct-current motors is required.
623. A combination of armature-resistance and field control m:
be used to advantage where reduced speeds are required for comparativr
short periods, and the expense of installation can be materially reduc
by such procedure. It will also be found where a wide range of speed
required in connection with the Ward-Leonard system (Par. 641, No. ^ 1

Fig. 67, that it will be advisable to regulate the field strength of the moi"
well as that of the generator.
624. Self-starting speed regulators. In machine-tool practice, -
starters are used to start and stop machines whose speeds are adjustable 1>\
regulator controlling the motor fields. Such self starters may beequipi"
with a vibratory field-regulating relay, the winding of which is connc ;

in series with the motor armature. When the armature current reaeh
predetermined value this relay will short-circuit the field rheostat, '

increasing the motor field strength to normal. The field strength is contii
at normal until the armature current decreases sufficiently to allow the i

to drop, thus inserting the field resistance and increasing the armature cm
because of the reduced counter e.m.f. Increase in armature current i-n
the relay again to short-circuit the field rheostat, and the relay continue-
vibrate, alternately short-circuiting and cutting in tlie field resistance, im
the motor has accelerated to such an extent that the field resistance may
left in circuit without causing the armature to take a current in excess of i

relay setting.

1350
 INDUSTRIAL MOTOR APPLICATIONS SeC. 15-525

526. Series-parallel control of two motors ia a convenient and efficient

means of obtaining two speeds, one speed being one-half the other. Such
a control system has the added advantage of reducing the current required to
produce a given starting torque. This system of control is most widely
used in railway work (also see Par. 541, No. 10).
526. Speed control of squirrel-cage motors may be accomplished in
two ways: first, by changing number of poles; second, by varying the com-
bined voltage and frequency
impressed on the primary. L\
The number of poles may be
changed by the use of sepa-
.. . J
rate windings and selective
?nergization, or by regroup- H Speed
ing the windings to change
ihe number of poles. The
ornier method is employed
where more than two speeds
ire required. To obtain a 1
2 ratio the windings are
 —
Sec. 15-530 industrial motor applications
revolve in the same direction and in different concatenation when the second
("B") tends to oppose the first ("A"). See also Par. 641, No. 6. Th.i
synchronous speed for each of the concatenated connections can bo deter'
mined as follows: '

„ cycles X 120 . , ,„!

S =--p-^-^^ ,
(rev. per mm.) (Oi

where S is the synchronous speed in rev. per min.; Pi is the number of pole
of motor "A;" Pi is the number of poles of motor "B." The plus sig:
should be used when, the motors are in direct concatenation, and the minu
sign when in differential concatenation. The diagram in Fig. 61 shows th
connections for a cascade system.
Motor B
Vw^\/WA

Motor A
Starting
Beslstance

Fig. 72. — Cascade connection of two motors.

There are so many methods by which the speed of one or more slip-rin
motors can be varied (see Par. 641, No. 6, 7, 15 and 26), that it is impos.sib,:
to cover them all in the limited space available.
630. Single-phase motors of the repulsion type may have their spee
varied either by the use of primary resistance, or by shifting the brushe
The results obtained by various motor manufacturers are so widely divers,
as to make it almost impossible even to outline the limitations of sue
systems.
631. Synchronous motors are not susceptible of speed control; see Pi
641, No. 22.
ELECTRICALLY OPERATED BRAKES
632. Classification. In the control of electric motors it often becoiiu
desirable to provide a brake which is electrically released and applied b,\
spring or weight.
the band and the shoe type.
—
Such brakes are made in three types the multiplc-di-

633. Band brake. In one type of band brake, a wheel is attached to tl

shaft to be braked, and this wheel is encircled by a band lined with a sui
able friction material. Normally the band is brought into frictional engag-
ment with the wheel by means of a spring; a solenoid is provided for the pu*
f)ose of compressing these springs and relieving the brake band. The bat
jrakes are manufactured for either alternating-current or direct-ourrei
service.
A multiple-disc brake is illustrated in Fig. 73. This typical for
634.
of brake is manufactured only for direct-current service. It consists >

a hub which is mounted on the shaft to be braked, to which hub are keyt
one or more discs and a stationary frame, in which are carried, by means >

keys, two or more stationary discs. Normally the rotating discs are clampi
between the stationary discs by the action of a spring, and by means ()l :

electromagnet this spring can be compressed and the pressure on the fricii
discs relieved.
636. Shoe brake. A typical shoe brake differs from the band brako <

in that the movable friction face is in the form of a shoe rather than in

1352
 —
INDUSTRIAL MOTOR APPLICATIONS See. 15-536

form of a band. These shoe brakes are also made for alternating-current or
direct-current service.
636. Advantages of the various types. The disc brake has the advan-
tage, over either other type, of imposing no side strains on the shaft to which

Fia. 73. —Exploded view of multiple-disc brake.

it isapplied. Naturally, it also provides equal braking for either direction
of rotation, whereas some forms of band and shoe brakes do not possess this
feature. The band-type brake, generally speaking, is superior to the shoe-
type, because of the larger proportion of the brake wheel which is in actual
service, and the consequent reduction in unit pressure on braking surfaces.
Moreover the band-type brake possesses the tendency to wrap itself around
the wheel, consequently it can
le operated by means of a
(mailer solenoid than is re-
^
Series Field _
juired for a shoe brake of ain'^noist
,.,.„^i
^^
Brake Solenoid
iorresponding rating.
DYNAMIC BBAKINQ
637. Classification.
Firat-hoist
I
O —~
nsTPSV^ •S
I "'-vwwvwvw-
dynamic braking may be de-
ined as the retardation of a
Qachine by a motor acting as 0«-
.generator, which takes no
urrent from the line other
han for excitation. The sub-
set of dynamic braking may
e divided into two parts as ^'* Lower
.ollows: first, for the purpose
if effecting a quick stop;
2Cond, for the retardation of
descending load.
638. For the purpose of
3tarding: the descending
Max' Lower
»ad on cranes and ore-hand-
ng machinery, it is common
ractice to employ dynamic ., ..i. ,

•aking. The motors used for'^ '

. ,

lisservice are almost invaria-' ^Vla.-*7'4 -Retarding a descending load by

,y series-wound, and in start- dynamic breaking.
,g down it is necessary to take
-irrent from the line by a separate circuit in order to energize the series field,
-he systems employed are almost innumerable, and it is impossible to de-
ribe them all here. The connection diagrams. Fig. 74, illustrate the
iBory of a control system of this character. It will be noted that in hoist-
?, the motor armature and field are first connected across the line in series
ith a resistance. This resistance is removed step by step as the control
/eris advanced toward the full-speed position. A
mechanical brake set by
weight or spring serves to hold the load in any position, and a series-

1353
Sec. 16-539 industrial motor applications
wound solenoid, "B," is adapted to release this mechanical brake wheni
hoisting or lowering is taking place. In the "off" position, the circuits to!
both motor and brake solenoid are open, and consequently the mechanical
brake is set. In the lowering positions the motor field and the brakeJ
solenoid are connected across the line in series with a variable resistance;]
the motor armature is bridged across the field and the brake solenoid. Aw
the control lever is advanced toward the full-speed lowering position, the!
resistance included in the field-brake circuit is increased until all the resis-i
tance is inserted. Further movement increases the resistance included be-|
tween the armature and the series field until the armature is finally connected*
directly to the line. The higher the resistance included in the armature!
circuit, the greater will be the speed at which a given load will descend; andj
the lower the value of resistance included, the lower will be the descendingj
speed. Should the descending load be insufficient to overhaul the motor, thw
latter will run as a shunt-wound machine, and actually drive the hoist drumej
in a reverse direction, paying out line to the descending hook. For sendinifl
a light hook down at high speed, the series field is weakened by shunting. |
639. Dynamic braking of direct-current motors for the purpose of^
eSecting a quick stop is employed quite extensively in connection with,
elevators, printing presses and machine tools, centrifugal extractors, etc
The arrangement generally provided consists of a switching appliance foi
connecting a fixed step of resistance across the terminals of the motor arma-
ture after the line circuit is interrupted. As a result of this procedure the
motor acts as a generator and serves to retard and stop the machine which il

drives. While it is possible to effect a quicker stop by this method than if i-

were not employed, it does not provide for the quickest stopping that cai
be obtained; it is obvious at once that as the motor speed decreases, the poten
tial generated by its armature correspondingly decreases, and. the reductior ,

in current which the armature will send through the fixed step of resistanci
results in a gradual diminution of the braking force, until it reaches zen
when the armature stops.
Inductive resistance is often employed in the braking circuit for the imr
Cose of prolonging the period during which the braking current remains ;i

igh value, and quicker stoppage can be effected by its use. Where th
quickest possible stop is desired, a variable resistance should be connect! >

across the motor armature; this resistance should be reduced by a series n

magnetic switches, the successive closure of which will be halted whenevc
the braking current exceeds a predetermined value. With such an equip :

ment, the braking current can be maintained at a high value throughout th' i

entire stopping period, and much faster results obtained than are possible b; i

any other method. In the interest of economy the starting resistance an( -

the accelerating switches are generally employed for graduated dynami (

braking. Thus the same apparatus which is used to limit the current o i

acceleration, serves also to limit the current of retardation.

640. Alternating-current motors can be used for dynamic brakini <

only when direct-current is available for their excitation; the method i •'^

seldom used, for this reason. For quick stopping, the reversal of the primar; i

and the inclusion of a high resistance in the secondary is equally effcctiv, •

and does not require direct current. For the retardation of dcscendin
loads it has not been very popular, largely on account of the general unpopu ;

larity qf alternating-current motors for this class of service, direct-curren ;

machines being better adapted on account of their inherent characteristic

(Par. 641, No. 11).
BIBLIOaRAPHT
641. Selected references to literature on motor control
1.
—
Whitino, M. a. "Motor Control." Trans. Assoc. I. & 8. E. E., \'.>

page 42.
2. "Automatic Motor Control for Direct-current Motors." Trang. A-
&1S. E. E., 1911, page 25.
I.
3.* Crocker, F. B. — "Electric Motor Regulation." A. I. E. E., Vol.
page' 237.
4. Leonard, H. Ward.
—
"Volts, vs. Ohms." Trans. A. I. E. E., \
XIII, page 377.
5. Storer, N. W.
—
"Three-wire System for Variable Speed Motor Work
Trans. A. I. E. E., Vol. XX, page 127.

1354
 INDUSTRIAL MOTOR APPLICATIONS SeC. 16-541

6. Spbcht, H. C. —
"Induction Motors for Multispeed Service." Tram.
A. I. E. E., Vol. XXVIII, page 1177.
7. "Multiapeed Induction Motors." Trans. A. I. E. E., Vol. XXVIII,
page 601.
8. Henderson, C. T. —"Electric Control for Rolling Mill Motors." TrofW.
A. E. E., Vol. XXVIII, page 897.
I.
—
Whiting, M. A. "Automatic Motor Control." Trans. A. I. E. E.j
9.
Vol. XXVIII, page 913.
: 10. Fowler, Geo. W.
—
"A Series Parallel System of Speed Control."
Trans. A. I. E. E., Vol. XX, page 143.
11. Henderson, C. T.
—
"Dynamic Braking for Coal and Ore-handling
Machinery." Trans. A. S. M. E., Vol. XXXVI.
. 12. Kelsey, C. a.
—
"Electrical Requirements of Certain Machines in the
.lubber Industry." Trans. A. I. E. E., Vol. XXXII, page 1597.
; 13. CoET, Stuart C.
—
"Advantages of Automatic Control, in Steel-
Trans. A. I. E. E., Vol. XXXI, page 539.
i)lant Operation."
14. Morse, E. C. —
"Application of Electric Drive to Paper Calen-
Trans. A. I. E. E., Vol. XXXI, page 1635.
ders."
r 15. Meyer, F. W. and Sykes, Wilfred. —
"Economical Speed Con-
rol of Alternating-current Motors Driving Rolling Mills." Traris. A. I. E. E.,
'ol. XXXI, page 2175.
16. Cheney, H. W.
—
"Electrical Control of Large Mine Hoist." Trans.
'.. I. E. E., Vol. XXXI, page 215.

17. Specht, H. C.
—
"Electric Braking of Induction Motors." Trans. A.
E. E., Vol. XXXI, page 583.
.

18. Henderson, J. S., Jr.

—
"Electric Drive for Paper Machines."
^rans. A. I. E. E., Vol. XXXI, page 1383.
19. McCoRMiCK, B. T.
—
"Electrification of Reversing Mill of the Alfoma
Trans. A. I. E. E., Vol. XXXI, page 297.
'
,teel Co."
20. Lincoln, P. M.
,
—
"Motor Starting Currents as Affecting Large Trans-
Trans. A. I. E. E., Vol. XXXI, page 951.
is.sion Systems."
21 . Sykes, Wilfred.
—
"Operation of a Large Electrically Driven Reversing
Trans. A. I. E. E., Vol. XXXI, page 559.
olli.ng Mill."
22 Fechheimer, C. J.
—
"Self-starting Synchronous Motors." Trans. A.
E. E., Vol. XXXI, page 305.
23. Eastwood, A. C.
—
"Automatic Motor Control for Direct-current
Trans. A. I. E. E., Vol. XXX, page 1563.
otors."
24. Sykes, W. —
"Electrically Driven Reversing Mills." Trans. A. I. E.
Vol. XXX, page 1285.
,

25 Barnum, T. E.—"Elevator Control." Trans. A. I. E. E., Vol.

. XXX,
ge 1583.
26. Maier, Grs A.
—
"Methods of Varying the Speed of Alternating-current
Trans. A. I. E. E., Vol. XXX, page 2511.
otors."
27. Radley, G. R. and Tatum, L. L.
—
"Some Limitations of Rheostatio
)ntrol." Trans. A. I. E. E., Vol. XXX, page 1605.
2** — Ad. Ernst (J.Springer—
LuM, W. O. — "Alternating-current and Direct-current
Hebezeuge. Berlin).
'

Magnetio
Elder, R. — "Switches and Switchgear," D. Van Nostrand Co.
ro! forAuxiliary Motors."
.1.

>1. James, H. D. — "Controllers Electric Motors," D. Van Nostrand.

for

135$
^A^/
 .

SECTION 16

ELECTRIC RAILWAYS
BY ALBERT H. ARMSTRONG
Asst. Engineer, General Electric Company, Member, American Institute of
Electrical Engineers
Assisted by E. E. Kimball, General Electric Company, Associate
American Institute of Electrical Engineers, American
Railway Engineering Association
NORMAN W. STORER
"eneral Westinghouse Electric and Manufacturing Co., Fellow,
Engineer,
American Institute of Electrical Engineers
{
Assisted by Robert D. McManigal, Vice President and Treasurer,
Ohio Radio Laboratories, Associate Member American
Institute of Electrical Engineers

AZEL AMES
Engineer, Kerite Insulated Wire and Cable Co., Associate, American Instituti
of Electrical Engineers

ALBERT F. GANZ, M.E.

'rofessor of Electrical Engineering, Steveris Institute of Technology; Fellow,
American Institute of Electrical Engineers
AND
ALBERT S. RICHEY
onsulting Engineer, Fellow of American Institute of Electrical Engineers, Pro-
fessor of Electrical Engineering, Worcester Polytechnic Institute

CONTENTS
{Numbers refer to Paragraphs)
ELECTRIC TKACTION
itroduction 1 Trucks and Car Bodies 240
rain Resistance 4 Self-propelled Cars 256
)eed-time Curves and Motor Electric Locomotives 260
Characteristics 30 Power Distribution for Railway
lergy and Power Consumption 77 Electrification 273
iilway Motor Capacity 120 Distributing Systems 277
lilway Motor Control 145 Substations 365
'pes of Railway Motors 196 Bibliography 472
aking 203
RAILWAY SIGNALLINQ
neral 382 Track Circuits for Electric
pes of Fixed Signals 387 Railways 397
oUey-operated Signal Systems 389 Interlocking 404
e Track Circuit 392 The Block System 421
Bibliography 427
ELECTROLYSIS
Uure and Causes 430 Electrolysis in Concrete 462
Surveys
I ctrolysis 440 Municipal and State Regulations 465
Ivention 447 Bibliography , 471
Fm Grounded Distribution
ystems 459

1357
 SECTION 16

ELECTRIC TRACTION , ,

'•
BY ^
ALBERT H. ABMSTRONQ
Asat. Engineer, General Electric Company Member, American Inxtihite Ele
trical Engineers
Revised with the Assistance op

I General Engineer,
American
MOBMAN W.
Weslinghouse Electric and
STORES
Manufacturing
Institute of Electrical Engineers
Co., Fillox

INTRODUCTION
1.Considerations affecting general design. All railway estimate
are based upon the performance of the rolling stock, as this determines tl
type of equipment to be used, its capacity, the possibilities of schedu
speed, and the power input to the train, both maximum and average. Th
last-named factor in turn determines the characteristics of the low-potentl
distribution system, whether trolley or third-rail, and its capacity. Thei
considerations lead up to the determination of substation capacity am
finally, the capacity and cost of the generating station. It is importan
therefore, that the characteristics of the different types of motive powi
be thoroughly understood, as a false assumption or error in the preliminai
calculation of motive-power capacity and train energy consumption nia
lead to very serious errors in laying out the entire generating and distributit
systems.
2. Classification of systems now employed. There are four types (
motors available for railway service, giving rise to three systems of distr
bution: (a) the direct-current series-wound motor used at line voltages <

from 600 to 3,000 volts, fed from a synchronous-converter or motor-gene:

ator substation, tied into a high-potential three-phase alternating-currei
transmission system; (b) the alternating-current series-wound motor fe
directly from an alternating-current high-potential transmission sy.stei
through intermediary step-down transformers; (c) the alternating-currer
three-phase induction motor fed directly from an alternating-current thre<
phase transmission system through step-down transformers; (d) the altei
nating-current polyphase induction motor, fed from a single-phase circu
through an intermediate phase converter ("split-phase system").
All four systems enjoy the advantage of alternating-current gencratio
and transmission of power at high potential, the direct-current and ind '

motor system demanding multiphase generation, while single-phase u

tion and distribution best serves the needs of the single-phase altern: ii,
current motor and split-phase systems.
3. Method of studying traction problems. The various steps to h
followed in the determination of the proper relation of motive power cr}"
ment, distribution and generating systems, are as follows: (a) a knowb
train-resistance values; (b) calculation of pos.sible schedule with tho fn <;

of stops, train weight and other fixed factors entering into the problt^i., ,

determination of train input as obtained from train resistance and energ

consumption values; (d) determination of motor capacity; (e) calculutioi
of train diagrams; (f) determination of capacity of low-potential distnbi
tion system and substations; (g) determination of generating-station capi
city; (h) estimate of cost of the various parts of the electric railway system i

determined by the capacity found above; (i) approximate cost of operatiMj

(J) approximate gross income as determined by comparative statistics; w
dividend earning power of road. I

1358
 ELECTRIC RAILWAYS ScC. 16-4

TRAIN RESISTANCE
4.Tests. Careful experimental tests, carrieci out during the past few
ears with electric locomotives and motor-cars, have thrown' new light on the
luch discussed question of train resistance at the higher speeds. Without,
1 any way, disparaging the care taken in tests made with steam locomotives,
; was not until electrical methods of measuring power introduced greater
ccuracy than was possible by use of the steam indicator, that consistent
3sults became obtainable with light trains operating at very high speeds.
The electric motor was the means of introducing the single-car train
perating at speeds up to 70 miles per hr. At that time no data were extant
jncerning the operation of single-car trains. It was soon found that such
car operating alone required an input out of all proportion to the power re-
uired to propel a train composed of several such cars operating at the same
')eed, consequently new adjustments had to be made in train-resistance for-
mulas then existing.
During the spring of 1900, a series of teata were made by Mr. W. J. Davis,
•., on the Buffalo & Lockport Railway, which consisted in running a 40-ton

lectric locomotive alone and with trailers at speeds approaching 60 miles

!r hr., as a maximum. These tests probably constitute the first consistent {
tempt to utilize the benefits of greater accuracy which electrical methods of
cording afford. Since then other tests, taken under better conditions and
th various classes of equipment, afford data from which it is possible to
edict, with a considerable degree of accuracy, the total resistance (wind,
.aring and rolling) opposing the movement of cars or light trains up to
eeda of 100 miles per hr.
'5. Train resistance may be expressed in pounds tractive effort ex-
;ed at the rim of the driving wheels of the prime mover of a train. It
'eludes all losses in bearings, losses due to rolling friction, bending rails,
nge friction, etc., and the wind-resistance loss. The last item is made up
head-on resistance, skin or side resistance and eddy currents caused by the
^tion at the rear of the car or train. All these variables depend upon
condition of bearings, design of trucks, condition of the road-bed, shape
i cross-section of cars, direction of wind, etc., so that any tests, to furnish
h 'itativedata, must be sufficiently comprehensive to eliminate the errors
ly local conditions. As no such elaborate series of tests have yet
ade, any formulas predicated on the data available must at best be
I

.,;u.^imate.
Oata are available on the performance of locomotives and cars of modern
t.struction as follows: Buffalo and Lockport experiments in 1900; Zossen
'h-^;>ped tests in 1902-3; tests on New York Central type locomotive at
rtady, 1905-6; tests on car No. 5 at Schenectady, 1906; tests made by
itrio Railway Test Commission, on the test car "Louisiana," 1904-5;
-• Vork Subway tests, 1905; Dynamometer car tests by Prof. Edward C.
fcmidt. University of Illinois, 1910, and by Schmidt and Dunn in 1914
a: 1917.
lany isolated tests have been made from time to time other than those
nuioned above, but either the data was not sufficiently complete or the
editions were too unfavorable to justify using the results obtained as
» lying to other than local conditions. The data comprised in the tests
g ^n above are sufficiently general, as they include the operation of trains
V ,'ing from a single 35-ton car, to a train of 532 tons, and at speeds up to
1 miles per hr. in the Zossen tests.

Frictional resistance. The laws governing the friction of journal

rings are fairly well understood, and such bearing friction opposing the
'
n of a train, need introduce no undetermined factors in a calculation
'1resistance. Such friction losses decrease with the pressure on the
igs and are a function of the speed. Hence, the expression, /' =» A' -f-fi'S,
'J'e/' is bearing friction expressed as lb. per ton. A' and B' are constants
(Krmined by experiment (see Par. 8) and S is the speed expressed conven-
le y in miles per hr. Rolling friction (see Par. 22) is due to the friction of
m il rolling on metal where the surfaces are not perfect; the bending of
rs; due to insufficient support, or meager cross-section of rail; and flange
In on between rail and wheel flange. All these factors are proportional to
iVX and hence may be represented by a straight line function of speed.
Ae tearing and rolling friction are both approximately proportional to the
fp-1 they may constitute the first two terms
of a train resistance formula,
/i = A +BS (lb. per ton) (1)

1359
 Sec. 16-7 ELECTRIC RAILWAYS

7. The friction constant, A, has been determined by experiment to i

from 3.5 to as high as 12 lb. per ton, depending upon the weight concentri
on the journal bearings. Both the Zosaen cars and the New York Cen
locomotive have indicated in test a value of A =3.5 to 5, both the cars
locomotive having a weight of approximately 200,000 lb. concentratec
twelve journal bearings. Tests on Car No. 5 at Schenectady on the o
hand, gave a value of approximately 8.5 for A, this car having 68,800 lb
eight bearings. Hence, the impossibility of giving a single value to A \

will obtain over wide variation in type of equipment.

The factor. A' can be expressed in terms of the train weight and the foU
,

ing purely empirical term is suggested as agreeing remarkably close \

experimental results.
50
A= ,1-
y/W
where W = tons weight of train.
In using such a term it is necessary to limit A to a, minimum value of

I 20-ton
30-ton
40-ton
50-ton
car
car
car
car
8.
11.2
9.12
7.9
7.07
Values of A (Par. 7)
60-ton car
80-ton car
100-ton car
200-ton car
6

5
fi

3
9. The friction constant B. The coefficient of S in the second term
train resistance formula (Par. 6), takes cognizance of the increase of rol
and bearing friction with speed. This coefficient can be determined exp
mentally by operating a tram with and also against a wind of known veloo
Given a wind of say 10 miles per hr. in the direction of the test track,
series of runs be made at 40 rniles per hr. against, and 60 miles per hr. »
the wind, the effect of wind resistance would be the same in both cases,
the other hand, any difference in the total train resistance found would ra<
ure the (journal and rolling) frictional difference occurring for a speed cha
of 20 miles per hr. Unfortunately the published data of the Zossen test
incomplete in this respect, and offer no material upon which to place a vs
for the second term coefficient. Other tests, made for the purpose, t,

values of B for speeds up to 80 miles per hr. with trains of any conipositi
As the effect of B is small with heavy trains and almost negligible with sir
cars operated at high speed, any errors introduced by reason of insutfiei
data, do not seriously affect the accuracy of the train resistance fornmls
applied to the classes of equipment commonly met.
Values of B obtained experimentally vary from 0.03 to 0.07, depend
upon the type of equipment and condition of track. For practically
operating conditions a value oi B = 0.03 will give sufficiently accurate resu
using higher values of B for very light equipments (under 30-ton cars) i
poor track conditions, such as scanty rail, accumulations on rail, etc.
10. Wind resistance. By far the moat important term of a train rei
tance formula (Eq. 4) for light trains is the term expressing the relation
tween effect of wind and speed of train. It is in this term that the ms
elaborate tests made with steam locomotives have failed in affording accur
data, especially for very light trains operating at high speeds. Such te
have usually been made either with steam indicator or dynamometer oar
the means of determining the effect of wind pressure. The indicator Ci
included in its readings all the intermediate internal friction losses of i

locomotives, thus making results obtained by its use of small value wl

applied to other types of motive power having much smaller internal loM
The dynamometer car, while giving accurate readings of the draw-bar p
required to haul the succeeding trailers, failed to indicate the amount
head-on wind pressure, which constitutes by far the larger proportion of i

total resistance opposing the progress of a light train at high speed. Hen
the tendency to discard in a large part, the experimental data obtained fr
steam locomotive tests and place reliance upon the data obtained from 8i,
tests as the series listed in Par. 6. ,

Tests made upon small models (Gosa in 1897) and by means of whirl!
surfaces, seem to indicate that wind pressure increases as the square
velocity.
The Zossen experiments also indicated that the wind effect upon the
increased as the square of the speed, thus following along the line of labo

13G0
 ELECTRIC RAILWAYS Sec. 16-11

toryexperiment and previous experimental train tests by Davis in 1900.

Hence, that portion of train resistance which results from the effect of wind
may be given by the relation
/, = -^ (lb. per ton) (3)

where the wind resistance in lb. per ton, C is a constant, o is the

ft is
projected area, and W
is the train weight in tons. This equation leads to
ihe third term of Eq. 4.
Values of C (Kernot, 1894)
?« 0.004 for flat surfaces, C = 0.0020 for cylinder,
7 = 0.0024 for octagonal prism, C = 0.0014 for sphere.
11. Method of making wind resistance expeiimenta. The simplest
ind most accurate is the coasting method, where a moving train is allowed
drift until it reaches standstill, the rate of speed decrease and elapsed time
leing accurately noted. The efforts of most experimenters have been
lirected toward securing such data during periods of no wind in order to
Uminate this troublesome feature. However, a series of runs taken with
.nd against a wind of known velocity offers much data not otherwise avail-
ble, and affords a ready means of solving directly for the coefficient of the
i
second and third term of the train resistance formula (Eq. 4).
> For example, given a wind of 20 miles per hr. velocity, a series of runs
jiade with and against such a wind will, at say 50 miles per hr. train speed,
;orrespond to a wind pressure at .30 miles per hr. with the wind and 70 miles
rer hr. against the wind, the rolling friction being constant at the value ob-
.lining at the train speed of 50 miles per hr. As the wind pressure varies as
le square of the speed, such a series of tests affords a means of determining
le coefficient of S^ for the particular type of equipment used.

12 The shape of the car end has a large influence upon the coefficient
^ -uch a result being reasonably expected from the results of experiments
.laiss, Kernot and others: in fact, Davis checked up the values of 0.004
und by Kernot for flat surfaces. As a matter of fact, no cars or locomotives
*ed for high-speed service have perfectly flat ends, and hence, all experi-
ental values of C have been found to be less than 0.004.
 Sec. 16-13 ELECTRIC RAILWAYS

of theextreme type, while the average rounded end suburban car and eli
trielocomotive with sloping front give rise to values of C from 0.002
0.0025 (see Par. 10),

I
 ELECTRIC RAILWAYS Sec. 16-15

It is very possible that the higher values obtained at the maximum speeds
ere influenced by reason of the track being not rigid enough for speeds of
20 miles per hr., and hence increasing the value of B.
15. A consideration of trains of
iveral cars makes it necessary tointro-
icean additional factor in the third term
the proposed train-resistance formula
.atshall express the effect of the wind re-
itance upon the sides of the succeeding
rs. The head-on wind resistance is
irne by the leading car, and hence addi-
 Sec. 16-18 ELECTRIC RAILWAYS

18. The complete formula for any weight and composition of tra
(see Par. 23) now becomes,
50
'<
^=x7^+^-°'^ ^'-w—V^-io) (•''• P^^ *°"^

The above formula is presented as being an expression of the knowled

of train resistance with the data extant, but any such formula is large
empirical, and is subject to change from time to time as the results of adi
tional tests become available.

Max. Height
RuQniug I'os.

Fig. 7. — N. Y. C. locomotive, side elevation.

Figs. 9 to 13 show curves based upon this train resistance formula, a
express the resistance encountered with cars of from 20 to 60 tons weight c
erating singly and in trains. Also, for high-speed locomotive service, a seri
of curves is plotted for train values up to nine-car train operation, i

these results assume a perfectly level tangent track, free from any forei,
matter, such as street accumulations, sand, snow, etc. The effect of su
matter is to increase seriously the value of B, hence the curve values shou
be increased if conditions are unfavorable.
lUU

%^ dip
 ELECTRIC RAILWAYS Sec. 16-20

The results of a series of dynamometer car tests conducted by the Engi-

leering Experiment Station of the University of Illinois, are given by Prof.
i^dward C. Schmidt in a paper read before the A. S. M. E., May 14, 1910.
rhese tests covered a wide range of car weights and train speeds; Fig. 14
Ives the results thereof.

100

1 W
0,50

25
 ELECTRIC RAILWAYS

5 10 15 20
Pounds per Ton
Fig. 13. —Train resistance, locomotive train.
14
 ELECTRIC RAILWAYS SeC. 16-23

listance calculations except in the calculation of locomotive constants

iigned to mountain grade service, where both sharp curves and heavy
ides occur.
23. are expressed in percentages, being the ratio of the distance
Qrades
e train is raised to the distance travelled, in other words, the ratio of the
linate of a right-angled triangle to the hypothenuse. A grade of plus 1
r cent, is one where the train is raised vertically 1 ft. for each 100 ft.
ivelled; a minus 1 per cent, grade is one where the train falls 1 ft. for every
3 ft. of distance travelled. It follows that a plus 1 per cent, grade calls
a tractive effort of 20 lb. per ton, while a minus 1 per cent, grade iB equiva-
t to deUvering a tractive effort of 20 lb. per ton to the train.
Where gradients are small it is not necessary to consider the reduction
train weight due to the angle of direction of travel to the true horizontal
Icalculations of friction (Par. 6) and adhesion (Par. 28). However, with
•

excessive grades, it is necessary to correct for effective train weight.

Srades are divided in railway parlance into virtual grades and ruling
des.

{
1

;4.Virtual grades are of limited length and are so called as they ex-
133 the equivalent grade, a value always something less than the true
(de. A train running at constant speed can surmount a certain grade
edetermined by the maximum tractive effort available. The -moving
tn however may be compared to a flywheel, and has stored in the moving
ti» a large amount of energy, which is usually expended in heating the
tke shoes during the period of stopping. This stored energy may be used
Eurnish the extra tractive effort required to ascend a heavier grade than
available locomotive tractive effort alone would permit, but in such a
!the grade must be of short length. Hence, the actual grade may be
eiiiderably in excess of the virtual grade, provided it is so short that the
iitia of the moving train can supply the additional energy required to
a: nd it.

i. The ruling grade means the maximum grade encountered on a

gi.n section of track and may be the actual grade, where such is of long
eint, or the virtual grade, where the inertia of the train may be used to
iimtage in overcoming a heavier short grade. The ruling grade of freight
hiing roads should be limited to 2 per cent, or less when the topography
if u> country will permit, in fact, on a modern freight road any grade
la 1 per cent, maximum would be considered excessive, and would
the use of helper locomotives.
1 While low grades are not so impor-
t'lectric suburban railways where the income is largely derived from
_' r receipts, the future possibilities of freight trafiic over these lines

low gradient desirable whenever possible.

1

Coefficient of adhesion expresses the ratio between total tractive

.

«fii and weight on drivers. Coefficient =Fe/ IF where F, is the maximum

|K) ble tractive effort in lb., and W
is the weight on the drivers in lb.
is is expressed in per cent, and is a variable depending upon the con-
dita of track and composition of wheel. See Par. 27.
Is good practice to design the motive power of a car or locomotive so
thi it can slip the wheels on a dry rail, this practice not being strictly fol-
lovl in very high-speed motor-car equipment, owing to the enormous
fuint input that this would demand of such an equipment, designed pri-
" for low tractive effort and high speed. In steam locomotive practice,
r, it is customary to rate the locomotive at the tractive effort corre-

ig to a coefficient of 22 per cent, of the weight upon the drivers, that

actically the slipping point of the drivers. This practice is handed
(im steam-locomotive practice, where the tractive effort is fluctuating
"ue revolution of the driver, hence on account of the perfectly uni-
rque exerted by the electric motor, the electric locomotive could
1)0 rated about 15 per cent, higher in tractive effort for the same
upon the drivers.
27. Coefficients of adhesion with uniform torque (approx.)
lean dry rail 30 per cent.
• »'t rail 18 per cent, with sand 22 per cent.
ail covered with sleet 15 per cent, with sand 20 per cent.
ail covered with dry snow 10 per cent, with sand 15 per cent.

1367
 1:

Sec. 16-28 ELECTRIC RAILWAYS

In using these figures allowance must be made for unequal distribul

of weight on drivers due to weight transfer from pull on drawbar or tr
centre pin. The minimum driver weight must be used unless drivers
connected by side rods.
28. Maximum allowable grades. The values for coefficients of
besion given in Par. 27 are based upon the assumption that the mo(
power gives a perfectly uniform torque. Thus, while 30 per cent, is the m.
mum value given, tests with electric locomotives have recorded as hig
coefficient as 35 to 40 per cent, under very favorable conditions. For sir
motor-cftr service where all axles are equipped with motors, the tract
effort available with a coefficient of adhesion of 22 per cent, is 22 per c<
) of 2,000 = 440 lb. per ton, or sufficient to carry the car up a 22 per c<
grade, taking no account of train resistance or reduced effective weigh
car on such an extreme grade. Par. 23. A motor car, however, has to O)
ate under all climatic conditions, and hence is liable to meet conditions wl
the coefficient of adhesion may drop to as low as 10 per cent., so that
maximum grade in practice should never exceed 12 to 13 per cent. She
I such extreme grades be necessary, some form of track brake should
provided as an auxiliary to hand or air brakes in order to ensure safet;
operation. Moreover, all curves encountered should be compensated wi
grades are heavy, especially if the rigid wheel base of the trucks is large i

the radius of curvature small. i

29. Deter m.ination of locom.otive tonnage rating. In determiij

the tonnage rating for any locomotive in a given service usually two metlj
are employed, one for light grades and level track and the other for heJ
grades. On level track and light graden it is usual to allow 6 lb. per tonj
train resistance, 10 to 20 lb. for acceleration and 25 per cent, coefficieni
adhesion for the slipping point of the wheel. Thus when the train is u
speed the tractive effort required to keep the train running is approximai
only 6 to 10 per cent, of the weight on the drivers. On the other hand if j
rule is used for determining the tonnage rating on a heavy grade, say 2,;
cent., the train resistance will be 6 lb. for resistance, 30 lb. for grade and Vf
for acceleration making a total of 56 lb. per ton at starting and 46 Ib.i
ton running, or when the train is up to speed the tractive effort requini
*%6 X 25 = 20.5 per cent, of the weight on drivers. For satisfactory p
tical operation it has been found that the tractive effort required to ke ;i

train running on ruling grades shoulb not exceed about 18 per cent, ano
this reason electric locomotives in freight service are given a tonnage rai
equivalent to a tractive effort of about 18 per cent, of the weight on dri's
and on light grades and in passenger service a somewhat less percentaj >
the weight on drivers is taken depending upon the speed required.
SPEED-TIME CUBVES AND MOTOR CHAKACTEBISTICS
30. Acceleration. The many problems connected with train accoiero.i
can be treated either analytically or graphically. As will be shown l:r
there are so many variables entering into the consideration of train mi'
ments at variable speeds that the analytical method becomes 8ome\'il
complicated and difficult to follow. The graphical method is equal! J
accurate, much easier to work with, and the final results are given in «
form that they are of general application without calling for the faraili! J
of terms and symbols made necessary by the analytical treatment.
There are several terms used in connection with train acceleration %
nomena which are defined in Par. 31 to 37. jj
31. Tractive effort is the torque in pounds developed at the rim ot^
wheels.
32. Braking effort, also expressed in pounds is the opposite of tra'1
effort, expresses the force tending to retard the motion of the train and 1
it to rest. . .

33. Rate of acceleration is the rate of increase in speed of train,

may — J
be expressed in feet per sec. per sec., or miles per hr. per sec. us'ff
the latter.
34. Rate of braking is the rate of decrease in speed of train. Bothi
of acceleration and rate of braking may vary considerably during suooe
periods of time, depending upon type of motive power and brake rif'l

used.

1368

•
i
ELECTRIC RAILWAYS Sec. 16-35

00 --]
 —

Sec. 16-41 ELECTRIC RAILWAYS

The velocity in miles per hour,

S = 0.01098 ft.,

/ being expressed in lb. per ton.

The distance covered in any given time may be expressed

^ = l^x4?2So=«-0««°^^'^ (ft. per ton) C

(See Par. 60)
41. Actual speed-time curves. In practical operation it is not possi]
to choose the rate of acceleration and braking with such niceness as shown
Fig. 16, a greater or less period of coasting being required. Introduci
coasting gives rise to the form of speed-time curve shown in Fig. 17, showi
three friction rates f—0, 15 lb. per ton, and 30 lb. per ton respective
With no friction the speed-time curve. A, B, C, D, is constructed, the sjk
being maintained constant at 40 miles per hr. during the coasting peri(
With 15 lb. per ton friction, the speed-time curve. A, E, O, D, is formed, a
with 30 lb. per ton friction the speed-time curve. A, F, H, D. The inti

I cluction of friction occasions a falling off of speed during the coasting peri
proportional to the friction value taken, which for the sake of simplici
is here assumed to be constant at all speeds.
The speed-time curves shown in Figs. 16 and 17 both indicate the comp
tion of the run of 5,280 ft. in 120 sec, although in one case the rate of accele;
tion was that produced by 65.7 lb. per ton, and in the other case by 100
per ton. These curves are of equal area, as the distance in each case
5,280 ft. Thus, it becomes possible to produce any number of speed-ti;
curves, for a given distance and elapsed time, by varying the rate of accele'
tion with consequent variation in time of coasting.

cu
 ELECTRIC RAILWAYS Sec. 16-43

mce of 5,280 ft. run, and to apply the results so obtained for any other
istance by using a factor expressing the relation of the square roots of
le distance travelled. This is shown in Fig. 19, where A, B, C, D, repre-
snts an area of 1 mile, or one stop per mile. A, F, I, L, two stops per mile

ith = 0.707; A, E, H, K, four stops per mile with a fac-

a factor of l/\/2
)r l/\/4 = 0.5, and A, G, J, M, one stop in IJ miles with a factor of
of
''0=1.225.
Referring to Fig. 17, it is 00 - -- -
jvious that a similar sheet;
)uld be prepared for any
apsed time other than 120
c, using the same train
aistance and braking values
15 and 150 lb. per ton
spectively.
,43. Imposed time limits.
I 20 is shown the time
Fig.
nits imposed by 15 lb. per
n train resistance, and 150
per ton braking for any
-igth of run and any rate
I
The dotted curves indicate the loci of the several maximum
acceleration.
,eeds reached with different accelerating rates for a run made in a given
^ipsed time. Thus the dotted curve terminating
at 80.7 lb. per ton is a
production of the similar dotted curve, A, B, given in Fig. 20, and gives
Is maximum speed reached with any rate of acceleration for a run of
 '

Sec. 16-45 ELECTRIC RAILWAYS

Thus, in a run completed in 120 sec., the minimum accelerating rate coi
spends to 80.7 lb. per ton (gross), with no coasting introduced, for h(
braking commences as soon as acceleration ceases.
If a higher rate of acceleration than 80.7 lb. per ton be used for a cy»]
completed in 120 sec, for example 132 )b. per ton (gross), coasting md
be introduced between the accelerating and braking lines. This coastij
line may be plotted, with 132 lb. per ton acceleration, by drawing a liJ
parallel to full line C,D (Fig. 20). This line starts at the intersection!
accelerating line, 132 lb. per ton, and the dotted line to 80.7; and terminau
at the intersection with the braking line ending at 120 sec. )

45. Application of general speed-time curves. By the use of F^

20, it becomes possible to determine the time required to make a run o\
any distance with any rate of acceleration, provided the train resistance
15 lb. per ton and braking corresponds to 150 lb. per ton retarding efTort.
Example: Given a distance of 8,000 ft., train resistance 15 lb. per tc
braking effort 150 lb. per ton, tractive effort gross 67.4 lb. per ton (inch
ing 15 lb. per ton train resistance), what is the minimum time required
perform the run and what maximum speed is reached?
\ Solution: From Fig. 20, minimum elapsed time with 67.4 lb. tracti'
effort is 130 sec. with no coasting. Ratio of distances = V 8,000/5, 28(
1.23. Hence for 8,000 ft. time of run = 130 X 1.23 => 160 sec; maximi.
speed for 5,280 ft. = 55.6 miles per hr.; hence for 8,000 ft., speed = 55.6 X 1
= 68.5 miles per hr.
200U 50

IGOU 40

1200 5 30

800 ^20
 ELECTRIC RAILWAYS Sec. 16-48

48. Electricmotors used in railway service are of the following types:

(1) Series-wound direct-current motors,
(2) Single-phase alternating-current motors,
(3) Polyphase alternating-current induction motors.
In addition to the above, there have been several attempts at operating
hunt-wound direct-current motors, but as such motors have not come into
van partial use, owing to the superior qualities of other types, the shunt-
ound motor will not be discussed.
49. Direct-current series- wound motor characteristics and appli-
ations. The direct-current series motor has the general characteristics

5000

4000
^
3000 Z
a
2000l
n
1000

120
Sec. 16-52 ELECTRIC RAILWAYS

62. The alternating-current series-wound motor must operate at

lower flux density than its direct-current competitor and hence has a mot
characteristic that is even more drooping than that of the direct-curre
series-wound motor. In consequence, there is less straight-line operation a:
more motor-curve operation during the accelerating period, resulting it
lesser peak-load demand upon the distributing system. Thus, while cc
stant rate of acceleration with direct-current motors may be carried up to
per cent, of the free running speed, this ratio may be reduced to possibly
per cent, with the alternating-current motor.
PF63. Speed with series-wound motors. The maximum speed attain
during the performance of a service run, however, will be practically the sai|
for either direct-current or alternating-current series-wound motors, and;
preliminary speed-time run may be deduced from Fig. 20, straight lij
characteristics.
|

64. The polyphase induction motor is practically a constant-spcj

motor, its speed dropping only approximately 5 to 10 percent, fromj
load to maximum tractive effort developed. During the accelerati
period, therefore, this type of motive power labors under the disadvantag«
demanding full rate of acceleration carried up to full free running ape
a condition calling for a very large peak load as compared with either dire
current or alternating-current series motor performance.
 ELECTRIC RAILWAYS SeC. 16-57

fort with cars having cross seats, provided the rate of acceleration is
attained gradually with no abrupt change. The following accelerating rates
abtain in practical operation.

87. Table of accelerating rates

Locomotives
?teani locomotives, freight service . 1 to . 2 miles per hr. per sec.
5team locomotives, passenger service 0.2 to 0.5 miles per hr. per sec.
Electric locomotives, passenger service. ... 0.3 to 0.6 miles per hr. per sec.
Motor Cars
Electric motor cars interurban service ... .0.8 to 1.3 miles per hr. per sec.
lilectric motor cars city service 1.3 to 1 8 miles per hr. per sec. .

'electric motor cars rapid transit service. ..1.5 to 2 00 miles per hr. per sec. .

lighest practical rate 2 00 to 2 5 miles per hr. per sec.

. .

'
68. Limits of acceleration rate. The rates given in Par. 57 apply only
o that part of the accelerating period during which the current is maintained
practically constant by means of cutting out successive sections of the
xternal starting resistance. The higher rates from 1.0 to 2.5 miles per hr.
er sec. demand a gradual increase to those values in order to avoid the
iscomfort to passengers that would surely result from a sudden application
r cessation of such rates.
The coefficient of adhesion (Par. 26) also determines the accelerating rate
y limiting the available tractive effort, thus giving rise to the values given
j(ive for locomotive practice. As the practice is common to run loco-
utives very close to the limit of adhesion for full-speed operation on grades,
leaves but a small excess of tractive effort available to accelerate the train.
igli acceleration demands that all axles shall be equipped with motors,
id if trains are run, that all cars must be motor cars, that is, no trailers are
; ;rmissible when extreme accelerating rates are required to make the schedule
!sired.

69. Limits of braking rate. The limits reached in acceleration hold

I
lually true in braking. As a matter of fact, acceleration may be at a
gher rate than braking, for two reasons: first, discomfort to passengers is
cater during braking of cross-seat cars, as the inertia of the passenger tends
carry him away from his seat and he lacks the suppoHin^ back that pre-
nts discomfort during rapid acceleration when his body is pressed back-
vrd; second, in braking a train to standstill, it is necessary for the operator
stop within a distance of a few feet of a fixed spot, and the skill shown in
dging speed and distance will determine the braking rate. During accelera-
•n no such limit exists; the motorman has absolute freedom. There is,
wcvor, a system of rnotor control available that will bring about uniform
automatic acceleration, the rate being determined by the necessities of
• service.
SO. The inertia effect of revolving parts must be considered. This
tor reduces the effective accelerating and braking rates. In other words,
^ necessary to expend from 4 to 12 per cent, more tractive effort during
elcration and braking in order to overcome the inertia of car wheels, gears
1 motor armatures, than is required to accelerate the car or train longi-

linally on a level track. This inertia may be calculated as follows:

The energy of a rotating body = Vf ^gV^=W^g ^-V^ (ft-lb.) (11)
re V = the speed of the centre of gravity of the body in ft. per sec.
V = speed of train in ft. per sec.
r = radius of gyration in ft.
R = radius of rim in ft.
'the effective weight = Wr'^/R^. The ratio rVK^ has been found from a
;e number of tests
I
to be approximately 0.6 for ordinary designs of car
^ 'els, hence the effective weight of the wheels
= 0.6X weight of wheels (lb.) (12)
ratio, r-/R-, for armature is approximately 0.5. For geared motors it
portant that allowance be made for the higher speed of the armature.
fence the effective weight of the armature = 0.5 (^. — ——
'—,- ;
, X gear
Mi, Voia. of wheel
<)* X weight of armature (lb.) (13)

1375
 Sec. 16-61 ELECTRIC RAILWAYS

It is common practice to use 100 lb. per ton instead of 91.2 lb. per ton for l'
mile per hr. per sec. acceleration, and take dead weight of train only. Thif
allows for approximately 10 per cent, equivalent weight due to the inertia ot
rotating parts. It is a very simple method and its results are very near th{
proper amount for street cars. For more accurate calculations, see Par. 61
61. Per cent, of total tractive effort consumed in rotating parts
Electric locomotive and heavy freight train 5 per cent
Electric locomotive and high-speed passenger trains 7 per cent
Electric high-speed motor cars 7 per cent
Low-speed motor cars 10 per cent
The above percentages added to 91.2 and multiplied by the rate of accel
eration will give the total pounds tractive effort per ton required for acceler
ation.
62. Calculation of acceleration rate. In figuring upon accelerating
and braking problems for different classes of service, the percentages in Par. 6
should be added to the actual train weight to obtain the effective train weight
The net tractive effort as determined by the gross tractive effort minus th
\ train resistance can then be used in connection with the effective train weigh
to arrive at the rate of acceleration as expressed in miles per hr. per sec.
63. Schedule speed, expressed in miles per hr., denotes the average spec'
of a train including all stops, slow downs, etc., being the distance run in mile
divided by the elapsed time in hours, including time of stops enroute. Se
Par. 64.
6i. Duration of service stops
Through trains, steam 5 min.
Local trains, steam 2 min.
Interurban cars, electric 10 to 30 sec.
City rapid transit trains, electric 10 to 20 sec.
City surface cars, electric 5 to 12 sec.
The following frequency of stops are characteristic of the different classf
of railway service:
66. Frequency of stops in service
Steam locomotive through service 1 stop in 100 miles.
Steam locomotive local service 1 stop in 20 miles.
Steam locomotive suburban service 1 stop per mile.
Electric interurban express 1 stop in 10 miles.
Electric interurban local 1 stop in 2 miles.
Electric suburban 1 to 2 stops per mile
City elevated or rapid transit 2 to 3 stops per mile
City surface lines 5 to 10 stops per mil i ;

66. The relation between schedule and maximum speed wlfji

varying frequencjr of stops is expressed in Fig. 26, which indicate*,jtjJ
schedule speed possible to make with trains having a free running spee4]l
30, 45, 60 and 75 miles per hr. respectively.
Thus with a train geared for a free running speed of 60 miles per Ii|J
it is possible to make a schedule of 45.5 miles per hr. with one stop in tfiy.
miles, 37.5 miles per hr. with one stop in 2 miles, etc. _
_
'

For frequent-stop service, a low free-running speed is desirable as it|

easier on the equipment, calls for less motor capacity and less energy OCJ
sumed in performing the service. Hence, it is advisable to use the lowfj
maximum speed that will give the schedule desired.
67. Effect of acceleration on frequent-stop service. When usi!
Fig. 26, it should be recognized that where stops are more frequent than di
per mile, the rate of acceleration becomes a controlling factor, and as sho^i
in the curve, when the frequency of stops approaches three or more per tai«
the maximum free-running speed of the equipment does not have any api£
ciable effect upon the possiole schedule speed. Hence, for frequent sfi
service where it is of great importance to attain the highest possible schedif:
speed, recourse should be had to Fig. 20, in order to determine the advanta|
of higher rates of acceleration than the 120 lb. gross which forms the bf'ji
of Fig. 25.
'
68. Effect of track curves on rapid service. In all classes of serv|i
due recognition should be paid to the effect of curves of such short radii W.

1376
 ELECTRIC RAILWAYS Sec. 16-69

demand slowing down while rounding them. The safe speed at which a
curve may be taken will depend upon the elevation of the outer rail, but a
greater elevation than 8 in. is not common. Also curves having a spiral
approach will ride much easier than those in which the tangent leads
directly into the curve.
69. Safe maximum speed on track curves
Radius of curve, ft 10,000 5,000 2,000 1,000 500 200 100 50
Speed, miles per hr 100 75 50 35 25 15 10 6
The above values apply only when full elevation may be given outer
rail. Speeds will be less when operating in city streets where such eleva-
tion is not possible, and where wheel flanges of three-quarters of an inch or
ess are the rule.
70. Limitations of theoretical schedules. On any road abounding in
urves of short radius, it will not be possible to reach the schedules given in
25.
;''ig. No general rule can be given to fit all cases, as each problem must
)e treated according to local conditions. There is sufficient leeway in the
[chedules given in Fig. 25 to allow for irregularities of stops, as there is in-
lluded a period of 10 sec. coasting that may be cut out when a stop has

r
 Sec. 16-73 ELECTRIC RAILWAYS

73. Example of calculation of speed-time curves;* tractive forcei

The best step-by-step method of plotting curves consists in assuming smal
speed increments, two-mile increments giving sufficient accuracy in prac
tically all cases.
Example: Given a car weighing 32 tons, with an equipment of 4 motorsl
Motor characteristics as per Fig. 21. Average line voltage 500. Find th
relation of speed, amperes, distance and time for normal acceleration withi
the capacity of the motors.

\
205 8

10 20 30 40 50 60 70 80 SO 100 110 120 130

Time iu Secouda

Fig. 26.— Speed, distance, and current time curves.

Solution: Reduce problem to consideration of the performance of
single motor as all motors may be assumed to equally divide the work.
Hence, 32/4 -^ 8 tons per motor.
Assume safe accelerating current per motor = 140 amp.
From (Fig. 20) 140 amp. = 1,090 lb. tractive efTort at speed of 27 miles perhi
Car friction per motor 116 lb. (Fig. 9) at 27 miles per hr.
1,090 —116 = 974 lb. net available for acceleration of car and rotatio
parts (Par. 60).
974/8= 122 lb. per ton net.
74. Example of calculation of speed-time curves, acceleratioi
To find acceleration expressed in miles per hr. per sec. from a given fort
expressed in lb. per ton, proceed as follows.
Acceleration, expressed in miles per hr. per sor.
[(32.2X0.682)/2,000)Xlb. per ton = (lb. per ton)/91.2. The above vali
of (lb. per ton)/91.2 applies only to the net lb. per ton available for i-
acceleration only. In this particular problem assume 7 per cent, of tl
accelerating tractive force as being required to overcome the inertia of tl
rotating parts, then the factor of acceleration expressed in miles per hr
sec. = (net lb. per ton)/(91.2X 1.07) = (lb. per ton)/97.5. Hence— :i

eration= 122/97.5= 1.2.5 miles per hr. per sec.

Assume that car resistance remains constant at all speeds up to 27 mil
per hr., as error introduced thereby is so small as to make it unneceasiii
to plot the curve step by step until motor-curve running is reached ut 1

miles per hr.

The several relations may be calculated as given in Par. 76.
76. Example of calculation of speed-time curves; effects of trac
curves, grades and coasting. The above example is worked out on ba.-
of level tangent track. The calculation of speed-time curves is general
based upon this assumption. Where it is necessary to predetermine 'I
performance of a motor operating over grades and around curves, ailtl
deduct tractive force so consumed from gross tractive effort and procecil
in Par. 76. Also see Par. 22 and 23.
Completing the speed-time cycle by introducing coasting and brakii
requires the same treatment as in Par. 76 except that both coasting ai
braking are equivalent to negative acceleration. Another method of plotUi
• For other methods of plotting speed-time curves see Mailloux, C. '

" Notes on the Plotting of Speed-time Curves," Proc. Am. Inst, of Elf
Eng., 1902, Vol. XIX. p. 901. E. C. Woodruff, Trans. Am. Inst, of Elf
Eng„ 1914, Vol. XXXIII, p. 1673 and Discussion.

1378
 ULECTRIC RAIL WA YS Sec. 16-76

Speed-time curves is given by Mailloux in Proceedings American Institute

of Electrical Engineers, June, 1902.
76. Relation of speed, distance, amperes and time (Par. 73);
example of detailed calculations

1
 ..
.

Sec. 16-80 ELECTRIC RAILWAYS

80. The efficiency when the car is at full speed is generally lower with •

motors of the geared type, owing largely to the losses in gears and also in
the magnetic circuit of the motors themselves. This lower efficiency at
higher speeds does not hold true of motors of the gearless type as indicated
in Par. 78. The advantage of using gearless motors for high-speed passenger
service is clearly indicated by the extremely high efficiency at light outputs.
On the other hand, such motors do not compare favorably with the geared
type for heavy freight haulage as the efficiency falls off rapidly at the over-
loads characteristic of this class of service.
81. Power requirements at constant speed. To determine power
required to propel a car or train at any constant speed, proceed as follows:
^„ FX2XWXS ,.
*^-^ ,
,,..
,X1,000^ /^'V
wherein F is the train resistance in lb. per ton (from Figs. 9 to 14 inclusive);
W the weight of the car or train in tons; S the speed of the train in miles
per hr., and i; the motor efficiency with the train at full speed.
82. Calculation of power requirements of motor-car trains. Th«
tables show the kilowatts input required for motor-car trains, and also fot:
high-speed passenger-train and low-speed freight-train operation. These
tables are based directly upon the train-resistance values given in Figs. 9
to 14 inclusive, and represent the kilowatts input that would be expected
with well-ballasted rail when trains are running at constant speed.
Constants assumed in these calculations are: efficiency at full speed, 7,"
per cent, based upon the use of direct-current geared motors; and train
resistance as obtained from the formula
50 0.002a5'
Tractive effort 4-0.035 +
Vw '
(lb. per ton)
w 0+^)
(15)

Cross-sectional area of cars 20-ton car, cross-section 90

is as follows:
«q. ft.; 30-ton car, cross-section, 100 sq. ft. 40-ton car, cross-section, IH
;

sq. ft.; 50-ton car, cross-section, 120 sq. ft.; 60-ton oar cross-section, 12(
sq. ft.
83. Train Input for constant-speed running on level tangeni
track, motor-car service
{Input values expressed in kilowatts)
Speed (miles per hr.)

Train weight
10 20 30 50 60 70 80 ^ 100

2-20'ton cars., 9.3 22.4 42.5 72.5 116.0 .

2-30]ton cars.. 11.5 51.4 87.01137.01206

2-40 ton cars., 13.2 59. Oj 99.3 156.0 234 336
2-50 ton cars.. 14.8 66.3 111.0 175.0 261(374 520 699
2-60 ton cars., 16.3 71.7 119.0 185.0 274 390 540 720 945

20 ton car. . . 6.5 16.2 32.0 56.7 93.5 ...

30 ton car. . . . 8.0 19.5 38.4 67.3 109.0 167
40 ton car. . . 9.4 23.1 44.1 76. 2! 124.0 188 276
50 ton car. . . . 10.4 25.6 49.2 84.8 137.0 210 305 4301 584
60 ton car . . . 11.5 27.9 52.8! 90. 21144. 0i218 316:442

3-20 ton cars., 11.427 2 50.,9) 84.,1|136.0 ...... ...

3-30 ton cars.. 14.0 33 3; 61. 8:103. 162.0|240 ..I....

3-40 ton cars., 16.3 38 5 119. 185.0271I391L. .

3-50 ton cars., 18.4 ,6|134. 0206.0 308 437602

3-00 ton cars., 20.1 ,41144. 222.01326 460 635
I

5-20 ton cars., 14.8 65 4109, 171.0

5-30 ton cars. 18.3 80 ,0 133, 0:205.0 303
5-40 ton cars. 21.3 8 93 ,2:154, 0' 237.0 348
5-50 ton cars. 26.2 9 112 ,01183 01279.0 406
5-60 ton cars. 31.3 8 130 ,0 208, 312.0 448

1380
 .
.

ELECTRIC RAILWAYS Sec. 16-84

84. Train input for constant-speed running on level tangent

track, locomotive passenger service
{Input values expressed in kilowatts)

Speed (miles per hr.)

Gross
train
weight I
10 20 30 40 50 60 70 80 90 100

200 tons. 17.5 41 2 75. 8 124 196 277 398 530 710 920
300 tons.
26.1! 60. 5! 108, 172 258 369 511 689 905 1,160
400 32.0' 79.
tons. 139. 219 330 462 635 840 1,100 1,405
500 41.0 99.
tons. 170. 0268 395 563 755 995 1,295 1,645
600 tons 50.0 118. 203. 0315464 645 875 1,150 1,489 1.890
700 tons. 59.0,135. 363 530
235. 735 996 1,305 1,682 2,132
800 tons 69.0 154. 0267. 410|596 828 1,117 1,460 1,878 2,375
900 tons. 77.0; 173. 300. 0:459 663 920 1,238 1,615 2,070 2,620
1,000 tons. 85.0;193. 330. 01507730 1,011 1,358 1,771 2,261 2,860

85. Calculation of power requirements of passenger-service loco-

motives involve the following assumed constants: efficiency at full speed,
i90 per cent, for locomotive using series-wound direct-current motors of the
jgearless type; cross-section of cars, 110 sq. ft.; weight of car, 50 tons; weight
jf track rail, not less than 80 lb. per yd.
86. Power required on gr&dea. The values of power required to drive
A car at any speed, apply only for constant speed on tangent level tracks,
pn up grades there is required an additional tractive eflFort of 20 lb. per ton
or each, 1 percent, grade. Hence, to calculate power required on grades,
jroceed as follows:
;
The total train resistance is Fo=F+Fi,, in lb. per ton; wherein F is
-he train resistance in lb. per ton found from the curves, and F, the tractive
jffort due to the grade (F, = per cent, grade 20). Then the power X
nput is
„ 2WFoS
^-ToooT <^«>
vherein W
is the weight in tons of the train; Ft the total train resistance
n lb. per ton; S the speed in miles per hr., and ij the efficiency of the motors.
Example: Given a train of three 40-ton cars operating up a 2 per cent,
rade at 40 miles per hr. what kilowatt input is demanded by the motors T
Answer: From Fig. 11, a three-oar train requires a tractive effort of 9
!3. per ton at 40 miles per hr.

To this add for grade 2 X20 «-40 lb. per ton (see Par. 23).
Tractive effort from Fig. 11 = 9 lb.

Total tractive effort 49 lb.

Train weight =3X40 = 120 tons.
Assuming that the excessive output demanded by the grade will almost
ompletely load the motors, the maximum efficiency of the motor will be
iahued on the grade; with an 80-h.p. motor this would be 87 per cent
„ ^. 2X120X49X40 ,.„,.,
Hence input
1,000X0.8
7"" ^^^ kilowatts.
87. Energy of acceleration. The above power values
are based upon
le assumption that the train has reached full speed and the power values
-e those required to maintain the train at constant speed. During the time
lat the train is attaining full speed, however, it is necessary
to impart to
the energy required to accelerate the mass in the direction of
travel and
so to accelerate the rotating parts around their several axes.

Energy of acceleration =-—- =—— (ft-lb.) (17)

here w is the weight in lb.; v the velocity in ft. per sec, and a the Kravitv
instant (32.2 ft. per sec. per sec).
88. Power required to overcome train resistance. In addition to
e energy of acceleration, it is necessary, during the accelerating period,

1381
 Sec. 16-89 ELECTRIC RAILWAYS

to furnish power to the train in order to overcome train resistance, a quantity

constantly changing with increasing speed, and finally to supply various
changing losses in the motive power and its system of control. The straight-
line diagram furnishes the simplest means of attacking the speed-time prob-
lem, and it also furnishes the fundamental data for all energy-consump-
tion curves, as it eliminates the question of motive power with its internal
losses, and considers only the moving train itself.
89. The energy required to move a train from rest to a giyen
velocity is represented by
pr = ™^'fFoL (ft-lb.) (18)

wherein m isthe mass; v the velocity in ft. per sec; Fo the total train re-
sistance in lb., and L the distance in ft. covered.

\ IGO

S 80
 ELECTRIC RAILWAYS Sec. 16-91

'JUO
 Sec. 16-92 ELECTRIC RAILWAYS

conjunction with the speed-time curves of Fig. 20 permit of the complete

solution of any acceleration problem so far as relates to performance of tlit
train and its net energy consumption. For convenience, both speed-
time and energy curves are made up with the same elapsed time for a mil*
run as abscissa, this distance run being chosen as being a convenient basii
for comparison.
Having determined the watt-hours per ton-mile for a mile run, the sami
value holds true for any other distance run as long as the speed-time cum
is entirely similar in every respect and the areas are proportional to thi
respective distances run. Thus, a mile performance in 120 sec. with !

tractive effort of 90 lb. per ton (including 15 lb. per ton train resistance
will require an output rate of 73 watt-hr. per ton-mile, and the same energy
73 watt-hr. per ton-mile, would be required to perform a run of half th
distance in 1/^2 times 120 sec, or 84.8 sec.
Thus while the speed-time curves must be changed in area proportions
to the distance travelled, the value of energy consumption found for on
distance holds equally true for any other distance made with a simila

I speed-time curve.
92. Example of calculation of energy congumption. Given a ru
of 1,760 ft. to be made in 75 sec, train weight 100 tons, 33.5 per cent, o
drivers, coefficient of adhesion 12 per cent., train resistance 15 lb. per tor
Find energy consumption.
Available tractive effort -200,000X0.335X0.12 -8.000 lb. -8,000/100 :
80 lb. per ton.
To reduce to mile basis v'5,280/1,760 X 75 - 130 seconds. (See Par. 48,
From Fig. 29, 1 mile in 130 sec. with 80 lb. tractive effort gives 6
watt-hr. per ton-mile. ... , , ,
The same value, 60, is true for 1,760 ft. made by similarly shaped speec
time curve in 75 sec.
93. Motor-curve acceleration. Instead of being able to accelerate .

train at a uniform rate until maximum speed is reached, all types of electr
motors operate best with a certain amount of motor-curve acceleration at
rate constantly falling off from the initial or straight-line acceleration whic
is only carried part way to full speed. Also, the electric motor has intern,-,
losses, electrical and mechanical, which together with certain losses inherei
to its system of control make it necessary to add a greater or less percentage t
the net energy-consumption curves given in order to obtain the input to tl
train. The different types of motors have their distinctive internal lossi
and type of control, and the performance relation of the several mot(
equipments to the net energy-consumption curves is best expressed by tl;
efficiency of acceleration of the several systems.
94. The efficiency of acceleration is the percentage of the net eners
consumption of motor output, to the gross input of the train. The valui
given in Figs. 28 and 29 hold true as the net output of any type of moti
and control system, hence, given the efficiency of acceleration of any sy
tem, the net energy values form the basis of calculating train inputs for ai
operating conditions. See Par. 97, 107 and 112. ,-•..•*
The losses in the motor equipment during acceleration are divided int
internal motor losses including loss in gears, and losses incident to method
control.
96. Internal motor losses consist of copper I'R in armature and fiel
hysteresis and eddy-current losses in the iron circuit, brush-friction ai
DR loss, bearing friction and gear losses. All these losses are included in t
curves furnished by the manufacturers for normal 500 volts constant notenti
at the brushes, but no such values are readily available for fractional-voltSi
operation during the accelerating period.
96. Starting resistance losses. It is customary to assume full-Ioi
current of a railway motor during the straight-line acceleration perio'i
~

at standstill the IR drop in the motor copper will approximate 50 vol'

is necessary, therefore, to provide sufficient starting resistance in seru
the motor to take up the remaining 4,'>0 volts or the difference botwei-n i

line potential and the motor copper drop. This starting resistanc is cut o
fn
in successive steps as the motor armature gains speed and establishes its
counter-electromotive force, until a period is reached, when the stnr"
resistance is entirely short-circuited and the full line e.m.f. is just suff
to maintain full-load current through the motor. This period comph t

1384
 ELECTRIC RAILWAYS Sec. 16-97

straight-line acceleration, as after this point the series-wound motor will still
accelerate the train, but at a constantly decreased rate, until full constant
speed is attained. It is evident then, that a large amount of power is con-
sumed in the starting resistance and to reduce this excessive loss at starting,
the method was introduced of connecting two motors in series during half the
peribd of straight-line acceleration, thus reducing the amount of starting
resistance required (Par. 49).
4 Motors Series, S«ries-
2 STotora Series Parallel paraUel, and Parallel
AU Motors iu Parallel
Sec. 16-99 ELECTRIC RAILWAYS

99. Example of calculation of energy consumption during accelera-

tion with the two-motor series-parallel combination. In this system
the efficiency of acceleration ranges from 56 per cent, to 75 per cent. A typical
speed-time curve will require approximately 30 per cent, of straight-line
acceleration, hence, the efficiency of acceleration which meets general operat-
ing conditions, will be approximately 73 per cent, for geared motors of 75 h.p.
or over and 68 to 73 per cent, for smaller motors. The value of 73 per cent,
efficiency may be used directly in connection with the energy values given
in Fig. 30, that is, the energy-curve values divided by 0.73 will give the gross
train-input watt-hours per ton-mile at the train, allowing for no losses ia
the distribution system.
Example: Given a mile run made in 135 sec, tractive effort of 110 lb.
per ton including 10 lb. train resistance, find average input for 100 ton train.
Answer: J'rom Fig. 30, energy consumption net = 38 watt-hr. per ton-
mile. Input = 38/0.73 = 52 watt-hr. per ton-mile.
Train makes 1 mile in 135 sec. = 1 mile in 147 sec, including 12 sec.
stop = 24.5 miles per hr. schedule speed.
Hence, the power input is
P=52X 100X24.5= 127 kw. per hr.
100. Relation between schedule speed and frequency of stops is
shown in Par. 102. In other words, an effort has been made to proportion
properly the maximum free-running speed of the equipment to the schedule
speed obtaining for a given number of stops per mile. Thus an equipment
operating with one stop per mile can make 24 miles per hr. schedule with stops
of 12 sec. and should properly be geared for 40 miles per hr. If the equip-
ment were geared for higher maximum speed than 40 miles per hr., the re-
sulting schedule speed would not be much in excess of the 24 miles per hr. given,
while the power consumption would have been considerably greater. On the
other hand, an equipment geared for somewhat lower maximum speed than 40
miles per hr. could still make24 miles per hr. schedule with a 12-sec. stop occur-
ring at every mile, but requiring a higher rate of acceleration than the 1.1 mile
per hr. per sec. assumed. As a high rate of acceleration is undesirable with
high-speed equipments, the rates given in the table should not be greatly ex-
ceeded unless there are strong local reasons making such high rates necessary.
101. Interruptions to service treated as "equivalent stops." The
table of schedule speed includes little or no leeway to make up for lost time,
and where such interruptions of service are liable to occur they should be
treated as additional stops per mile, and the proper schedule speed, maxi*-
mum free-running speed, etc., should be taken for the equivalent number of
stops per mile, including actual stops, slow-downs for curves, crossings, etc.,
and a margin for unexpected delays. Thus, with one actual stop of/ 15 »t'c.
duration occurring every 2 miles, there may be slow-downs for curves, etc.,
making the equivalent number of stops approximate one per mile, in which
case a 24-mile per hr. schedule with 40 miles per hr. maximum speed of
equipment would be a safer estimate of speed possible than the 32 and 45
miles per hr. respectively given for one stop in 2 miles. In other words,
keep the maximum speed of the equipment at the lowest value that will
admit of maintaining the schedule desired with the frequency of stops given.
Not only is there a saving in energy consumption resulting from the use of
lowest possible maximum speed, but, as will be shown later, there is also a
large saving in the capacity of motor required to perform the service.
103. Train input in kw., frequent-stop service, tangent level track

Stops per mile i i

Schedule speed, miles 50.0 40.0 32.0 24.01S.6 16.5 1«?712;5n.7 11.0
per hr.
Maximum speed, miles 65.0 65.0 45.0 40.0130.0 25.0 23. obl. 0120. Ol 19.0
per hr. I

Stops, seconds i30.0 20.0 15.0 12.0J10.0! fl.Oi 8.0 7.0 6.0 5.0
per cent. 75.0 75.0 75.0 74.0|72.0i70.0 69.0 68.0 67.0'65.0
Eff. of accel., 1

Accel., miles per hr.j 0.8j 0.9 1.0 l.ll 1.2| 1.3i 1.41 1.5 1.6! 1.7
per sec.

The above data are common to all trains.

1386
 ELECTRIC RAILWAYS Sec. 16-103

Stops per mile

 :

Sec. 16-107 ELECTRIC RAILWAYS

Owing to the fact that the characteristic curve of the single-phaae motor ll
more sloping thaneven that of the direct-current aeries-wound motor. Fin
21 and 23, the period of straight-line acceleration will be a lesser percental
of the total time power is supplied to the car; that is, the motor-curve runnini
will commence at a lower speed than in the case of direct-current motor opera
tion, thus giving rise to a factor of 20 per cent, as the percentage of straight
line acceleration to the total acceleration period of a typical run.
107. The efficiency of acceleration for the single-phase moto
equipment may be assumed to be 70 per cent. This value includes all losse
in the step-down transformer required, and hence the net energy value-,
given in Figs. 28 and 29 when divided by 0.70 will give the total input at th
car for such equipments. Where cars are operated over city streets, it i'
sometimes necessary to run on direct current in which case the motors ar
controlled like direct-current motors.
108. The free running efficiency of single-phase equipments ma
be taken at from 70 to 7.5 per cent, for equipments ranging in capacity fror
50 to 200 h.p. per motor, hence giving to the alternating-current equipmen
an all round efficiency of about 70 per cent., whether accelerating or runnin
at constant speed, a performance closely approximating that of the direct
current motor equipment. j

109. The three-phase induction motor is installed upon but a fe'^

roads. It is practically a synchronous motor, there being a maximum r'
but 5 per cent, difference in speed between full-load and free running. Th
variation from synchronous speed is proportional to the tractive effort. Th
efficiency of acceleration corresponds to that of a direct-current shunt-woun
motor with constant field.
110. There are two methods of control of induction motors availab
for railway service, reduced voltage in the primary and variable non-inductiv
resistance in the secondary. Reduced voltage introduces an exceeding!
poor power-factor during the starting or fractional speed period, and ah
entails a prohibitive IiR loss in the secondary, if this be of the short-circuitc
(squirrel-cage) type. Voltage variation is only used in special cases whei •

the excessive size of the required motor is no handicap.

Secondary-resistance control of three-phase slip-ring motors t j

the method ordinarily employed. The rotor winding is terminated in thn

rings, which allow the insertion of non-inductive resistance in the roti
circuit. This resistance is decreased as the motor comes up to speed, ac
the rings short-circuited at approximately 10 per cent, below synchronoi
speed. This method of starting results in a poor efficiency of acceleratic
(Par. 112).
111. Concatenation control may be employed to increase the efficien-
of acceleration of three-phase slip-ring motors. As the speed of the induri
motor is fixed by its frequency of supply and not by its impressed e.m.f
not possible to connect two such motors in series. It is possible, howevii
connect the stator winding of motor No. 1 to the line, the rotor winding
motor No. 1 to the rotor winding of motor No. 2 short-circuiting the st;it
winding of motor No. 2; this constitutes the concatenated method of co
necting induction motors and corresponds in results to the series connecti<
of direct-current series-wound motors. With induction motors so co
nected, stability is obtained with half-speed of the rotors and a concatennti
set can be treated in all respects as a single induction motor having dnu!
the nuhiber of poles in its field.
Concatenation is feasible only with rnotors of low frequency, 25 ( ".

or less, owing to the low power-factor incidental to such a combinai

In general, however, concatenation is used with railway induction mn\
not to effect a possible increase in the efficiency of acceleration, but to pm
a second efficient running speed for the low-speed requirements interini;
yards.
112. Efficiency of acceleration; three-phase induction motors

Per cent, straight-

acceleration
Efficiency per cent
 ELECTRIC RAILWAYS See. 16-113

The accelerating efficiency of an induction-motor railway equipment

V.

;
n
indicated for parallel operation only, concatenation not being considered
As straight-line acceleration will constitute fully 50 per cent, of the total
period during which power is supplied in a typical rapid-transit run, an
mduction-motor equipment will have an efficiency of acceleration not to
exceed 55 per cent.
,
This represents the power efficiency and does not include
the power-factor which will approximate 80 per cent, during acceleration
with non-inductive resistance inserted in the secondary circuit, thus making
the apparent efficiency of acceleration approximately 44 per cent,
I

i
Hence, for acceleration problems involving a consideration of railway
induction motors of the polyphase type, divide energy values given in
Figs. 30 and 31 by 0.44 to obtain the volt-amp. input at the train and not
;

including any trolley or distribution losses. The proper field of the induction
i motor IS the haulage of trains at constant speed behind locomotives and the
t use of this motor will be further discussed under
Locomotives.
)* lis. SegeneratiTO (dynamic) braking. In service calling for frequent
starting and stopping of trains, it ia evident that the mv*/2 constituting
the
"energy loss in heating brake-shoes and wheels, forms a considerable per-
centage of the total energy input to the train. As the electric motor is
reversible, that is, can absorb power and give out mechanical energy, or
can
give out electric power when mechanically driven as a generator, it
seems
feasible to expect that some means of control can be designed
which will
enable a train to be braked electrically with reduced wear and expense
of
brake-shoe maintenance, besides returning to the line a considerable
per-
centage of the energy delivered to the train during acceleration. Also on
roads having excessive continuous grades, it is desirable to return energy
to
the line partly for the economy thus effected, but largely in
order to reduce
jthe danger that goes with braking long heavy trains by
means of brake-shoes.
I 114. Motor capacity for regeneratiTe braUngr.
, The standard direct-
current motor, being of the series-wound type, cannot be used
directly as a
direct-current generator, and some modification of shunt winding or
excita-
ition of the series field at low potential must be used in order
to enable the
.motor to act as generator when braking the train. Of the total energy
i^hvered to the train during a typical city run, neariy one-third
of the amount
isted due t9 the inefficiency of the motor, gears, and
method of control
:ie rentiaining two-thirds, fully 25 per cent, is to overcome train
....ot-ance, leaving 50 per cent, of the original train
input as available for
,
egenerative purposes. Owang to the complications required to make a series
lirect-current motor equipment available for generation, it would not be
oossible to effect the same efficiency of deceleration as the 70 to 75 per cent
jossible during acceleration. Furthermore, the capacity of a railway motor
,° do work IS hmited by its heating, and this heating is dependent upon the
uperfacial area and weight of the motor, hence, if
the motor is chosen with
jiue regard for its safe temperature rise when
used for accelerating the car
.ts thermal capacity must be
increased in due proportion to the amount of
xtra motor loss entaUed in electrically braking the car. This extra
1 equipment will in turn entail an additional expenditure of energy weight
he accelerating period, so that the effect of braking
during
the train electrically
j.^th the same motive power used for
acceleration, will be to increase the duty
I such motors considerably,
and, hence, their weight and first cost.
Economy of regenerative braking. Assuming that an efiiciencv
,"f-
Iou per cent could be obtained during retardation by
electric braking ft
•ouldmean the possible saving of 30 per cent, in the energy consumption
the car, provided the car weight were not increased
due to the larger
lotoT capacity demanded. It is not possible, however, to effect any such
oonomy as the figure indicated, and from 15 to 20 per cent,
saving of gross
iput would more nearly represent the possibilities
of regenerative control
^ a Class of service calling for very frequent stops. It is evident that where
ops are infrequent as in high-speed interurban service,
the effect of regenera-
on would become negligible so far as economy
of operation is concerned,
first cost of regenerative control, and the
maintenance offset the advantages derived from a possible increased cost
m!;,.?'^®
smaller energy
^* '^ °°* ^"^ "?"''^ *•* "P^^^- 1*»«* *he car equipment
nf hfin.V"'' ° ^ f ^i'"'' -o per cent in weight and first cost if regenerative con-
ui hp Ia Ta"^and
De adopted, ^""a^.^.^^
the possible 15 to 20 per cent, energy must be balanced

1389
Sec. 16-117 ELECTRIC RAILWAYS

against the interest on the additional first cost and cost of maintaining tho
equipment.
As any system of regenerative control depends upon the counter e.m.f.
of the revolving armature, it is evident that when approaching zero speed
there will be no torque developed by the motor, and hence, regenerative
braking must be used in connection with air brakes, with resultant decreased
saving in economy. For street-car service, including interurban service,
it can be said that there is small attraction in regenerative control, not because
such control is not possible, but because the added complication and expense
brings no adequate return in the cost of the energy saved.
117. Regrenerative control used in connection with locomotives
for heavy passenger or freight service on mountain-grade sections,
offers many advantages far outweighing in importance the possibility of a
small amount of energy saved. One of the disadvantages attending the
operation of long heavy trains on mountain grades, is the danger incurred
in braking the trains on the down grades. More accidents occur when trains
are running down grade than when operating up grade, due to the fact that
overheated brake shoes and car wheels may cause a derailment, and also
due to breaking apart of long trains when the brakes are released momen-
tarily for the purpose of recharging the train pipe. On such classes of
service, a regenerative system of control offers .safer means of holding trains
on down grades than exists with present air-brake control, and its claims '.

in this direction make it worthy of very careful consideration for this class 'j

of service. Also see "Electric Locomotives," Par. 260, et seq. ;]

118. Westinghouse direct-current regeneration system. The sys- ^

tem of regeneration used with direct-current railway motors by the Westing-

house Electric & Manufacturing Company is fundamentally shown as in
Fig. 31. This figure shows the armature of the main
motor, A, the main motor field, F, the balancing or
stabilizing resistor, R, and the exciter, E. Inherently, a
series direct-current generator has no stability of voltage
and some external means is necessary to control it when
regenerating. In the figure, the exciter, E, furnishes cur-
rent which flows in the path indicated by the dotted
arrows. This current excites the main motor field and
causes the armature, A, to generate a voltage opposed ,

to the line voltage. The voltage of E can be regulated

either by regulating its field strength or by inserting or
removing resistance in series with its armature. When '

the voltage of A overcomes the line, a current starts to

flow from the ground through R and A to the line. Thus
R carries both the main regenerated current and the
exciting current.
The stabilizing effect comes from the resistance R, since
any variation in the regenerated current will vary the
drop across the resistance and thus, assuming the voltage
of the exciter, E, to be fairly constant, will have an im-
FiG. 31.— Direct- mediate effect on the field of the main motor to counteract
current regenera- such a variation. For instance, if a train is regenerating •

tive braking. down grade with the exciter voltage set so as to give
the proper excitation to the main field to furnish the
necessary braking effort, and the line voltage should suddenly drop, the
regenerated current would immediately tend to increase. However, the
increased current which tends to flow, increa.ses the voltage drop across the
resistance R, and directly reduces the exciting current, thus maintaining a ,

balanced condition as before. f

It is important in a direct-current regenerating system, to have this regu- j^

lating influence as nearly direct as possible, since, changes in line voltage ,

may, at times, be so great and so sudden that unless the regulation is simul-
taneous with the variation, a condition of unbalance between the armature ,

and field of the motor may be sufficiently great' to cause flashing at the
commutator.
The excitation for the main motors is supplied by a separate generator,
driven either by a motor or from an idle locomotive axle through gearing
The regulation of the braking is then obtained by varying the exciter field
strength or by varying the amount of resistance in the stabilizer circuit.

1390
 ELECTRIC RAILWAYS SeC. 16-119

119. Alternating-current regeneration. Regeneration with poly-

phase motors is obtained very simply by driving the rotors above synchronous
pheed No change in connections or separate means of excitation are re-
.

quired. This method of regeneration has been in successful operation for

a number of years.
Several schemes of regeneration with single-phase commutating motors
have been devised, but none have been put in operation in this country,
although a form of regeneration or dynamic braking has been placed in
operation in Switzerland by the Oerliken Co.
RAILWAY MOTOR CAPACITY
Limitations of design. The capacity of railway motors to do work
120.
cannot be measured by the same standards governing the rating of motors
of the stationary type. Conditions of operation demand that the motors
shall conform to the requirements of a 4 ft. 8i in. gage track, and fre-
quently a wheel base of not over 78 in., and preferably less. The re-
stricted space thus available makes it imperative that the weight and out-
side dimensions of railway motors shall be scaled to the lowest possible linriit
consistent with the average and momentary output demanded by service
requirements. It is customary, therefore, in railway-motor design, to force
the density of the magnetic circuit far in excess of what is considered good
aractice in the design of stationary motors. The effect of this high satura-
;ion of the iron circuit is to entail an iron hysteretic and eddy-current loss
)f such a high value as to preclude the possibility, in many cases, of running
he motor continuously at full voltage without overheating it due to the
ron loss alone. It is evident, therefore, that recourse must be had to methods
A comparative rating of railway motors other than the usual continuous
unning at full voltage, obtaining in the case of stationary motors. On
t)co motives these space restrictions can be largely overcome by use of the
ide-rod drive with the motor mounted above the wheels.
121. The nominal rating of a railway motor is given in the A. I. E. E.
Standards, Sec. 24, Par. 6203.
122. The continuous-rating input of a railway motor is given in the
i. I. E. E. Standards, Sec. 24, Par. 5203.

123. The maximum load on railway motors does not usually exceed 150
cr cent, of the nominal rating.
124. Two factors determine the capacity of railway motors, namely:
ommutation and heating. During the accelerating period the current input
emanded by a railway motor is always considerably in excess of the current
fterward required to run the car at full speed on level tangent track. The
,alue of this current will depend upon the several conditions entering into
•le problem, weight of train, schedule speed, and frequency of stops, these
.ictors determining the rate of acceleration and maximum speed required as
reviously outlined. A motor must be selected which can commutate the
bnormal current required during the accelerating period without excessive
parking at the brushes.
125. Division of load between motors. For close calculations it is
scessary to plot the actual speed-time curves obtaining with any individual
lOtor. In dividing the total current input to the train by the number of
lOtors, in order to obtain the current per motor, it can be assumed that
ich motor will take its equal share of current at all speeds, provided the mo-
)rs are of the same type and capacity, and have the same gear ratio.

'
126. Effect of acceleration rate and maximum speed on capacity.
is evident from working out a few examples, that high rates of acceleration
m be used only when low maximum speeds are possible, and that an
;)normally large motor capacity will be essential if high rates of acceleration
•e demanded in connection with high maximum speeds. Thus, although
,otor equipments of the direct-current series-wound type can always
rnish enough current to slip the driving wheels, such high current inputs
11 be demanded as will considerably exceed the safe rated commutating

pacity of rnotors operating cars at 50 miles per hr. or more, common to

terurban high-speed service. Various devices have been brought out for
e purpose of limiting starting currents to safe predetermined values, and
e current-limiting device now forms a component part of certain types of
ntrol equipment.

1391
Sec, 16-127 ELECTRIC RAILWAYS

127. The heating of railway motors in operation is caused by interna;

copper, iron and brush losses. These losses vary not only in intensity bu I

also in distribution with different types of motors and classes of service]

At zero speed, the losses are all in the copper of field and armature, beinji
divided according to their relative resistance. As the armature spoeil
increases there is an iron loss distributed between the iron of armature anci
pole face and tips, depending upon the design of the motor. This iroii
loss starts from zero at standstill and increases to a maximum at the momen'
of cutting out starting resistances, after which it decreases somewhat
this again is a matter of motor design. As the various losses are the caus.;
of temperature rise in the motors, it is necessary to trace their influence upon
the individual part of a motor under study. !

128. Internal motor losses. As the heating of a motor is the result o'
the average losses within it, the average losses and their distribution up t'j
any moment of shutting off power must be determined.
Internal motor losses during fractional-speed running are indicated \\\\
Fig. 32 where abscissas give elapsed time and ordinates represent power lost
In other words, the losses depicted are not instantaneous losses at any give:
speed, but integrated losses from the time of starting from rest, to gaining tha
speed.
Equally irnportant with the determination of the various internal losse
is their distribution. Thus in a closed motor the armature loss must b
conducted through the field structure before it can reach the outside surfac
of the motor and be dissipated into the surrounding air. Added to the hea
imparted to the field structure by its own I''-R losses and pole face lo-sses
there is, therefore, considerable heat delivered to it by virtue of its service as
conducting medium for the armature heat. On the other hand, the fiel
structure would conduct the armature heat at a more rapid rate were it nc
for its own internal loss. It becomes important to establish a relation fc
this interchange of heat between field structure and armature, the relation bein
best expressed by the ratio of armature loss to field loss, as indicated in Fig. 3i
|

J
 ELECTRIC RAILWAYS Sec. 16-131

rating IS given in amperes at half, three-fourths and full voltages. To deter-

Jn'ie the sufficiency of the motor for a given service, a typical speed-time run
should be plotted and from that the square-root-of-the-mean-square (r.m s
)
current should be obtained. This should correspond to the rated continuous
current. With the modern self-ventilated motors, this practically controls
the temperature, since the increased speed that goes with higher core losses,
also causes a better circulation of air through the motor and carries
off mor«
heat. It is found that ventilated railway motors carry practically the
same
current at all voltages. Enclosed motors carry 5 to 10 per cent, more current
at the lower speeds corresponding to low voltages and frequent stopping
service than at higher speeds and
voltages corresponding to inter .20
urban service.
3.18
131. Application of thermal-
capacity curves. Any given
•
service operation, although made
up of short and long runs, can be
resolved into a single typical
speed-time curve which will call
same internal losses and the
for the
same distribution of motor losses
I
'as would obtain under service con-
editions. By utilizing data as given
•in the thermal capacity curve, Fig.
34, for a given motor, it is possible
to predict, with reasonable acou
 1

Sec. 16-133 ELECTRIC RAILWAYS

133. Short method of determining horse-power rating of trolley-

car equipments. Because of the many conditions which have to'be taken'
into account in the selection of motors for various classes of trolley carj
service and the varying characteristics of railway motors, some such process!
as outlined above is usually adopted when close recommendations are re-j
quired. The process is too elaborate for approximate estimates and because >

of this there are several approximate short-cut methods which are some times
used. There is a feeling, however, that there are many cases where the
service can be made more or less to fit the equipment and the problem boils;
down to a selection of a rational equipment ior various weights of trainsi
geared for various maximum speeds. For short-stop city service the econ-.)
omy of light-weight cars geared for low maximum speeds and capable of'
high acceleration is being appreciated more and more. In considering the,
equipment for such a service the motors will be required to give a highi
rate of acceleration without exceeding the 1-hr. rating, whereas for hign-i
speed service the accelerations are not so frequent and high rates of acceH
eration are not so essential, consequently the 1-hr. rating of the motorsj
can be somewhat exceeded during acceleration. Thus cars geared for ai
maximum speed of 25 m.p.h. should be equipped with motors which ca:^
accelerate the car at approximately 1.5 m.p.h. per second without exceeding
the one-hour rating of the motors, whereas cars geared for 50 m.p.hi
probably would not be used in a service where they would have to acceli
erate at more than 1 m.p.h. per second in which case a motor equipment
which would produce this acceleration at 30 or 40 per cent, overloaop
would ordinarily have sufficient capacity to handle a service which would^
require such a high maximum speed. The following table (Par. 134) has
been prepared along these lines to show relatively the hores-power capacitipi
for low- and high-speed service and is useful as a means of selecting from ;

list of standard motors the equipment which will come nearest meetinc tin
requirements of any particular service. A temperature rise of 65 deg. cent
has been taken in order to ensure a reasonably long life to the motor insula ;

tion, a much higher temperature rise causing a too rapid deterioration. li

this connection may be mentioned the possibility of running motors at mucl
higher temperature when they are provided with mica and asbestos in.sul:i
tion with no fabric.
131. Horse-power motor capacity required; standard direct-curren
railway motors, ventilated type

Max.
i ELECTRIC RAILWAYS SeC. 16-136

rmature and field losses are carried off independently of each other by the
itroduction of external air, hence the ratio of losses in such motors becomes
.' secondary importance.
Its. Division of capacity for single ears and trains. For single-car
Deration a four-motor equipment is preferred for double-truck cars, this
iing especially true where snow or heavy grades are characteristic of the
rvice. For train operation, two-motor equipments are used, as the dia-
lling of a single unit will not incapacitate the train.
137. Power requirements with single-phase equipment. Owing
the short perioa during which single-phase motors have been operated,
eir design has not yet become standardized, nor is there sufficient operating
ita upon which to base anything more than general conclusions of the horse-
iwer required for a given service. The single-phase motor is essentially a
i?h-8peed motor, having a high copper loss and low core loss, hence, is
Dre particularly adapted to constant-speed running, and suffers in com-
'rison with the direct-current series wound motor when used for accelera-
>n work. There is no lack of starting torque with the alternating-current
>tor, but a large tractive effort is obtained only at the expense of a large
pper loss, so that alternating-current motors are unsuitable for rapid
inisit service demanding repeated high rat« of acceleration, not because
bh motors cannot furnish the tractive effort required, but because the
oper loss incident to such high tractive efforts will heat the motors unduly
tiaed exclusively for acceleration service. Thus the alternating-current
itor becomes much heavier than the direct-current motor on the basis of
'vice performed with frequent stops.

lis. Single-phase equipment for a service embracing infrequent

^ps. In interurban or express service with infrequent stops, the smaller
,6 loss of the alternating-current motor brings it more nearly on a par with

direct-current series wound motor as regards output per pound weight

J

motor. It is possible therefore to use the figures of Par. 134 as applying

'alternating-current motor capacity, where stops are not greater than one
miles.
[5 However, the table should not be used in connection with higher
iiuency of stops given, as then the resulting motor capacity indicated in the
tie must be largely increased when applied to alternating-current motors. .

'wing to the fact that the chief advantage of the single-phase motor
1' in its ability to utilize the benefits of trolley potentials of 11,000 to
1 KJO volts as compared with the 600 to 3,000 volts used with direct-current

I' '>rs, questions of safety limit the field of operation of alternating-current

r- to lines operating over private rights of way except where alternating-
-direct-current equipments are used or a lower alternating-current
t

. 41' is used on the trolley as is sometimes done.

39. Three-phase equipment. Owing to the few applications of three-

pse induction motors to motor cars, no statements can be made regard-
1! the capacity of such motors for service performed. The induction type
Oi.lternating-current motor is not at all adapted for acceleration work,
O'lg to the poor efficiency of the car equipment during fractional speed
niing. The field of the three-phase induction motor lies in the direction
pi service calling for constant effort at constant speed, and the problems
Wrein this type of motive power can be considered are so special and infre-
Qut as to place it entirely beyond consideration for general motor car
»! ioation.
0. Locomotive motors. Locomotive operation demands a special
tr ment of the motor capacity subject, in
most cases requiring such special
kivledge of the motor construction as to prevent any general conclusions
b«| drawn with the limited data at hand. The locomotive motor is de-
Bij'd more along the lines of a stationary motor, that is, owing to the
Density for operating a locomotive close to the tractive limit, its motive
PCT is running continuously at nearly its full-load. With a locomotive
*' ing at 75 per cent, or more of the slipping point of the drivers, there is a
P9bility of but small overload and hence the motors may be designed
»T lower density, in fact like a stationary motor.
With the absence of
w me overloads, the question of commutation becomes secondary and the
sel.ion of a motor becomes a matter of its ability to radiate the heat
ge>.ated for the service specified. The whole question of motor capacity
loi comotives
is so intimately connected with mechanical problems of loco-

1395
Sec. 16-141 ELECTRIC RAILWAYS

motive design, that it must be placed in the list of special problems requin
the careful cooperation of the manufacturers. Locomotives for switchi
service use the motor intermittently, and the above remarks do not appl
141. Standard Oeneral Electric railway motors, commutating-iM
type
600 Volts
 ELECTRIC RAILWAYS Sec. 16-142

142. Forced ventilation is being resorted to especially in the case of the

larger motors for locomotives, as owing to the limits imposed by standard
jage and allowable wheel ba.se it often becomes extremely difficult to concen-
trate the required motor power without exceeding safe temperature limits.
Is the size of locomotive motors is largely determined by their ability to
adiate heat, the use of forced ventilation naturally follows as the next step
advance.
143. Standard Westingrhouse direct-current commutatinK-pole
railway motors

Motor HP-
%^
^°-
600
volts
 A
B

Sec. 16-144 ELECTRIC RAILWAYS

144. Alternating-current single-phase railway motors

Weight of
No. of motor
motors Weight gear, gear Weight
Type Type of of case, axle of drive
H.p. per Service
No. control CDntrol bearings details
equip-
(lb.) and axle (lb.)
caps
(lb.)

135- 76 Unit switch 8,525 4,500 lb. Motor car

132- 100 Unit switch 9,670
! 5,300 lb. Motor car
148- 125 Unitswtich 9,300
I 6,100 lb. Motor car
409- ,B 175 Unit switch 15,400 6,900 lb. 800 1b. Motor car
412 225 Unit switch 11,500
;
7,200 lb. Motor car

BAILWAT-MOTOR CONTKOL
146. Classification. There are two general types of control used with
direct-current series-wound railway motors, namely: drum control and
multiple-unit control. With each of these types there are two systems which
may be used, these being known as the straight rheostatic control system and
the series-parallel control system.
146. With the straight rheostatic system of acceleration the motor!
are connected permanently in series or parallel according to the arrangement
desired, and the full starting resistance is connected in series with the motors.
This resistance is then notched out of circuit, step by step, until full potential
is applied to the motors. This arrangement is used for single-motor equip-
ments, two-motor equipments on doubh
2 Motors Series Connection
voltage (two 600-volt motors insulated tc
TroUer^^ ^^ .. Ground
withstand 1,200 volts on a 1,200 voli
circuit), and for slow-speed industrial car.'
Motors Purallel
t:
or mining locomotives of small capacities.
147. The chief advantages of t
series-parallel control system are thai
two running speeds are obtained, and tha:
economy is effected during acceleration
4 Motors Ser
The motors or groups of motors (Fig. 36
/0'<in^-> /-0*-''nJ5^ are first connected in series with the ful
SroUej/
\J \Grouna starting resistance in the circuit. This re
V/-v^__/^
yj^uaw \ ^
\<>-TO-^
/ sistance is then notched out of the circuit
g^gp by step, until full-line potential h
4 Motors Parallel applied to the motors or groups of motor:
in series. A portion of the resistance i:

next re-introduced in the circuit, and thi

motors or groups of motors are connecte(
in parallel. Finally, the resistance is cu
out of the circuit step by step until full-lim
potential is across the motors or groups o :

Motor connections. motors in parallel.

148. Three methods of transition from series to parallel are in use '-

these being known as the shunting or " K" method, the bridging method
and the open circuit or "L" method. Shunting transition derives its nami
from the fact that in changing from series to parallel, resistance is re-intro
duced into the circuit, then one motor or group of motors is short-circuite(
(shunted) and is sub.sequently thrown into parallel with the other. In thi
bridging transition, after the motors are running in full series with no resistanci
in circuit, a portion of the main resistance is thrown in parallel with each of tin
motors or groups of motors. Following this, the circuit between the motors i

opened in such a way as to leave resistance in series with each of the motor
or groups of motors, and the latter in parallel. The open-circuit transitioi
derives its name from the method of opening the power circuit entirely befon
changing the connections.

1398
 ELECTRIC RAILWAYS Sec. 16-149

149. The distinctive feature of cylinder (drum) control is that the

various electrical connections are made and broken manually, by means of a
land controller. This consists of an upright cylinder upon which are
nounted the contacts and against which stationary fingers press. When
,he cylinder is rotated (by means of a handle) the contacts connect the proper
ingors to form the required electrical connections.

J?
 ,

Sec. 16-151 ELECTRIC RAILWAYS

Type " R " Controllers are of the rheostatic type and are designed to contrc
one or more motors by means of resistance only. Certain of these controller
are arranged so that the motors may be grouped either in series or in paralU
at the option of the operator, but as this must be accomplished by throwin
a separate lever, these controllers are not used as series-parallel controllers ani
their fieldis limited.
Type "B" controllers may be either of the rheostatic or the series-paralle
types, but they differ from the ordinary rheostatic or series-parallel con
trollers by having the contacts arranged so that if desired, the power may b
cut off, the motors reversed and then short-circuited through a variabl
resistance, the motors thus acting as series generators. Beside the brakin,
effect of the motors acting as generators, use is sometimes made of magneti
rail brakes or axle brakes, the coils of these magnetic brakes being in serie
with the short-circuited generators.
161. Capacity of drum controllers. Two ratings are given to drui
controllers, conforming to the double ratings presented by the A. I. E. E
for railway motors (see Par. 121 and 122). That is, the capacity of drui
controllers is defined by specifying the 1-hr. rating and also the continuou
rating in amperes at three-fourths voltage of the largest motors with whic
the controller can be used. It is necessary therefore in selecting controllei
for a given motor equipment to note that neither the hourly rating in hors
power nor the continuous rating in amperes is exceeded. It is further ne(
essary to define the number of motors the control is arranged for and als.
the maximum voltage of the circuit on which it can be used.
162. Standard series-parallel controllers —600 volts
No. of
Capacity No. of points Maximum
Type motors
potential, Remarks
H.p. Amp. Series [
Parallel volts

K-35 65 60 760
K-36 70 750
K-51 70 750 For tapped- .

field motors
K-63 40 38 750
K-64 110 105 750

163. Line circuit breakers with drum controllers. In order ^

eliminate the severe arcing from controller fingers when the main circuit
broken, an attachment is fitted to the lower end of the main cylinder shal
for the purpose of closing and opening the main circuit breaker. This ci
cuit breaker with an overload relay is enclosed in a sheet metal box ai
located under the car body. The line breaker used for this purpose is ma
netically operated and is provided with renewable contact tips and a powr
ful magnetic blowout coil with large arc chute. The attachment in the en
troller is essentially a ratchet switch which makes contact and closes i

circuit breaker when the control handle is turned to the first point and r
mains closed throughout all succeeding positions of the operating hiuuli
When the controller is notched back in the "oflf" direction the ratcli
switch opens and de-energizes the line breaker which opens the main ciroi
regardless of the position of the operating handle. Thus the current is c
off before the control fingers break contact. To close the line breaker ni::i
the operating handle must be turned completely off and brought back
the first point as before. In case of overloads the overload relay opera i

and opens the line breaker. In this equipment the hne breaker takes i
place of the hand-operated breaker which is usually located in the vestibu
184. Multiple-unit control is a term originally applied to a conii
system which was designed to permit a train of motor cars, when couple!
any combination, to be operated as a single unit from either end of t\n\
in the train. To secure this result several methods have been adni
Fundamentally the methods are essentially identical but the means
ployed have differed. That is, the control systems for each car inii.\
considered in two parts, one consisting of apparatus which makes the m;
connections, or motor controller, and the other part consisting of appar:it

1400
 ELECTRIC RAILWAYS Sec. 16-155

I'hich governs the operation of the motor controller, that is, a master con-
•oller. There are three ways in which this has been done as described in
,ar. 148.
I
155. General Electric contactor control employs magnetically-oper-
iled contactors or circuit breakers which are opened and closed in proper
iquence by means of train wires which are energized through a master
)ntroller.
166. The master control (Par. 155) Fig. 38 comprises those parts which
vitch the control current operating the motor-control apparatus. The
aster controller is operated by hand, and is located in the vestibule at
ther end of the car. The motor control is local to each car, and current
r this circuit is taken directly from the trolley or third-rail through the
ntactors, starting resistance and reverser to the motors, thence to the
ound. Where it is necessary to operate with a gap in the third-rail sys-
m, it is sometimes customary to install a train line so that any car^may
pply the motor current for the other cars of the train.
Tiro Wirf Cuircnt Limit Kelrj

Contactors
Contactors Closed on
 m .

Sec. 16-158 ELECTRIC RAILWAYS

control. The value of the current required is very small, not exceeding 2
amp. for each car in the train. The master controller is provided with tv
handles, one for operating and one for reversing the train niovenient.
The operating handle is provided with a button which must be ks]
down except when the handle of the controller is in the off position, as r
leasing this button permits an auxiliary circuit to open, cutting off the supp
of current to the master controller, and thus de-energizing the train-line ai
opening up the motor-control apparatus. This button is intended to ser
as a safety appliance in case of physical failure of the motorman.
The reverser handle is connected to a separate cylinder which establish
control connections for throwing the electrically operated reverser eith
forward or reverse position when the master-controller handle is on ti
off point. The operating circuit for the reverser is so interlocked that unle
the reverser itself corresponds to the direction of the movement indicated I
the reverser handle of the master controller, the line contactors on that c
cannot be energized.
168. The contactor (Par. 166) is a switch operated by solenoid coi;
and each contactor may be considered as the equivalent of a finger and J

corresponding cylinder segment in the hand-operated " K"-type controlh

It consists of an iron magnet frame with an operating coil and two main co-
tacts, one fixed and the other directly connected to the movable fingt
These main contacts open and close in a moulded-insulation arc chute pi
vided with a powerful magnetic blowout. Interlocks are provided for maki
the necessary connections in control circuits to ensure proper sequence
operating the different contactors.
All of the contactors are mounted in a box placed beneath the car, this b
being provided with a sheet-steel cover lined with insulating material.
169. The reverser (Par. 166) is a switch, the movable part of which ill

rocker arm operated by two electromagnets working in opposition. T

coils receive theirenergy from the master controller through the train-liK
and the connections are such that only one coil can be operated at a tinj
Leads from the motors are connected to the main reverser fingers, and |
means of copper bars on the rocker arm, the proper relations of armature a^
field windings are established for obtaining forward or backward motion|
the car. Also see Par. 178. a

160. Circuit couplers between cars (Par. 166) are so designed as

give a corresponding connection of train wires, this being secured by mei,
of proper mechanical design of plug and sockets, it being rendered impossi
to insert the plug in the socket improperly.
161. Automatic multiple-unit control. Sprague General Elect
automatic (Par. 166) provides for the acceleration of the train at a pre
termined value of current in the motor, this feature being provided withi
preventing the manual operation of the master controller at less than
predetermined current if desired.
The operation of the contactors is controlled from the master control
but is governed by a notching or current-limit relay in the motor circuit,
that the accelerating current of the motors is substantially constant.
This is accomplished by having small auxiliary interlocking switches
certain of the contactors, the movement of each connecting the operiit
coil of the succeeding contactor to the control circuit. The contactors
energized under all conditions in a definite succession, starting with
motors in series and all resistance in circuit; the resistance is subsequently
out step by step; the motors are then connected in parallel with all resista
in circuit, and the resistance again cut out step by step. The progress .

can be arrested at any point, however, by the master controller, and is ne

carried beyond the point indicated by the position of the master control
The rate of the progression is governed by the current-limit relay, so that
advance cannot be made at a rate so rapid that the current in the motors
exceed the prescribed limit. One of these relays is provided with each
equipment, so that while the contactors on each car of a train are cent
from the master controller in use for the application and removal of poi
the rate of progression through the successive steps is limited by the n
on each car independently, according to the adjustment and current reqii
ments of that particular car.
 ELECTRIC RAILWAYS Sec. 16-l(i2

162. The control for 1,200-volt, 1,600-volt, 2,400-volt and 3,000-volt

car equipments iPar. 166) is essentially the same as that described for
600-\'olt service except that two motors are usually connected permanently
in series. Series-parallel connection of the two groups of motors provides
for half speed and full speed, but when full speed is desired on 600-volt sup-
ply, a commutating switch is provided with the 1,200-volt equipments, thus
changing the motors from two in series to all in multiple. Usually, however,
two motors remain permanently in series, and provide half speed when 1,200-
volt cars run over terminal tracks supplied with energy at 600 volts. A
dynamotor or motor-generator set run from the trolley supplies current at
low voltage for actuating the switches. The air compressor and heaters
operate direct from the trolley circuit.
163. Protection against failure of power (Par. 166). Another
automatic protection for individual cars is provided by a second or potential
Telay, which has its coil connected to the lead from the collecting shoes of
the respective car. The contacts are so connected in the contactor circuits,
,that in case of failure of power to any car (such as would be caused by pas.^iing
over a dead section of rail), this relay is de-energized and causes the control
circuits on that car to be thrown back to the .series position with resistance
n circuit. When power is re-applied the control progresses step by step to its
ormer advanced position. This method prevents any surging or overloading
n such contingencies.
164. Train-wire circuits (Par. 166). There are five circuits leading
rom the master controller, and five corresponding train wires. The five
nrcuits comprise one for forward direction, one for reverse, one each for
leries and parallel, and the fifth for controlling the acceleration. When the
naster controller is moved to its first forward point a direction wire is ener-
3«ed which throws the reverser to its forward position, if it is not already so
hrown. The reverser is electrically interlocked so that it cannot be man-
lOlated when the motors are taking current.
The operating circuit is so arranged that unless the reverse is thrown for
le direction of car movement indicated by the master-controller handle,
le contactors and motors on that particular car are inoperative. When the
everser has moved to the proper position, connections are made by it from
he direction wire, through the forward reverser-operating coil, to the coils of
ae contactors which control the main or trolley leads to the motors.
166. Oeneral electric cam control. This is a later design of multiple-
it control than the contactor type (Par. 166) and is a more direct applica-
m of the principle of the drum controllers. In certain features it resembles
Mi. the drum controllers and also the contactor control. That is, instead
the main controller shaft of the dram controller with segments mounted
;

hereon and turned by hand, there is substituted in the new control a cam
}att which is operated by means of compressed air. This cam shaft oper-
8 the contactors by means of cams. It has been possible with this design
assemble the contactors, reverser, line breaker relays, etc., in one box
iiwath the car body. The electric control circuits are greatly simplified
id positive serial action of the contactors has been obtained without elec-
esl interlocks. It also weighs less than the older type of contactor control.
IW. Air-operated line circuit breaker and reverser. The line
eaker and reverser (Par. 166) are provided with individual air cylinders
id magnet valves. These magnet valves control the air inlets and outlets
cylinders which in turn close the line breaker and operate the reverser.
le operation of these valves is governed through train wires which are

'gized through the master controller.

17. Air-operated cam shaft. The contactors (Par. 166) instead of
^nng individual magnet valves and air cylinders similar to the line breaker
fi^xeveiseT are all operated by means of cams mounted on a horizontal
**Hi which carries a pinion at one end. This pinion engages with a rack
'^y>own in Fig. 39, which is moved back and forth by a double-acting air
lit^^ton. Air is admitted or released from either end of the air cylinder by
'.ns of magnet valves which are energized through the master controller
ain circuit.
Controller air cylinder. The ends of the controller air cylinder
[ai!|
i^.; 166) are fitted with magnet valves and are designated as the "on"
ff.
'off"ends. The "on" end is the end of the cylinder at which air is
1403
Sec. 16-168 ELECTRIC RAILWAYS

admitted to turn the controller "on" and likewise the "off" end is the end
at which air is admitted to turn the controller off. When the magnet valvei
are de-energized the normal position of the "on" valve is closed to the resor
voir and open to the exhaust. The normal position of the "off" valv«
when the magnet valve is de-energized is just the reverse, closed to the ex'
haust and open to the reservoir. When the car is stopped the magnel
On Val\/e

Fia. 39. —Cross-section of General Electric type

and magnet valves.
PC controller main engin'

valves are both de-energized, that is, air at reservoir pressure is admitte(
at the "off" end, and the "on" end is open to the exhaust; thus the pistoi
is forced in the direction which turns the motor controller "off," i.e., towan
the "on" end. When the master controller is turned on and the reverse
throws, the line breaker closes and both the "on" and "off" magneti
valves are energized, that is, air is admitted to the "on' side of the pisto
'

and exhausted from the "off" side and the rack revolves the cam shai

ffi^r-nqg^ym**

Resistors and
Motor Controller
must be insulated
fromground

Motor Controller^
Fio 40. — Motorcontroller,
controller arrangement of 600-volt car equipment with sm
type PC-5, General Electric Co.
making the first motor connections. The piston will continue to moveI
the same direction if both magnetic valves are kept energized, but
if

current flowing in the main motor circuit should exceed a predetermir

amount it will operate a relay which de-energizes the "off magnet ' val

thus closing the exhaust port and admitting air from the main
reserve
which in turn will equalize the pressure on both sides of the piston anU
si

1401
 ELECTRIC RAILWAYS See. 16-169

ts movement. When the current in the main circuit falls below this pre-
letermined value the "off" magnet valve is again energized and the motor
lontroUer moves on to the next point.
169. Master controller (Par. 166). There are three points on the master
;ontroller; the first point gives the first point series, the second all series
)ositions and the third all parallel positions. As shown in Fig. 40 there are
ive steps in series on the motor controller, all of which except the first are
)btained automatically by moving the master controller to the second
lotch. Likewise there are four steps in parallel on the motor controller,
11 of which are obtained by moving the master controller to the third point.
!'he progression from one point to the next will only take place as fast as the
etching relay, which energizes the "off" magnet valve, operates. The
am control is, therefore, inherently an automatic control which secures
onstant acceleration, but is simpler than non-automatic control with the
ontactor type.
170. Advance
lever. A third handle is located on the master controller
Par. 169) cap plate. This handle is known as the advance lever and is
sed to advance the motor controller point by point if in emergencies the
ir will not accelerate at the current for which the notching relay is set.
'
171. Overload relay. An overload relay is part of these equipments
ad its function is to trip the line breaker in case of overloads. In turning
|Tthe power the master controller is usually turned off faster than the motor
)ntroller can follow. When the master controller is in the off position it
-energizes the magnet valve on the line breaker and opens the circuit at
- iioint. The cam-operated contactors are, however, equipped with
.tic blowout coils and arc chutes so that current can be interrupted at
~ points also.
168. The Westinghouse unit-switch system of control is arranged
r use either on alternating-current or direct-current circuits, and for capac-
es varying from the smallest double-motor equipments to those of the
"gest locomotives. The control circuits for an alternating-current in-
\llation are usually energized from a storage battery, while those for a
rect-current installation may either be operated from a storage battery
: by the use of energy from the line. When the latter is used for the control,
resistance is inserted between the trolley and the ground whenever the
. ister controller is in one of the operating positions; taps leading from this
ntrol resistor provide various low voltages at which the control circuits
ly be energized.
Westinghouse unit-switch control equipments are classified according
whether they are arranged for hand (manual) or automatic acceleration,
lether they employ energy from the line or a battery for control,
i whether they have any other distinctive features, such as field control
\ -multiple operation with General Electric Co.'s. type " control. SomeM"
^these standard designations are as follows: HB, AB, HLF, AL, ALM, etc.
us it will be noted that " H" signifies hand acceleration, "A" automatic,
battery control, "L" hne control, "F" field control of motors, etc.
72. The Westinghouse "HL" system of control is widely used for
t control of direct-current motors on city and "interurban cars and is
tcribed in detail in Par. 173 to 196. A standard car equipment for the
c trol of 4-65 h.p. 600-volt motors arranged for double-end operation in
t ns included the following parts:

Main circuit apparatus Control apparatus

Trolleys 2 Master controllers

Lightning arrester 2 Control and reset switches
Main knife switch 1 Control resistor
Main fuse box 2 Train line junction boxes
Control box 2 Train line receptacles
Reverser (included in control box) 1 Train line juniper
Main grid resistor | 1 Set of pneumatic details

he general arrangement of this apparatus on the car is shown in Fig. 41.

1 main and control wiring is shown clearly in Fig. 42. This system of
ct rol uses the shunting type of transition from series to parallel.

1405
Sec.'16-172 ELECTRIC RAILWAYS
 ELECTRIC RAILWAYS Sec. 16-173

,
173. The main switch (Par. 172) is arranged for mounting underneath
he car and is enclosed in a box, wliioh protects it from the weather and
asures against accidental contact.
174. The main fuse box (Par. 172) is of the magnetic blow-out, copper-
ibbon type, arranged for mounting under the car. The fuse gives an
dditional safeguard in series with the circuit-breaking switches which ordi-
arily open the circuit in case of overload or short circuit.

Fig. 42. —Schematic diagram of control box, with four motors.

llW. Control box (Par. 172). The various main circuit connections are
Tide by means of a number of independent switches known as unit switches,
Itji provided with a strong magnetic blowout and normally held open by

fiowerful spring. Each switch is closed when desired, by compressed air

Sing on a piston. This action forces the switch jaws together against the
'ting pressure, the force being sufficient not only to compressthe sjiring
I. also to apply a heavy pressure at the switch jaws. The air is admitted
tor exhausted from tne cylinder through a valve which is operated by
1 ^n8 of an electro-magnet in the control circuit. The control box includes
t assembly of a number of these unit switches and blowout coils, reverser,
t-out switches, and overload trip relay in a common frame, completely
elosed by removable sheet-steel covers lined with asbestos. A crqss-
B ion view of the control box, indicating the construction and operation

he unit switches is shown in Rg. 43.

76. Interlocks are provided to make the necessary changes in the
ctrol circuits in order to secure the proper sequence of switches and
t.afeguard against improper operation. Tnese interlocks consist of cop-
P contacts, mounted on an insulated base, which is mechanically connected
ti'the movable switch element. Stationary fingers press against this
i^ik and rnake the necessary control-circuit connections in the "IN" or
JT" position of the switch.
n. Line switch (Par. 172). On equipments where it is necessary to
he an increased number of switches to secure a larger capacity, two of
tlswitches are mounted in a separate frame with the overload trip. This
bly constitutes what is termed a "hne" switch. The overload trip

IT 1407
 6 1

Sec. 16-178 ELECTRIC RAILWAYS

relay includes a series coil connected directly in the trolley circuit. Witk
this coil is mounted a movable plunger to which are attached insulat
metal 'discs connected in the control circuit. Excessive current throui
the coil moves the plunger and opens the control circuits of certain switci
which cutloff the power. The plunger is held in the normal position 1

gravity assisted by a spring, but when actuated is latched in the open positi^
and must be released manually or by energizing a reset coil from the conti
and reset switch in the cab. Calibration is accomplished by an adjustme
of the air gap.

[^

\ Heani Ccpfxr/irma Tps

WrfufheArc Ckifmm the
Buff Contact under tfie
Impetus ofFbwerful
McKjnefic Bhwouf Cbih

Copper ButtConfacf
100 U>s. Pressure insures.
H^h Current Ccpacity

Milve Mechanism wliici

under fhe action ofttie
Electro Mi7gnetConHvk
Atmissiorrof^lr tv ffie
SwitcJt Qjlihf/er ^. ^ArAixmbh I

I
including Air Ptsmf,
IcmiHfmi/ Cciinrresai\
\\6pring IhrDpenySi^

FiQ. 43. — Electro-pneumatic switch unit.

178. Reverser (Par. 172). The direction of rotation of the motor

changed by reversing the main fields. The reverser consists of the nec'.
sary number of main circuit fingers mounted on a stationary base, a
arranged to press against contacts carried on a movable drum. The drii
with its contacts is moved to the forward or to the reverse position by o
or the other of two pneumatic cylinders, closely resembling those in the c(;
trol box, except that no springs are used. Each cylinder is controlled bj
magnet valve similar to those in the control box. The reverser is mount
on one end plate of the control box (Par. 176), which greatly simplifies 1

main circuit connections and the mounting of the apparatus.

179. The master controller (Par. 172) is a small drum-type control*!
which governs the application of power to the control circuits. Althou''
much smaller in .size, this controller is similar in construction to the us
main drum controller, having one handle governing the direction of mot:
and another governing the acceleration, the two handles being mutua
interlocked. Energy for the control is obtained from the line by taki
low- voltage taps from a resistor connected fromline to ground. This resis
is connected to the line through high-voltage fingers and contacts on i

master controller and a fused control switch. A magnetic blowout coil

provided for rupturing the arc at the high-voltage fingers. In opcratil
the controller connects the trolley potential to the control resistor and a
regulates the connections of the low-voltage control circuits to the varii
operating coils.

1408
 ELECTRIC RAILWAYS Sec. 16-180

r The control resistor (Par. 172) consists of a number of resistance

180.
mounted in a common frame with a sheet-iron cover. Each unit is
inits
laade by insulating a slotted steel ribbon with mica and enclosing this insu-
ated ribbon in a sheet-iron scabbard. The scabbard is firmly pressed against
he mica insulation, and being waterproof renders the resistor especially
uitable for railway service.
181. The control junction boxes (Par. 172) are provided for making
onvenient control-circuit connections between the master controller, the
rain line receptacles and other control apparatus. Each box contains an
isulating base, pro\ided with a number of terminals, and has a hinged lid
^
facilitate installation and inspection.
182. Train line receptacles are provided when multiple operation of
ars is desired. These receptacles together with the necessary train line
impers complete the control circuits between adjacent cars, allowing
multaneous operation of all equipments so connected.
183. Pneumatic details (Par. 172) for supplying air at the proper pres-
ire for the control, are furnished with each equipment. These consist of
air strainer, a reducing valve (when the main reservoir air pressure is
)Ove 75 lb.), a check valve and a control reservoir. The check valve and
mtrol reservoir permit the operation of the control system in event of fail-
e of the main air supply, the control reservoir having sufficient air capacity
operate the control a great number of times. Local conditions sometimes
quire extensive control operation even though the main air supply fails;
such cases an emergency control reservoir is employed. The use of air
r braking purposes has proven that very little trouble may be expected
}in this source if the piping is properly arranged and the reservoirs drained
proper intervals. The use of air for operating switches insures a heavy
ntact pressure at the switch jaws, which pressure is, of course, indejiendent
trolley voltage.
184. Westinghouse type "AL" control. Where service conditions
irrant the use of automatic acceleration a modified type of equipment is
iployed. The operation the switches which commutate the main
of
jostor circuits and establish the series or parallel connection of the niotors
ar. 172) is governed by a sequence switcn which in turn is operated from
J master controller under the control of a limit relay.

186. The sequence switch (Par. 184) is essentially an electrically con-

illed, pneumatically operated drum which carries contacts arranged for
iigizing the valve magnet coils of the control box. It consists of two air

"Offor/merkd
Mqgnef Valve [

Exhausl

Airlnlef

Fia. 44. —Cross-section of differential air cylinders.

e nders with the pistons connected by a rack which transmits the move-
Diit of the pistons through bevel gears to the drum carrying the contacts.
vnpressed air is admitted or released from the cyUnders by means of a
n?net valve at each cylinder. The magnet valves are similar in general
c itruction to those in the control box, but the operation of one valve is
a !rent in that when this magnet valve coil is energized, air is released
II the cylinder and when the coil is de-energized, air is admitted; this is
1

c J the "off" magnet valve. The other valve admits air to its cylinder
' n the coil is energized and releases air when the coil is de-energized;
< called the "on" magnet valve and is the same in operation
as the valves
control box. If both magnet valves are energized simultaneously,
iiient of the drum results since air is admitted to one cylinder and

1409
 Sec. 16-185 ELECTRIC RAILWAYS

1410
 ELECTRIC RAILWAYS Sec. 16-186

released from the other. With neither magnet energized, the air in the "on"
valve magnet cylinder is at atmospheric pressure, while that in the "off"
valve magnet cylinder is at reservoir pressure, thus holding the pistons and
drum in the "off" position. Energizing the "on" magnet balances the
pressure on the two pistons but causes no movement. Thus to move the

ston and drum in successive steps, it is only necessary to energize the "on"
agnet from the supply circuit and the "off" magnet through the limit relay
mtacts. The general construction of the cylinder, pistons and valves is
lown in Fig. 44.
186. The limit relay (Par. 184) is a solenoid tjrpe with a series coil con-
xted directly in the main motor circuit. The relay armature carries con-

1411
 j

Sec. 1&-187 ELECTRIC RAILWAYS

tacts, which are connected in the control circuit to the sequence switch.
The relay armature lifts when the main motor current reaches a certain pre-
determined value, thus interrupting the control current to the "off" valve
magnet and baiting the progression of the drum. As the motor speed in-
creases, the current will fall until a value is reached where the limit relay
plunger will drop again, closing the operating circuit to the sequence switch.
This performance is repeated until the control has reached the notch indi-
cated on the master controller.
Three points are provided on the master controller switching, series and
parallel.
—
The first one gives the first point series; the second automatically
progresses the control to the full series position, and the last to the full par-
allel position.

187. A notching relay (Par. 184) is included which, in connection with

a small notching lever incorporated in the master controller, provides a
means for obtaining step-by-step notching on heavy grades or under similar
conditions of operation where the current required by the motors for accel-
eration is above that for which the limit relay is set. The diagram of con-
nections for an automatic equipment of this type for four 40-h.p. niutors is
I shown in Fig. 45.

188. Automatic equipments for subway or elevated service. On

elevated or subway equipments where long trains and high-speed service
are common, it is usual to employ bridging transition to insure smooth
acceleration. The operation of the control equipment is essentially the
same as described above. The wiring diagram for an equipment of this type
is shown in Fig. 46. Energy for the control circuits is provided by a storage
battery, which is charged by connecting it in series with the air-compressor
circuit. A battery-charging relay is provided to disconnect the battery
from the compressor circuit when the latter is not running. |

Transformer Main Transformer

^ - Seiy/yeffce ofMiches J/lfj J^" \A,

^ MB Mi
Trans'

Fig. 47. —Schematic diagram of main

current, with two motors.
circuit control, 11,000 volts alternating;
'

189. Tap-potential control of single-phase motors. The single

phase motor is essentially the same in its characteristics as the direct-currenl
series-wound motor, and can be started at low voltage by means of insertinf
series resistance according to the direct-current standard method. With
alternating-current supply, however, it is possible to obtain fractions
voltage without sacrificing efficiency, as the step-down transformer forminf
part of the alternating-current car equipment can be constructed with tapi
so that it will furnish fractional voltage without the nece.s.sity of introducinj
starting resistance. The universal method of starting single-phase moton.
ia,therefore, by the so-called tap-potential control, and the function of thi

1412
 ELECTRIC RAILWAYS Sec. 16-190

control, whether it be hand-operated "K" type or multiple unit, is to con-

nect the motor terminals successively to transformer taps of increasing poten-
tial while starting.

190. The hand-operated control of single-phase motors is identical

with the type " K." controller used with direct-current motors, except that
advantage is taken of the fact that alternating-current arcs of considerable
size can be broken in the air without the aid of the magnetic blowout. Where
the cars are to be operated from both alternating-current and direct-current
trolley with the same equipment, the hand-operated control is provided
with magnetic blowout for direct-current operation, using the same controller
without the magnetic blowout for alternating-current operation, unless the
motor equipment be of large capacity.
191. Control of single-phase motors for combined alternating-
current and direct-current service. The control of single-phase
I motor is effected by connecting the motor terminals to transformer taps of
i increasing potential in order to vary the speed, while reversal is effected by
f.
reversing the series field-winding connections, thus calling for practically the
same combinations , as demanded in direct-current series motor control.
Alternating-current series motors are wound for low potentials not exceed-
ing approximately 300 volts per motor, and such motors in order to meet the
exactions of commercial operation must sometimes be adapted to run with
600-volt direct-current. In such cases it requires some additional features
.in control to perform this double service of alternating-current and direct-
current control.
192. The Westinghouse alternating-current motor control is very
^similar to the direct-curre;it control. Pantagraph trolleys are ordinarily
I!employed because of the j- ,,
j high voltages common for \"''^''^J/ ^^/„ Transformer
alternating-current opera- \^J_SiXn^iJlXX^^S^xnSJXnXiJS^JJ3^X!l33~^ '
iition. High-potential wires
are enclo.sed in metal tub-
which is thoroughly
5f<fueKe ofSm/c/res
grounded in order to insure M
ting
safety to operator and
'passengers.
I
When passing from one
^transformer tap to the
next, it is evident that
iny metal contact bridging
he gap between the two
ivill cause a short circuit
)n a portion of the trans-
i: ormer. It is therefore
lecessary to introduce
•ither a resistance or an
nductance in the circuit
vhen passing from one
ap to another. An in-
luctance, termed a "pre-
nttive coil, is most frequently used in both locomotive and motor-car
ervicc. See Fig. 48.
193. Combined alternatingr-current and direct-current equip-
aents. At times existing conditions may require the operation of an equip-
lent on both alternating-current and direct-current systems, an example
f this being the equipments of the N. Y., N. H. &
H. R. R. Co. which enters
le Grand Central Terminal in New
York City. No
change is required in the
ngle-phase motor for direct-current operation, but since the control is
ecessarily of a different character, some means must be provided for re-ar-
mging circuits. This is usually accomplished by means of a drum type of
lange-over switch, but if heavy currents are to be handled, individual knife
gjvitches are employed. The control apparatus used with a combination al-
ating-current-direct-current equipment is, in general, more complicated
equipments for straight alternating-current or straight direct-current
ration.
 -

Sec. 16-194 ELECTRIC RAILWAYS

194. Number of starting: points (Par. 195). Owing to the fact thai
the alternating-current motor characteristic is more drooping than that ol
the direct-current series-wound motor, fewer starting points are required
for this type of control. Since each point on the controller constitutes a
running point at full efficiency, it is not necessary to use series-parallel con'
nection of motors as is done in direct-current equipments. A total of sever
notches is usually all that is required.
195. Multiple-unit control equipments for single-phase motori
differ somewhat from direct-current equipments in the general plan oi
operation. This difference is confined chiefly to the main circuits and main-
circuit apparatus. The high-tension current passes from the overhead
collector through an oil circuit-breaker, to a transformer. Low voltag«
currents are fed to the main motors through a group of unit switches, whicl
can be arranged for automatic or non-automatic acceleration. Fig. 4(
shows the connections for a typical type "AB," 11,000-volt single-phas«
equipment.
TYPES OF RAILWAY MOTORS
196. Direct-current series-wound motor. Wound for potentials ol
from 500 to 1,200 volts is the standard railway motor. Motors of from 50C
to 600 volts are used in and around large cities, 1,200-volt motors beins
adopted on interurban electrified lines. Armature and field windings are
connected in series and the use of motors of the commutating pole type is
increasing. All motors designed for street, interurban and rapid transit cat
or train service have four field poles, the structure being entirely enclosed
with hand hole covers making it waterproof. Such motors transmit powei
by single-reduction gear, motors being suspended at one end upon the cai
axle and spring suspended at the other end.
For locomotive work, the General Electric Company ha^ brought out s
two-pole gearless motor, which design is also adapted for high-speed single-
car service calling for large motor outputs. The two-pole series motor if
especially adapted to very high speed service; it minimizes cost of repairs
and operates with decreased noise and greatly increased efficiency for express
service. For further description of gearless motors see locomotives (Par
270).
197. The single-phase series motor has been developed along severa
lines of which the series-wound compensated motor is the one most gcnerallj
used in the United States. The single-phase motor differs from the direct
current series-wound motor in having two fields, the series or energizing fiek
and the compensating field. The office of the latter is to compensate for
or neutralize the inductance of the armature produced by the alternating cur
rent therein. Compensation may be the means of raising the power-factor o
a single-phase motor to values closely approximating 100 per cent., and hav-i
j

ing an operating value above 95 per cent. j

This compensating field may be either conductively or mductively proi^
duced, depending upon whether the winding is traversed by the main nioto'!
current, or by the current produced in its own short-circuited winding b;,
the alternating armature flux. So far as concerns operation from altornat
ing-ourrent supply, one form is about as efficient as another, but the coinliu'
live compensation is an aid when the alternating-current motor is r^illi^
upon to operate as a direct-current motor.
The series-field winding of the single-phase compensated motor is con
nected in series with the armature, and the direction of rotation can be rei
versed by reversing the field-winding connections similar to direct-curreni
operation. The series-field winding may be distributed in a number c
skits in the field-magnet structure similar to the corapensating-field winding
or it may take the form of a concentrated winding, in which case it is siinila
to the winding of a direct-current series motor embracing inwardly project
ing poles. The concentrated field winding is largely used in alternating
current motors of the series type, while the distributed field windiiiK i

required for motors of the repulsion or similar types. As the series-con

sated motor is universally used in this country, and the repulsioii and p;!
types are limited to special cases demanding special characteristics oi
motive power, the series type motor alone will be considered.
•As the armature rotates in an alternating field, there is a short circu
developed when brushes touch two commutating segments at once, in

1414
 ELECTRIC RAILWAYS Sec. 16-198

short circuit is very large at starting, being reduced to a reasonable amount

when running at full speed. To reduce the amount of this short-circuit cur-
rent, and better the low-speed commutation, the alternating-current series
compensated motor is sometimes provided with resistance leads connecting
armature winding with commutator bars. Such leads are desirable with
motors of the series compensated type, where full field strength is used in
starting and there is no commutating-pole effect to neutralize the short-
circuit voltage when moving. -

198. The repulsion motor as originally developed by Thomson and

perfected is shown in Fig. 51. The field winding is very similar to the field
winding of an induction motor. The armature is an ordinary series-wound
armature short-circuited upon itself. The repulsion motor is very similar in
its operating constants to the single-phase compensated motor but cannot
be used for speeds much higher than 100 per cent, of synchronism, owing to
the imperfect commutation at the higher speeds. It has the advantage of
tutving its field circuit distinct from the armature arcuit, henee, permitting

Plain Serfeft

With Commutating
Pole

Fig. 49.

Fig. 52. Fig. 53.

I'fa field winding of any potential best suited for control or operation. With
Ij^hiatype of motor it is possible to operate 3,000 volts "direct on the field
'rinding if desired.
Best results appear to be obtainable from a combination of repulsion-motor
ionnections for starting and operation at low speeds, changing to series-
lotor connections for speeds above synchronism. This is effected automatic-
,lly by relays.

•
199. In the Latour motor, which is a niodification of the Winter-
'ichberg motor the armature winding is short-circuited in part only, rather
lan through diametrically opposite brushes, with the result that the arma-
ire I^R loss is reduced. This type is limited in its field of application to
JBcial cases. , . . ,
.
,

200. The three-phase Induction motor has all the 6haraoteri8ticB of

direct-current ehunt-wound or constant-speed motor, and comprises a
iree-phase primary winding either star or delta connected, with a three-
lase secondary winding either star or delta connected. The secondary
rminates in collector rings across which non-inductive resistance is inserted
iring the accelerating period, after which the collector rings are short-
"cuited. The induction motor may be wound for the trolley potential if
sired, as the potential of the secondary winding is entirely independent
that of the primary. The constant-speed characteristic of this type of
Dtor is especially adapted for duty of a constant nature, such as haulage
er a regular profile, either level or up a uniform gradient, in other words,
lere there is no combination of slow-speed grade haulage and high-speed
'el service.

1 1415
 ,

. Sec. 16-201 ELECTRIC RAILWAYS

j|

201. The single-phase induction motor haa been used for railwaj*
purposes on experimental roads, but owing to the zero starting torque o
this motor it is necessary to operate it in conjunction with an auxiliary start
ing device and throw the motive power into action by mechanical clutclu'
or other means after full motor speed has been obtained. This type of moiiv,
power is very limited in its field of application.
202. The split-phase converteV system comprises a method of obtainini
polyphase current from a single-phase trolley, for the operation of polyphas'
motors. It consists of a phase converter which is essentially a polyphasi
induction motor the capacity of which is approximately 75 per cent, of th'
capacity of the motors it supplies. As the phase converter is operated fron
one phase only, it requires a starting motor to bring it up to near synchronou
speed. In all applications of this principle, the single-phase current has bee?
converted into two-phase current. In the Norfolk & Western locomotives
these two phases are changed to three-phase by a connection similar to th
well-known Scott system. The advantage claimed for the three-phase i

that the motor has a better performance and is also better for pole changiu
while it entails no more regulating switches and has fewer leads.

BRAKING
203. Betardingr factors. In order to bring a moving train to a stop, i

is evident that some external force opposed to the motion of the train mus
be applied. The ideal force would be applied at the centre of gravity c
the car (producing no tendency for the car to rotate) and would be sufficier
to atop the train in case of emergency in the shortest possible time, withoD
undue shock to passengers or equipment. With the exception of a few ii
stances, such as short cable roads up a mountain side, the only availab!
force which may be utilized in stopping a train is the friction which exist
between the wheels and the rails. This force, besides being applied at th^
lower rim of the wheel and consequently not at the centre of gravity of tl:'
car, is also a variable quantity of uncertain magnitude, and therefore not a'
ideal retarding force. For instance the adhesion between a dry rail and whe;
may be equal to about 30 per cent, of the pressure between wheel and rai
whereas with a wet rail it may be only half that amount. The addition i

sand to a slippery rail will increase the adhesion from 16 per cent, to abov
25 per cent, of the weight on the rails, and this amount can usually be relic
upon in making emergency stops. This force of 25 per cent, of the weigl
on the rails applied to a' car will produce a retardation equal to one-quart(
the acceleration due to gravity, or 8.04 ft. per sec. per sec, or nearly 5.5 mil
per hr. per sec. If it were possible to apply this force instantly and uniform,
throughout the stops, a stop from an initial speed of 60 miles per hr. cou
be made in about 11 sec, or in a distance of 480 ft. This force, however,
only available when the wheels are rolling on the rails, for as soon as slippii
occurs the adhesion rapidly decreases. Therefore the force which oppos
the revolution of the wheels, namely the brake-shoe friction, must never e
ceed that which is keeping the wheels turning, namely the adhesion betwec
the wheels and rails. This opposing force is obtained in several differs
ways, the most familiar being by applying brake-shoes to the rim of the whet
with considerable force by means of hand or power brakes. Another methq
which is applicable in electric traction, is known as electric braking, as di
tinguished from mechanical braking, and consists in oppasiug the reyolutii
of the wheels with the counter-torque of the motors or by the friction e
electrically operated brake discs.
|

204. Tests to determine friction coef&clents. About the first ayi

tematic tests to determine the value of the coefficient of friction betwe
brake shoes and wheel, and between wheel and rail were conducted I

Sir Douglass Galton and Mr. George Westinghouse in 1878 and 1879 on t
London, Brighton & South Coast Railway, England. A report of the.se te:
appears in the proceedings of the Institute of Mechamcal Engineers
London, for April, 1879. The table in Par. 206 gives the results of these tesi
 ELECTRIC RAILWAYS Sec. 16-205

20S. Coefficient of frintion at various speeds, Cast-iron brake

blocks on steel tires
Speed Coefficients of friction
Number of experi-
ments from which Miles Feet per Extreme Observed
the mean is taken
per hr. sec.
j

maximum minimum Mean

12 60 0.123 0.058 0.074

67 55 81 0.136 0.060 0.111
55 50 73 0.153 0.050 0.116
77 45 66 0.179 0.080 0.127
70 40 69 I
0.194 0.088 0.140
80 35 51 ! 0.197 0.087 0.142
94 30 44 0.196 0.098 0.164
70 25 36i 0.205 0.108 0.166
69 20 29 ! 0.240 0.133 0.192
78 15 22 0.280 0.131 0.223
54 10 14J 0.281 0.161 0.242
28 7i 11 325
. 0.123 0,244
20 Under 5 Under 7 0.340 0.156 0.273
Just Just 0.330
moving moving
• Fleeming Jenkin (steel on steel) 0.0002 0.337 0.365 0.351
to 0.0086.

;Rennie. Static Friction under

Pressure of 180 lb. per sq. in 300
Presssure of 336 lb. per sq. in 347

206. Variation of friction coefficient with speed. From the values

:iven in Par. 196, Mr. R. A. Parke has developed the following formulas.

.u mean values 0.326 .,_,

rem the 1
// = , rT n^i^^^ tl9)
1+0.03532
,

S
0.382
om the maximum values / = (20)
1 + 0.2933 S
here/= coefficient of friction, and S = speed in miles per hr. The latter
)rmula gives values corresponding more nearly to recent experiments.
207. Coefficient of friction as affected by time*

Miles
nor hr.
 '

Sec. 16-209 electric railways

209. Oeneral laws affecting friction coefficient. The absence of mor<

extended observations and the complex nature of fluctuations of the coeffi
cient of friction make it impossible to formulate a practical mathematics
equation which will determine the rate of retardation under varying condi
tions. However, the results of the tests shown in the tables above indicat
a law of variations which may be briefly stated as follows, regardless of th
materials used.
(a) The coefficient of friction increases with the decrease in speed;
(b^ Decreases with the increased distance through which orake.-i ai
applied, and
(c) Decreases with the increase of pressure.
210. To obtain a uniform braking effort throughout the stop, tb
brake-shoe pressure must be varied to compensate for the fluctuations in th
coefficient of friction, that is, the brake-shoe pressure must be decreased a;
the diminution in speed increases the coefficient of friction, and increased a
the distance of brake application decreases the coefficient of friction, an
further increased to compensate for the decrease of the latter with increase
pressure.
For certain speeds the increase in coefficient of friction with decrease i
speed is practically neutralized by a decrease due to increased distant
of frictional contact. For lower speeds, however, the increase from tb
former cause is more rapid than the decrease from the latter, necessitatin
an almost abrupt decrease in brake-shoe pressure near the end of a stop, i
order to avoid slipping the wheels on the rails and discomfort to pas.sencer
211. Efficient emergency braking. For the same pressure, tli
efficient of brake-shoe friction at 60 miles per hr. is only about half th
20 miles per hr. It is therefore evident that an emergency stop for hi^
speed is less efficient than for a low speed, since an emergency applicatidj
implies that the maximum pressure which will not slip the wheels near t!
end of the stop, is instantly applied at the very outset. A considii
'
"

shorter stop may be made if the pressure applied during the earlier p^
of the stop is greatly in excess of that which will slip the wheels at low ~i
but in the absence of the motorman's skill, some means must be providea i

decrease the pressure near the end of the stop, in order that the limits of rsi
friction will not be exceeded, and the efficiency of the stop thereby decrease'.
This provision, however, requires additional apparatus, which on generi
principles is objectionable unless the showing is so favorable as to warrail
further complications. ]

312. Application of the retarding force. Thus far, attention has bet
devoted to outlining methods for overcoming the obstacles presented by tl,
complex nature of the fluctuations of the coefficient of brake-shoe frictit
which prevent the utilization of the theoretically possible retarding forcf
The nature of the application of these forces imposes difficulties which pr
vent the full utilization of the weight on the trucks and wheels, there!
directly affecting the braking force.
At the present time it is customary to equip double-truck cars with eith
two motors or four motors, depending upon the nature of the service. In t

former case both motors are usufilly placed on one truck thus perraittii
the use of a lighter truck for a trailer. The pressure which may be safe
applied to the wheels of the motor truck without causing the wheels to sli' :

cannot be applied to the wheels of the trailer truck. Hence the brake riggi^j i
must be so proportioned that the greatest portion of the braking is doiji
upon the wheels of the motor truck. Considering, however, the case whe'
the normal distribution of weight is equal for all wheels, it is found that. •

ing braking, a greater pressure may be applied to the wheels of the fo;
truck without causing them to slide than may be applied to the wheels '•'

rear truck. The explanation is somewhat simplified when considering

_ .siiii:

car operation, since draw-bar forces may be eliminated.

213. Vertical thrust on forward truck. Theresultant of allthcpnr
'

forces,which act on the elementary masses of the car tending to keoi'

motion, is equal to the sum of all these forces acting through the con-
gravity of the car and in the direction of motion. Directly opposed t

motion of the car is the wind pressure, which is exerted normal to tb'
mentary surfaces, the resultant passing approximately through the '

1418
 ELECTRIC RAILWAYS Sec. 16-214

)f gravity of the car. Wind pressure, however, is suflScient to cause only a

ilight retardation compared to that obtained with the brakes, and its effect
laa been neglected in this consideration. The retarding force of the brakes
lets at the surface of the rail and as all parts of the structure are retarded
squally, the king pins must transmit the force required to produce the same
etardation in the car body as is produced in the truck. The total retarding
orce less the amount required for retarding the wheels and trucks therefore

Direction of ilotion

Fig. 54. —Braking-stress diagram.

;t8at the points of support, which are somewhat lower than the centre ol
•avity of the car body. The moment of these forces about the centre of
avity of the car, is balanced by the moment produced by the increased
•assure of the forward truck acting upward through the point of support;
the same time the weight on the rear truck is decreased.
214. The distribution of weight on the wheels of each truck ia
'fected in the same manner, except that the retarding force transmitted
rough the king pins to the car body, also reacts to further increase the
pressure on the front pair of wheels
of each truck. Because either end
of the car may at some time be-
come the rear end, it is essential
that the brake-shoe pressure be
kept the same for all wheels which
necessarily restricts the maximum
pressure which can safely be em-
ployed to that which will not slip
the wheels with the least weight.
In the case of the eight-wheel pas-
senger car,_ the effective wheel
pressure which may be utilized in
braking is only about 85 per cent,
—
Fig. 55. Stress diagram. of that permissible with the total
weight on the wheels.
IS. Location of brake-shoes affecting recoil at instant of stopping.
* account of the stored energy in the revolving wheels, gears and armatures,

Vch may amount to 5 or 10 per cent, of the total stored energy of the car,
a)nsideration of the effect of these forces upon the truck through the brake
k gers is essential. With outside-hung_ brake-shoes the pressure due to the
f tion between brake-shoes and wheel, is downward for the leading wheels,

t eby causing compression of the forward springs of the truck. For the
t ling w^heel the pressure is upward, thereby relaxing the rear springs of

t' truck. The recoil of the forward springs results in the backward motion
he car body so disagreeable to passengers at the instant of stopping.
Vh inside-hung brake-shoes, the brake-shoe friction force acts upward
tF'Ugh the hanger links of the forward portion of the truck and downward
tl^ugh the hanger links of the rear portion of the truck, thus tending to
nvralize instead of aggravate the effect of the rotating influence of the car
D</. The problem of proportioning the length of brake-shoe hangers and
tiproper inclination of the same to the tangent at the point of contact

1419
Sec. 16-216 ELECTRIC RAILWAYS

of the centre of the shoe, in order to compensate exactly for the rotating in-
fluence of the car body, is too involved for presentation here. For this \

reason reference is made to Mr. R. A. Parke's excellent paper in the Proceed* '
ings of the American Institute of Electrical Engineers, Vol. XXII, Dec, 1902.
216. A common form of hand brake consists of a vertical shaft at eacbi
end of the car fitted at the top with a ratchet handle or crank, or geared to
a hand wheel. By means of this mechanism, the motorman can wind up a
chain, one end of which is fastened to the lower end of the vertical shaft and!
the other end to a rod which connects with a system of brake levers. Byj
means of a pawl (or dog) which engages in a ratchet wheel on the vertical'
shaft near the floor of the car, the motorman is enabled to maintain a pre»-'
sure on the brake-shoe while he gains a more favorable purchase for applying*
more pressure, or until such times as he desires to release the brakes. This!

Fig. 56. — Diagram of brake rigging.

brake has been found capable of supplying sufficient braking power for the
safe control of light cars running at moderate speed, but for heavy cars and
high speeds the physical effort and time required to properly apply the brakef
render it necessary to provide other means of supplying the proper force ir
a minimum length of time. Hand brakes, nevertheless, are always providec
as an additional safeguard, even though the cars may be equipped with power
brakes, as it is always customary to set up the hand brakes on all cars whei
they are left standing.
217. Air-brakes (Par. 218 to 238) in some form, have been universallj
adopted on all steam roads for braking both passenger and freight trains, am
the results have been attended with such success that modifications and im
provements of the old steam-railroad air-brake system have been develojpe^i
and adopted by a vast majority of electric lines operating heavy hifh
speed interurban cars, either singly or in trains. On account of the varyini:
character of the service on different electric roads, it has been found neoes
sary to develop several systems, or modifications of the same system whici,
will be best adapted for the service in hand. _
!

The most familiar types at present are known as the following: the straigh
air-brake system (Par. 218), recommended for single-car operation only; thi
emergency straight-air system (Par. 224), suitable for two-car operation, pari
ticularly when one is operated single most of the time and with a trailer addej
during rush hours; the automatic air-brake (Par. 227), suitable for eleotri
trains of three cars or more; the combined straight and automatic air-broM
(Par. 236), designed for locomotive operation, no matter whether steasLO
electric; the electroj)?ieumatic air-brake (Par. 287), at present in an expOT^
mental state, but particularly adapted to train operation, inasmuch a9 th'
time element in the application and release of the brakes on the rear end (

a long train is practically eliminated.

218. The straight air-brake system described in detail in Par. 219
223, consists essentially of a source of compressed air (either a tank filled
intervals from a compressor at charging stations, or an air compressor, mo
or axle driven, located upon the car) a reservoir which receives the air fr
;

the charging tanks or from the compressor and in which the pressure is ni;i
tained practically constant by means of a reducing valve, or by a goven
which automatically controls the operation of the compressor; a br;^
cylinder, the piston of which is connected to a system of brake levers in si.
a manner that when the piston is forced outward by air pressure the brn!
are applied; an operating valve mounted in each vestibule by means of wli
the compre.ssed air is either admitted or released from the brake cylind'
a pipe system connecting the above parts, including cut-out valves, extra he

14SI0
 ELECTRIC RAILWAYS Sec. 16-219

and angle fittings between cars. In order to prevent any possibility of accu-
mulating an excessive pressure, a safety valve designed to open at 100 lb. per
placed in the air-supply system.
sq. in. is A set of pressure gages is usually
supplied with each complete equipment in order that the motorman may
observe the pressure in the reservoir and remedy any defects in the govern-
;
ing apparatus.
;'
219. To operate the motorman's valve (Par. 218), the handle is inserted
; when the valve is in lap position, where the slot in the body of the valve ia en-
larged for this purpose (in order to prevent its removal in any other position).
In this position the valve ia set so that air can neither pass into nor out
j

j'of the brake cyUnder. Moving the handle to the left places the valve
tin "full release," that is, connects the brake cylinder to the atmosphere and
['allows the air which holds the brakes applied, to escape, and the spring
\ which is opposed to the air pressure, restores the piston and releases the
I brakes. After the brakes have been released the valve is returned to lap
[position, which is the normal running position. To partially release the
brakes, which is necessary in braking in order to prevent shocks as the
car stops, the handle is moved to the right and quickly returned to lap.
I This reduces the pressure on the brake-shoes, but does not entirely release
them.
220. To apply the brakes for a service stop (Par. 218), the handle is
Tioved to the right a little past the lap position, then back to the lap. This
onnecta the reservoir with the brake cylinder through a small opening in the

Gage Trolley

FiQ. 57. — General Electric straight-air brake system.

live, then holds the pressure constant until it is necessary to release or apply
'ore pressure. Moving the handle further to the right connects the reaer-
)ir to thebrake cylinder through a large opening, thus causing the cylinder
fill rapidly and instantly apply the brakes with maximum preaaure.
'.nd is usually applied to the tracks as soon as the handle ia turned to the
lergency position in order to avoid skidding the wheels.
221. In descending grades (Par. 218), a light application of the brakes
.ould be made and the handle returned to lap. A sufficient length of time
;ould be allowed for car to feel the effect of the brakes before applying more
sssure. If speed is higher than desired a second light application should
made and operation repeated as often as necessary until the desired apeed
obtained, or until the car has left the grade.
122. Use with trailer (Par. 218). The straight-air system of air-brakea,
'ihough only recommended for aingle-car operation, may be used when
'arating with a trailer. The equipment for trail cars consists of a brake
under and system of levers similar to the ones on the motor car, and a
Vgth of pipe running the entire length of the car and provided with hose
Uplings and cut-out cocks for connections to the forward and rear cars,
'connecting up train cars, all the hose couplings must be thoroughly united

1421
 ,,

Sec. 16-223 ELECTRIC RAILWAYS

to insure that, air will apply throughout the entire train. All the cut-outi
cocks must be open except those on the rear of the last car, and the front of
the first car.
Pump Goveruo

General Electric emergency straight-air brake system.

223. Field of application (Par. 218). So far as single-car operation i

concerned, the straight air-brake system is very satisfactory, as the desirf i

flexibility in the matter of graduations of applications and release of tl

brakes with due regard to the passengers standing can readily be secured, ai
this apparatus is usually so simple in construction that the motorman mi
become familiar with its operation to such an extent that accurate stops mi
be secured with a minimum amount of instruction. In trains of consideral
length, however, the response of the brakes on the rear cars is too slow, sin ;

all the air must pass from the main reservoir on the front car through ti
opening in the motorman's valve to the brake cylinders of each car. As tt
addition of each car adds to the volume of the brake system, the main res»
voir on the first car must be considerably in-
creased. The reservoir capacity must be so pro-
portioned that the pressure will not be reduced to
such an extent that the brake application will be
insuflScient and result in overrunning the desired
stopping place. These latter objections would not
necessarily prevent the use of this type of air-
brakes on short trains of two or three oars, were it
not for the objection that a broken hose connec-
tion or leaky train pipe renders the brakes on the
whole train inoperative.
224. The emergency straight air-brake,
described in detail in Par. 21S and 216, differs
from the straight air-brake in the details of the
motorman's valve and in the addition of an
emergency valve and reservoir line wliich con-
nects the motorman's valve with the emergency
valves (Figs. 58 and 59). In the case of a trail
car, an auxiliary reservoir (Par. 226) is also added,
as shown in Fig. 60.
In the ordinary operation of single cars or short
trains, the emergency valve is seldom brought
into play. It is necessary, however, to provide a short direct passe
the reservoir to the brake cylinder in order to ensure the quickest
action in time of emergency and to provide some means of autoin^
braking the rear cars shotild a break occur in the train line.

1422
 ELECTRIC RAILWAYS Sec. 16-225

times when it ia desired to make a service application or release, the air ia

admitted or exhausted through the motorman's valve the same as in the
straight air-brake.
226. Emergency application (Par. 224). With the motorman's valve
in the emergency position, it allows air to escape from the reservoir line and
causes the reservoir pressure, which is above that in the emergency valve, to
compress the spring which holds the valve in its normal position, thus
opening a port in the valve casing which communicates with the brake cyl-
inder for the direct passage of the reservoir air. The line from the reservoir
supplying the air for this process should not be confused with the reservoir
line. During an emergency application, all communication with the train
and reservoir lines is cut off. To release the brakes, therefore, it is neces-
sary first to return the emergency valve to its normal position by recharging

Brake Cyliudcr

{ Fia. 60. —General Electric emergency straight-air brake for trail cars.

jrhe reservoir line to the reservoir pressure. This equalizing of pressures

ililows the spring under the valve to return it to its original position, and the
.[rakes can be released in the same manner as after a service application by
'.xhausting the air from the train line. The recharging of the reservoir
ne is accomplished by moving the motorman's valve to emergency-release
osition at the extreme left of the slot in the body of the valve. With the
iotorman's valve in this position, a connection is opened between the main
iservoir and the reservoir line and also a connection between the train line
ud atmosphere. With the emergency valve in normal position there is a
irect passage to the train line and brake cylinder, and the service applica-
ons and release are made by increasing or decreasing the pressure in the
I'ain pipe.
,
226. Auxiliary reservoir with trailer (Par. 224). In the case of a
ail car,the auxiliary reservoir is charged during emergency release by the
r pressure equalizing on both sides of the slide valve through charging
coves in the valve casing. At other times it is charged from the main res-
voir through the charging grooves in the emergency valve on the motor
r.

In case of accident to the reservoir line the air can be exhausted from
e auxiliary reservoir and the train operated on straight air without inter-
pting the service. An accident to the train line has no effect upon the
tion of the emergency valve which still can be employed as ordinarily
throwing the motorman's valve to the emergency position. As the
aight air-larake principle predominates in this system, it is subject to the
lie objection which prevents the use of the straight air-brake on longer
ills, namely the time limit. For this reason, the automatic air-brake is
d on trains of three or more cars.
17. The automatic air-brake, described in detail Far. 228 to 236>
K^ frorn the straight air-brake in that the former requires a decrease in
p^ain-pipe pressure to apply the brakes, and an increase in pressure to

1423
Sec. 16-228 ELECTRIC RAILWAYS

release them, whereas in the latter, air is admitted to the train pipe to apply
the brakes and exhausted to release them.
228. The apparatus required (Par. 227) for this system in addition to
that already mentioned for the straight air-brakes is as follows: a set of
duplex pressure gages, which indicate simultaneously the pressure in the
main reservoir and in the train pipe; an auxiliary reservoir, for storing the
air used by each car in braking; a triple valve, the function of which is to
admit air from the auxiliary reservoir into the brake cylinder and to release
it therefrom (in release position, the auxiliary reservoir is recharged), and an
air-whistle reservoir, with suitable check valve for sup-
plying air to the air whistle.
This system is capable of a great many refinements
which may be added or omitted as requirements of a
particular service may prescribe. The main points of
difference between particular automatic air-brake
equipments will generally be found in the details of the
triple valves, and the addition of pressure miaintaining
and reducing valves. These features are essential in
certain classes of grade work in order to prevent brakes
"leaking off." These particulars have been intention-
ally omitted from this consideration in order to avoid Fio. 61.— S. I.
undue complexity. Two forms of triple valves, how- trijile valve.
ever, need to be considered here inasmuch as the plain
triple valve. Fig. 61, is only used on comparatively short trains, about fiv'
cars in length, whereas the quick-action triple valve, Fig. 62, is de.signed ti,,
be used on much longer trains.
229. Emergency application (Par. 227). For the emergency positior
shown in diagram. Fig. 62, the train line is open to the atmosphere, allowin
auxiliary reservoir pressure on the right of the slide-valve piston forcing i
to the left against the graduating spring, compressing it and uncovering th
brake cylinder port. Air is thus permitted to flow from the auxihar
reservoir directly into the brake cylinder; at the same time the ports leadin
to the atmosphere and to the train pipe are closed. :

230. Torelease the brakes (Par. 227), the main reservoir air is admitte
through the train to the chamber at the left of the slide-valve piston, forcin
it to the right, and connecting the braki
cylinder port to the exhaust pipe. At tl
same time, air at the main reservoir presstn
raises the check valve and recharges the au:
iliary re.scrvoir to main reservoir pressure.
A graduated release of the brakes may 1

obtained with this type of valve, by pipii

the exhaust from the triple valve to the mote
man's valve where a movement of the vah
handle will release the air the same as in tl
straight air-brake.
231. Necessary train-line reductic
(Par. 227). A service application requir
only a slight reduction in train-line pressu
Fig. 02. —
K triple valve. (from .5 to 7 lb.) which is .sufficient to pern
the slide-valve piston to slightly compress t
graduating spring and partially open the brake-cylinder port. When t

auxiliary reservoir pressure has been reduced to about the same valm-
the train-line pressure, the graduating spring will return the slide valv
lap position, closing all the ports before the brakes are fully applied,
auxiliary reservoir and brake cylinder are usually .so proportioned tlia;
brakes are fully applied when the brake piston displacement is sufficiei.
reduce the auxiliary reservoir pressure about 1.5 lb. Therefore, a train i>i
reduction greater than 1.1 lb. fully applies the brakes and is wasteful of :

because the train pipe and the auxiliary reservoir must be fully charged af
each application.
232. The quick-action triple valve (Par. 227), shown in Fig. 62, is
signed to be used on freight trains of considerable length, its function is-
apply and release the brakes on the rear cars so quickly that the runmng' '
.

and out of the slack is avoided. Fig. 64 is a diagrammatical section of

1424
 ELECTRIC RAILWAYS Sec. 16-233

triple valve shown in Fig. 62. In the full release position shown, air is
allowed to pass from the brake cylinder through porta in the slide valve, the
same as in the plain triple valve. The auxiliary reservoir is charged through
grooves around the shde-valve piston, and also through the raised check
valve and the uncovered port in the slide valve. The operation of the auto-
matic air brake (Par. 227) in conjunction with this valve is described in Par.
233 to 235.
Duplex
Gauge _Jo Trolley
^ Switch
Hotormau's Brake Valve Fuse Bl<
-Slide Valve
Puinp Governor,
Safetv Valve
y>
Main Reservoir

^Aux iliary Reservoir

-=$3 Triple Valve

Fia.. 63. — Westinghouse automatic air-brake.

233. Release with quick-action triple valve (Par. 827 and 232). In
lease position, the decrease in train line pressure allows the valve piston to
ove to the left, closing the charging grooves and feed port, J and exhaust ,

)rt, P. Just before valve piston strikes the graduating stem, a cavity in
.8 grading valve on top of the slide valve connects ports which allow com-

unication from the brake cylinder to the emergency chamber and train
pe. The piston in the emergency chamber is ortly loosely fitted, so that
" air which is admitted from the train pipe to the unseated check valve
- into the brake cylinder before communication is established between

the auxiliary reservoir and the brake

To Aux.Res.. cylinder. Owing to the friction in the
train pipe, a reduction of air pressure at
the front end of the train is not felt at the
rear end until some time later. Thus the
venting of the_ train pipe at each car re-
sults in hastening the reduction for each
car following; at the same time requiring
a less reduction at the engineer's valve to
apply the brakes with a given pressure,
since the auxiliary reservoir is not re-
quired to supply all the air to the brake
cylinder.
When
the brake-cylinder pressure is re-
lyPlG. 64. —K triple valve,
duced below that
in the train line, the
moves to the right with
slide-valve piston
the graduating valve and closes all ports
I' ling to the brake cylinder. The tendency for the brake-pipe and auxil-
li -reservoir
pressures to equalize through the connection's to the brake
Ctfider is prevented by the proportioning of the respective ports, so that the
a uiary-reservoir pressure decreases faster than the brake-pipe pressures,
«, insures the travel of the piston to the right.

,,'*• In retarded release with quick-action triple valve (Par. 227 and
•• the train line is quickly re-charged, forcing the valve piston to the ex-
ye nght. Thus is prevented the re-charging of the auxiliary reservoir

1425
 "
''

Sec. 16-235 ELECTRIC RAILWAYS

through the charging grooves before opening a small port in the slide valve,
would permit the train line pressure to raise the check valve and slowly
re-charge the auxiliary reservoir. The function of the charging device
(shown on the outside of the valve in Fig. 62) is to'prevent the inertia of the
slide valve from forcing it to the extreme right of its travel when the valve
piston is brought up against its stop. The restricted area at the left end of
the exhaust cavity of the slide valve partly closes the exhaust port, and allows
the brake-cylinder air to flow slowly into the atmosphere. On account of the
friction in the train pipe, it is impossible to re-charge the train line at the
rear of the train faster than the air will flow through the charging grooves
of the triple valves. As a
result, only the triple
H—IW- valves of the foremost cars
move to retarded release,
the others remaining in
full release, which releases j

the brakes on the rear cars s

quickly.
236. Emergency ap-ii
plication with quick-
action triple valve (Par. I

218 and 223) The sudden

.

reduction of train pipe'

pressure in the emergency
position of the engineer's
valve, moves the slide-
valve piston to the left,
compressing the graduat- .

ing spring and opening a .

port directly to the brakfi

cylinder, and also opening
another port to the emer-
gency chamber which un-
seats the emergency valve
At the same time the train-
line pressure opens ttir
check valve and air fl

from the train line dirt

into the brake cylinu
applying the brakes will
maximum pressure. Tin
quick venting of the trail
line insures the rapid seriii
action of the brakes on tli'
^%-A
rear cars.
Fig. 66. —Air compressor. -

236. The combinec

straight and automatii
air-brake, as the name implies, consists of two sets of motorman's valve
for the control of each system. The straight air-brake, operating w:
pressure between 55 and 70 lb. per sq. in., applies and releases the brake
the front car independently of the brakes on the other cars. The autonii
brakes operate witn air pressure from 100 to 110 lb. per sq. in., and apply 1
1
•

brakes on the remainder of the train independently of the brakes on the fron
car. The chief advantage of such an arrangement is the possibility of hoi !

ing the brakes on the locomotive applied while the train brakes are relea
for the purpose of re-charging the auxiliary reservoirs.
237. The electropneumatic systeta is practically the same as
'

present automatic system, except that the valves are operated by Bolenoicl
in much the same way as the contactors in the multiple-unit train control
At the present time air control is retained as a safeguard in case of failur; ^
of the electric control. With electric traction, the possibilities of this 6yi\ 4
tem seem to be unlimited and automatic retardation as well as acceleratloSj f
'
is quite feasible. '

238. The air reservoirs should have a capacity sufficient to supply aifa
for three or four applications without reducing the pressure more than from 1 § 1

to 15 lb. Otherwise every ordinary application of the brake will thro'''!|l

142G 1
 ELECTRIC RAILWAYS See. 16-239

he compressor into action, thus keeping the latter in a constant state of

tar ting and stopping, and causing unnecessary wear to both compressor
\nd governor. The Westinghouse Traction Brake Company recom-
aended the following sizes of reservoirs:
^^-, With 8-in. brake cylinders use 16 in. X48 in. reservoirs.
BF., With 10-in. brake cylinders use 16 in. X60 in. reservoirs.
^IT With 12-in. brake cylinders use 16 in. X72 in. reservoirs.
'
The lengths given above are over all.
I
These reservoirs are fitted with drain cocks, and should be drained
^equently in order to prevent any water, oil, or dirt, brought in by the
rompressed air, from being carried further into the brake system. If al-
_>wed to stand for several days, the reservoir will fill with water, thereby
Educing its capacity, and will also allow moisture to pass into the piping
ji'stem and collect in pockets, where it will be likely to freeze in cold weather.
t 239. Track brakes have been developed for operation in connection
:ith either power or hand brakes, the distinctive feature being the utiliza-
on of the power generated by the motors, when properly connected, to
lergize a powerful electromagnet, thereby drawing a suitable track shoe to
le rail with considerable force. The friction between the track shoe and
,iil is transmitted to the brake shoes on the wheels through a system of

,-ake levers, thereby adding to the braking effort of the brake shoes on the
heels an amount equal to the drag of the track shoes on the rails and the
)unter torque of the motors acting as generators. It is possible, because
the automatic regulation of the magnetic attraction between the track
.oe and rail, to utilize as great or possibly greater brake-shoe pressure than
customary with either hand or air brakes without skidding the wheels,
it in practice this is seldom required and considerably less braking pressure
customary. The friction, between the track shoe and rail, necessary to
•oduce the requisite brake-shoe pressure will depend upon the design of the
ik motion and the speed of the train. However, this is usually greater than
braking effort exerted by the wheel brakes, and where the speed is low,
('

vantage can be taken of a high coefficient of friction which is impossible

ieie the wheels are apt to skid, as in the case of power brakes. It is thus
ident that the retardation possible with track brakes is at least twice as
?at as with power brakes, rendering the former particularly well adapted as
lergency brakes for heavy grades, which are characteristic of scenic rail-
lys, etc.
It should be noted, however, that since this brake depends upon the
iromotive force generated by the motors when running as generators, it
I

nnot be depended upon to hold a train on a grade or bring it to a atop

less a connection is made with the trolley for this purpose. There are
•rious objections to resorting to this means of energizing the brake solenoid,
•!ept in an emergency, consequently the electric track brake is limited in
: applications to roads where it is necessary to provide an additional aafe-
,\rd at the expense of considerable complications to the ordinary form of
ikes.

TRUCKS AND CAR BODIES

Classification of trucks. The development of the self-propelled
!40.
I has led to some modifications in standard truck design. The several
ties of trucks all fall in two genera! —
groups namely, the single-truck
Ur, 241'), and the double or bogie truck (Par. 242).

41. The single-truck car is intended for city-street service, and where
t maximum speed does not exceed 25 miles per
hr. The two axles of the
»;le-truck are rigidly aligned by side frames, so that of necessity the rigid
'sel base must be short in order to negotiate sharp curves, thus limiting the
Ifjth of car used, because too much overhang is productive of much rocking
a unsafe riding, and is objectionable also when rounding sharp curves in
c .Streets. Id order to provide easy riding, the car superstructure is 9up-

1427
Sec. 16-242 ELECTRIC RAILWAYS

ported upon elliptic and coil springrs designed to take up the shock resultii
from riding over uneven track. Single-truck cars are limited to a maximui
length of about 30 ft. over all and a maximum weight including car bod
and trucks, but exclusive of electrical equipment of approximately 15,000 11
242. The double-truck car is equipped with two distinct trucks joine
together through the medium of the car-body framing. The swivel <
bogie truck consists essentially of two or more axles centred in conimo
side frames which are joined by a cross piece or bolster carrying a centi
plate and also side-bearing plates upon which the car body rests.
The bogie truck may comprise two or more axles mounted in a sing!
structure, the prevalent type, however, is composed of two axles for cai
weighing up to 50 tons total weight. For very high-speed service or f(
heavy cars, three-axle trucks are to be recommended.
243. Classification of bogie trucks. The standard four-wheel bog
truck is built along different lines depending upon the service which it is 1

perform. As the weight of the car body is carried upon the cross piece (

bolster connecting the side frames, it is evident that the construction i

this bolster and its support offers a means of cushioning the effect of shod
given the car wheels when riding over uneven track. There are three gener
types of bogie trucks, namely: the rigid-bolster type (Par. 244), the floatini
bolster type (Par. 246); and the swinging-bolster type (Par. 246).
244. The rigid-bolster type (Par. 243) is suitable for locomotive woi
only, as the cushioning effect of the car body by means of springs ism
carried to sufficient length for easy riding qualities. The bolster is solid
fastened to the side frames and forms an integral part therewith. The sprin
suspended car superstructure is sustained by means of box sprin,

Fig. 67. — Motor, locomotive-framc, rigid bolster.

E
laced between the side frames and the journal boxes. These springs m
e of semi-elliptic (Fig. 67) or spiral type (Fig. 70). This type of constn
tion offers no compensation for the swaying of the superstructure, and ,

therefore not adapted for high-.speed or passenger service.

24B. The floating-bolster construction (Par. 243), comprises in m .;

a bolster mounted upon elliptic springs which rest upon the side frames. T •.

bolster thus has an independent vertical movement, and travels in ways t

the side frame. This type of construction is best adapted to loconjoti"
trucks designed for slow-speed service, as the superstructure is not sufficient'
cushioned to provide easy riding for high-speed passenger service.
246. The swinging-bolster construction (Par. 243) comprises a nic <

able bolster traveling in a guide or transom and mounted upon elliptic sprini'r^
a construction very similar to the floating-bolster type. In the form'ji
however, the elliptic springs do not rest directly upon the side frames, b j(
rest in a saddle hung from the transom or side-frame construction in suctn.
maDoer that opportunity is provided for a transverse swing of the sup<t

1428
 ELECTRIC RAILWAYS Sec. 16-246

ructure. This arrangement permits the superstructure to swing or roll

hen rounding curves, and offers a very easy riding truck for high speed
issenger service. To increase the cushioning effect still further, the side
ames are not directly mounted upon the journal boxes but have coil springs
terposed, either placed directly over the journal boxes (Fig. 70) or between
le side bar and the truck frames (Fig. 69) or a combination of both.

FiQ. 69. — Bar frame, swinging bolster.

1
 '

Sec. 16^247 ELECTRIC RAILWAYS

847. Construction of bolster and side frames. The truck bolster ma,
be made of wood or metal, and both the centre plate and side-bearing platt
which it carries, may be ball or roller bearings, in order to reduce the frictio,
and permit the truck to respond readily to the demands of track curvaturt
The side frames may be built up of steel plates riveted together, or forge
or cast in a single piece. The construction is rigid and provides for gooj
alignment of the axles. ,,

248. Maximum traction trucks are designed for city service at speed
not much exceeding .30 miles per hr., and are useful where it is desired v
mount a single motor on a ij

truck providing for four

wheels, having a short
wheel base, and carrying
70 per cent, of the total car
weight upon the driving
wheel, which is larger in
diameter than the trailing
wheel. Maximum traction
trucks are not suitable for
high-speed service.
249. Classification of Fia. 71. —Maximum-traction truck (Brill Co)
car bodies. Car bodies i,
differ in construction according to local requirements. They may be diviaf
into two general types, namely: open cars, and closed cars. The dividi
line between these two types is not sharply defined owing to the introduotij
during the past few years of the convertible and semi-convertible type
car body, which permits the complete closing in of the car body sides,
partial removal thereof according to climatic conditions. The true type"
open-car body is arranged with cross seats which will seat five passengers
seat and in the larger cars seating 75 passengers per car. ^

pUUU'UiJUUUUM
Ln n n n n n n n nd
Fio. 72. —Seat capacity 44.
Besides the convertible and semi-convertible type of closed cars, a comby
tion open and closed car is used for warm climates, as it offers the great
advantages for all-the-year operation.
250. Arrangement of seats. The closed-body car may be provided y
either longitudinal or cross seats, the former being used in the shorter c
of 30 ft. overall and under, and the latter in the larger city and suburl
cars. In general it may be stated that longitudinal-seat cars are suits
only for short runs and medium rates of acceleration, and transverse se
should be used in order to provide comfort for the passenger wherej™
accelerating rates are high or the run extended. ,. t- to a i
The prevalent type of transverse-seat car is indicated in Fig. 72, anajH
ally contains short longitudinal end seats in addition. Owing to the pfl
bility of crowding at the car entrance, it has been found advisable to pro>
more standing room at these points. This leads to a composite type m
having longer longitudinal end seats and providing transverse seats in
centre portion of the car only. , .

In some instances it is necessary to provide narrow city cars, and vm

J

cient space is allowed for transverse seats capable of seating two pe^W
the side. A modification of transverse-seat car is constructed for suonci
having the longitudinal aisle and providing a two-passenger seat on one I

and a one-passenger seat on the other.

251. Entrances and exits. In rapid-transit service, where large <

mufit be handled with a minimum time allowed for stops, it is o^.^J" .

use doors at the sides so arranged that the crowd can circulate rapialjf*
as little interference as possible between tne boarding and the leavjnJJ
eengers. In some cases this is accomplished by end doors for entrancf„»^

1430
 '

ELECTRIC RAILWAYS Sec.ie-252

entre door for exit, while in one type of side-door ear there is a door oppo-
ite each seat, all doors being operated from one point by compressecf air.
"hese types of cars were originally installed for train operation on subway
nd elevated lines, where only station stops were made and where fares were
'ollecteJ before passengers boarded trains. It was some time afterwards
Sat serious thought was given to the adoption of a similar principle in car
designs for operation on surface lines, that is, before steps were taken
) separate the entrance from the exit or to collect fares as tne passengers
iody
oarded the cars. The first cars brought out employing this principle,
ere known as Pay-as-you-enter cars and were similar in design to other
Sirs then in use. The new features were closed vestibules with door control
kindles for the motorman and conductor and a fare box. Thus the front
latform was converted into an exit which relieved the congestion around
le rear plaiform when passengers deisred to get on or off. This arrange-
ent was a decided improvement over the older method of collecting fares
ter the passengers were seated and many lines charged over their old cars
make use of the jmy-as-you-enter principle.
The next step was the design of a new type of car body with a front
trance and centre exit. In this type of car the centre exit is assumed to
rtde the car into two sections, a pre-payment section in the rear and a
:y-as-you-leave section in front. The conductor is stationed just in
at of the centre exit and collects the fares as the passengers pass him on
"r way to the pre-payment section or as they pass out. Such a car has
advantage of quick loading at transfer points and gives the conductor
opportunity to collect the fares and distribute the passengers in the car
ore reaching the next stop. There have been a number of other new
tures added in the design of these cars, notably an air-operated sliding
w for the centre exit, low wheels and low step, vertical and horizontal
b rails instead of straps for standing passengers, dome shaped roof with
aust ventilators instead of Monitor roof, flush platforms and other im-
vements in car body which do much to reduce the weight of the car and
nomize in space.
SS. Safety or one-man cars. The development of safety features
a_ as closed vestibules and mechanical control of the doors has made it
rible to advance another step in the solution of the street railway trans-
lation problem. This advance is on the theory that if a more frequent
iway is maintained more passengers will ride and in the interval between
fewer passengers will assemble who will have to be accommodated,
h two-man cars the platform expense prohibits the operation of cars on
li^ort headway and the seating capacity of the ordinary two-man cars
.ore than would be required for the passenger who would ordinarily be
ed up on each trip, if such short headways were operated. The appli-
)n of this theory required the development of special features in car-body
~
so that one man could collect the fares as the passengers boarded
I

close the doors so that passengers could not get on or off while the
,

as in motion and also operate the car. The success of the venture is
^aisely to the details of the safety features which have been incorpor-
in the control which is so interlocked that one man can perform the
of motorman and conductor. The door control and other safety
are worked out in conjunction with the air-brake equipment.
Extra compartments on suburban cars (Far. S54). For sub-
service it is desirable to provide a smoking compartment divisioned
•cm the main portion of
and connected to it by fr^-^
r

Such a car should ^

Irably be run single ended
—
Tjthe smoking compart- nn'nnlnnn'fl'nnrd
^tefront. However, it is
BB practice to run such Fia. 73. —Single-ended car.
laouble ended, in which
^passengers may be compelled to pass through the smoking compart-
|in order to reach the main seating portion of the car.
to the necessity of taking care of baggage or express material on
.^' lines, many such cars are supplied with a baggage compartment
Ijjalso used as a smoking compartment, and in addition a toilet should
ied where the run is of considerable length.

1431
 1

Sec. 16-254 ELECTRIC RAILWAYS

204. Arrangement of Interurban cars. Many cars are heated (Se

22), with hot water instead
electrically, and the mo
elaborate high-speed inte
urban cars operating ov
long distances provide a cot
partment for express niattt
smoking compartment, ma
passenger compartment, toil
rooms, etc. The motormar
compartment is divisioncd <
from the baggage compai
ment and such cars are gen«
ally run single-ended, requiri
the use of a loop or Y at t
terminals, see Fig. 73.
26S. Double-deck cai
For certain classes of ci
service where the track capi
ity is limited and speeds j
moderate, recourse may be h,
to a double-deek or top-seaf<
car. Unless enclosed thi
cars are only suitable
climates having small temp
ature change and must
ojjerated at low speed (
miles per hr. or less) in ori
to prevent possibility of ov
turning. Access is had to i

upper seating portion of |

car by means of stairways.

'.

SELF-PROPELLED CAI;
206. Classification. S
propelled cars are divided i I

three general types, as folio i

storage battery (Par. 21

gasoline or oil motor (\i
208); ga.s-electric (Par. Wi\
207. The storage-batti
car is suited to very spej
conditions, and has not i

been considered for gen,

,

railway service owing to |

limitations in weight, cost

restricted mileage of the 1

tery. (iSee Section 20.)

208. The gas-motor t

has come into limited usi i

interurban lines and on fd

lines of steam roads. _

greatest disadvantage liei

the mechanical transmisffltf
power between motor.
driving wheels. \

209. The gas-electrlc

(Fig. 74) claims as ita »0
cage the elimination of all
chanical troubles by subst^
ing electric drive thn
generator and motors. '

cars are in service to a hn,

extent where operating c(!
tions are favorable. Gas-electric locomotives are possible only when

1432
 ELECTRIC RAILWAYS Sec. 16-260

•vice demand can be taken care of by the maximum output of the gas
>tor,not much exceeding 250 h.p. The possibilities of the gas-electric drive
inot yet fully worked out or appreciated by operating men, and the use of
3h equipment is influenced largely by the possibility of using a cheap fuel,
js are now in interurban service that consume approximately ^o gal. of
soline per car-mile.

ELECTRIC LOCOMOTIVES
260. Classification. Electric locomotives may be divided into four
leral classes as follows: (a) miscellaneous interurban freight service; (b)
rd-shifting and interchange freight; Cc) main-line freight; (d) main-line
ssengcr.
i61. LocomotiTOS for interurban lines are all of the same general type
construction and comprise a cab carried on two four-wheel trucks upon
mounted single-geared motors in the usual manner. The loco-
ich are
Itive is of construction similar to interurban cars, except as to super-

Pantograph Resistance
Ma/'n Switch Trolley Change-over Line
Ventilatori
Jwitch .
Styitch
Blower K
ntnotor': * ^ IP.
Errgineer's
'mpmy BrakeValve ft]
Dj^f
Valve

'Motors
dEnginei
Sec. 16-263 ELECTRIC RAILWAVa

the total weight may reach 100 tons when such locomotives are used betwe*
large yards for the interchange of freight. The service is interiiiittent ac
the average speed is below 4 miles per hr. The average energy input is le,
than 80 kw. for a 60-ton locomotive. Slow-speed armatures and a maximu.
gear ratio are best suited for the service. Often two motors are conneett
permanently in series in order to limit the maximum speed and power demai
to reasonable amounts. While yard locomotives will vary from 30 to 1(
tons total weight, good examples of the heavier types are given in succeedii
paragraphs.
263. Main-line freight locomotives present a great variation in desii,
and motor equipment. Main-line service demands a locomotive equipmej
capable of withstanding a large sustained output, and hence calls for differej
motor characteristics th l

those which meet the requii ]

ments of city and interurbs

railway service. Steam-loi
motive practice provides foi
locomotive rating on ruli
grade, based upon a tract!
eiTort corresponding to a coe
cient of adhesion of appro
mately 18 per cent, of
weight upon the drivers. '
is exceeded somewhat um
favorablerail and climatic c
ditions,but a lower ratinf
found necessary during win
months in cold clima'
Hence assumption of 18
cent, coefficient of adhes
may be considered good pi
tice in determining elec
locomotive rating on
grades.
 ELECTRIC RAILWAYS Sec. 16-266

of the locomotive will be less than would correspond to an 18 per cent

coefficient of adhesion.In consequence it is becoming recognized that main-
should be provided with motors capable of supplying
line freight locomotives
continuously and without injurious heating, a tractive effort corresponding
to approximately 16 per cent, coefficient of adhesion of the weight upon the
drivers, see Par. 266.

266.Bating of typical slow-speed main-line freight locomotive

Weight on drivers 200.000 lb.
Rated tractive effort, ruling grade 36,000 lb.
Corresponding coefficient of adhesion 18%
Continuous tractive effort 32,000 lb.
Coefficient of adhesion 16%
One hour output 40,000 lb.
Coefficient of adhesion 20 %
Starting tractive effort for .5 min 60,000 lb.
Coefficient of adhesion 30 %

Trolley Loched Dimn

R r 37'4'
"V ** t^- '"O I

.a. 78. — Butte Anaconda and Pacific 2,400-volt, direct-current locomotive.

IS7. Speed of electric locomotives for main-line freight service
fl, of course, be proportioned to meet requirements, but in general for
liuntain grades it will approximate 15 miles per hr. on ruling grade with
led tonnage, and will reach a maximum of from 25 to 35 miles per hr. on
tel tangent track. Special conditions calling for a higher speed either on
ling grade or level track can be met in electric-locomotive design to an
|i08t unlimited extent, due to the flexibility of electric motor construction
,control.

b:68. There are several types of heavy freight locomotives in service:

a) Those comprising a cab or superstructure containing the control appa-
r 1^, air compressor, blowers, operating compartment, etc., mounted per-
ontlyon the side frames which carry the drive wheels. The St. Clair
single-phase locomotive is an example of this type.
:iel
Those in which the cab is carried on two bogie trucks which are coupled
j

her by some form of link or hinge coupling.

t In both this type and the
previously described, the motors are geared to the axle like an ordinary
^,et car motor except that in the case of large motors it is usual to have twin
~ 'ing. The Cascade Tunnel three-phase and the Detroit Tunnel direct-
ent locornolives are examples of this type.
f) Those in which the cab is carried on two trucks each having two driving
s and one radial or pony axle. The motors are mounted above the axles
';he truck frame and geared to quills surrounding the driving axles, the
being connected to the driving wheels by long helical springs (Fig.
The cab rests on four spring-supported surface plates on each truck,
toucks are coupled together as in (,b) so that no draw bar strain is oar-
by the cab. The New Haven single-phase freight locomotives given
'.
They are also used for heavy passenger service
861, are of this type.
60 miles per hour.

1435
Sec. 16-268 ELECTRIC RAILWAYS

1436
 ELECTRIC RAILWAYS Sec. 16-268

puj jOhJ

1437
Sec. 16-268 ELECTRIC RAILWAYS

1433
 ELECTRIC RAILWAYS Sec. 16-269

(d) Those having cabs mounted on trucks as in (c) but having two motors
mounted rigidly between the side frames of each truck, geared to a jack shaft
through twin gears, and the jack shaft connected to the driving wheels
through side rods. The Norfolk & Western split phase locomotives (see
Par. 271) are of this type.
869. Main-line passenger locomotives are required to operate safely
at speeds of 60 to 75 m.p.h. and the heaviest service requires that trailing
loads of 1,000 tons be handled at these high speeds in order to meet the
requirements.
870. Construction of main- line passenger locomotives. The gear-
leas construction operated upon the New York Central electric zone since
1907 has proved very successful with high operating efficiency and low cost
of maintenance. The full
advantages of gearless con-
struction can only be realized
with direct-current bipolar
motors. The original instal-
lation of forty-seven locomo-
tives on the New York Central
have been supplemented by
twenty-six additional locomo-
tives of the gearless direct-
current motor type, but with
a different wheel arrangement
14000 S 40 better adapted to higher-speed
main-line operation, see Fig.
33000 30S CO 80.
The latest type of gearless
locomotive is a twelve-motor
design shown
in Fig. 82 for
heavy high-speed passenger
service over the Cascade
rmometer-UnWoTTn
Mountains, Chicago, Milwau-
kee & St. Paul Railway.
Gearless-motor construction
provides the simplest form of
IG. 83. —Locomotive motor characteristics mechanical drive possible to
(N. Y. C, 8-motor, 1913 type). use, and is well adapted to
meet the requirements of high-
peed passenger service. For the characteristic curves of a typical direct-
iirrentgearless-motor locomotive, see Fig. 83.
The York, New Haven & Hartford single-phase passenger locomo-
New
ves are of gearless construction but owing to the fact that the motors are
wing supported and the locomotives are free from nosing tendency, they
perate safely at speeds of 75 to 80 miles per hour. Forty-one of these
. icomotives have been in hard service since 1907. They are handicapped by
3ing obliged to operate on 600 volts direct current as well as on single phase
ternating current. These locomotives are also notable for the fact that
ley have field control on direct current, and voltage control on single phase.
The locomotives built for high-speed passenger service over the severe
ades of the Rocky Mountain and Cascade Mountain Divisions of the
hioago, Milwaukee and St. Paul Railway, see Fig. 82, are of the latest
sign of gear and quill drive. These locomotives operate on 3,000 volt
reot current. The New York, New Haven and Hartford have also put
service locomotives with this type of drive.
The electric locomotives on the Pennsylvania Terminal electrification in
ew York (see P. T. & T. locomotive in Par. 271) are built for the arduous
rvice of taking the heavy trains of steel cars through the tunnels leading to
d from the terminal and across the meadows. They regularly haul trailing
ids of 800 tons up the 1| and 2 per cent, grades at speeds of 30 to 40 miles
r hr. These locomotives have established good records for reliability and
1 cost of maintenance. They have the motors mounted high in the cab
aroughly protected from dust or dirt, and connected to the driving wheels
rough jack shafts and side rods. See Fie 84. Field control is also an
portant feature as will be seen from the table under Par. 271,

1439
Sec. 16-271 ELECTRIC RAILWAYS

^ ,„oo Si c-o.

;m
IN W r-1 (N O >-<
'^*
-I
<-< rH

< da^
2 i o So Aooo-*°?Qo o OOr-i ^ -o
I ' '

OOt,C0=^Mi„-00O
-* ,-1

OOO'^OO'-KM "^ "-l

tD-)<'-i .-I

OO
oo
P-ciN
>^OOcO >22B
•«— '"I g"o 2,
.-T'^
^
;ij (M »-l

22 •5'^^-flo

^ g

DO
E-3
s.t
•3^2
13 e
" 0! >
;
o 1 <« o' Ul

2 *S
cJ . o
u>c

4, J rt

Ph m f-i PM w Sflipj
 '

ELECTRIC RAILWAYS Sec. 16- 272

.^o oo gooo
o -wo a - 05
^ O

*T3 oo
,oo.
"r
5000
Tj-OO 0o<**0'0 ®
JJ•^>ao<Coo<^'oo^5•00
r-e^rtrtM rt
u O
C<3

00
00 ^1 O O Ko o o lOoOOjJ'* CO
w K^
-*

SS!"^ — Soofjoo'^^oc^
-^
© iM'-<
05
•O-000 •

-'N'-lOi
Keoco'io" 00 j^co F-i
6"^
M
^^^
_;
- QO
00 _,ooo
^ooo «',-'^«

p^rfO' OOW'iOTj'tO ?.
000 Q (N

<fl_T^ 00 §000 «ONC«5<

)00
Q

'='^71
0.0^ 00
00 XOOO
Sooo
rTTfi ^ooooo-*'^^£S - IN "-0 O M '*'
OS

00 o 000 O 00
2id)® 00 ^ OOP
^ ^ .^
gajgjnoSSOTt.'os^j; mo^wom^oo
J^rtrtt^ cO^irjiOO OS

OoC^'0§!N CO
10 • ^-CO IM .-I
O
•

<N -O Tf
CLOS *2 Wi-i —O r-i CO ,-1 esi <N ^

« « g -C 0"0 ^
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liJl-O tT S H S «
•3 1":
•Co-Co
_MI CJ Ml 03

ZmjmES -o H ^"^^ c ° » °^ii o

wHE-iE-iO^^QZEhOOE-i PMhP-imrtOaP

1441
Sec. 16-272 ELECTRIC RAILWAYS

1442
 ELECTRIC RAILWAYS Sec. 16-273

POWEE DISTRIBUTION FOR RAILWAY ELECTRIFICATION

273. There are three systems of power distribution that may be con-
idered for the electrification of main line railways, as follows:
(a) Single phase alternating current;
(b) Three phase alternating current;
(c) Direct current.

274. Single phase. One of the prime requisites for main-line electrifica-
on 13 a high voltage for distributing the power from substations to cars and
jcoinotives. This is necessary, first, to minimize the copper in the distrib-
ting system; second, to secure maximum efficiency of distribution; third, to
mplify the collection of currents for large amounts of power. The use of
ngle phase alternating current permits the use of very high voltages on the
olley —
as high in fact as there is any reason for using. In this country the
ullages vary from 3,300 and 6,600 which are used on interurbun lines and
)meof the earlier main-line electrifications, to 11,000 which is now accepted
1 the standard for main lines. In Europe voltages as high as 15,000 are in
ie, but it is felt in this country that this is higher than necessary. With
16 exoeotion of one small installation, 25-cycle current is used for all single-
jase railways in this country. In Europe, however, the preference is given
15 or 161 cycles. A
frequency of 25 cycles has the aavantage of being a
andard for power distribution in many localitie.s, and in lower cost of power
ition and substation apparatus. It has the disadvantage of greater siie
id weight of commutator-type motors, and thus limiting the output from a
ven space on a locomotive.
On short single-phase lines the energy may be fed directly from the genera-
rs to the trolley, but for long lines, it is necessary to use a high voltage for
insmission and feed the trolley from step-down transformers. These
,
insformers are usually located in substations but are sometimes of the out-
r 'or type. In either case regular attendants are not required.

Steam Boiler
4Cor- i-J?.':fi'S'.t"3...
Trolley Basef junction \
I
Revener. Box...

10$.—.
•Third RailStioe
Fig. 85 —Single-phase twin-motor geared locomotive.
Two types of equipment are at present operated from single-phase trolleys:
«) Cars and locomotives having commutator type motors with series chaiac-
istics;
b) Split-phase locomotives have induction motors which derive the additional
iJSjBS from the phase converter in the locomotive cab. The pha.se converter
iiaists of a polyphase stator and a squirrel-cage rotor, the combination
login effect an induction motor fed from single-phase supply and getting
"
polyphase field by means of its rotating armature.
Joth types employ step-down transformers on the locomotive so that the
tors have low voltages applied to them. The former type is particularly
;ed for passenger service with both multiple trains and locomotives. It
too well suited for high-speed freight and switching service. In such ser-
}_the variable speed characteristics are valuable. The split phase loco-
tive is particularly desirable where heavy grades are encountered which
essitate high tractive efforts and where the automatic regeneration of the
jore down grades saves power and decreases the liability of accidents.
he disadvantages attending the use of single-phase current are in the
tively high cost and low efficiency of motive power, the cost of supplying

1443
Sec. 16-274 ELECTRIC RAILWAYS

1444
 ELECTRIC RAILWAYS Sec. 1&-275

ingle-phase power and the inductive interference of the single-phase trolley

/ith neighboring telephone and telegraph circuits. The latter has been
irgely overcome by the installation of series track transformers, the primary
f which carries the trolley current and the secondary is connected in the
rack return circuit. This has the effect of keeping the return current in the
rack.
The great advantages of the single-phase system of distribution lie in the
the substations and trolley, and the low cost of the distribut-
ligh efficiency of
ng system.
Large single-phase locomotives with commutator type motors are in service
in the following main line electrifications:
New York, New Haven & Hartford Railway.
Grand Trunk Rwy.. St. Clair Tunnel.
—
Boston and Maine Railway Hoosac Tunnel.
Spokane and Inland Empire Railway.
This system has also been adopted for the New York, Westchester & Bos-
on Rwy., and the Pennsylvania Railway, both usin^ multiple unit trains,
he former for New York and the latter for Philadelphia suburban service.
The Norfolk and Western Rwy. is using split phase locomotives with
fciree-phase motors for heavy mountain grade service. See Par. 271.
£quid rheostats are used in starting these locomotives. The Pennsylvania
dMre also built one split phase locomotive, with which they have been
iperimenting.
275. Three phase. The three-phase system of distribution is not used to
.ny extent in this country chiefly on account of the difficulties arising from
ae double overhead trolley which complicates the yards and cross-overs so
mch. It is used extensively in Italy, and the three-phase locomotives in
se there are the lightest electric locomotives of their capacity in the world.

Fig. 87.- -Great Northern Cascade Tunnel three-phase locomotive.

hree-phase locomotives are usually used with about 3,300 volts on the trol-
j'ys and this voltage is applied to the motors without the use of lowering
l-ansformers. The Cascade Tunnel of the Great Northern Railway has the
oly three-phase locomotives in operation in this country. See Fig. 87.
276. Direct-current electrification consists of a direct-current motor
luipment fed from an overhead, trolley or third rail which receives power
om substations containing rotary converters or motor-generator sets.
; is the system in almost universal use in city and interurban electric
lilways, but varies as to the voltage of the direct-current supply. As
result of perfecting the commutating or interpole motor, it has been
Jssible to wind motors for higher voltages, and 1,500-volt direct-current
lOtors are now in commercial operation. These motors are connected
vo in series and are fed from a 3,000-volt trolley. Still higher voltage
luipments are entirely possible, as indicated by factory experimental ap-
tratus built and tested, and every requirement of the heaviest main-line serv-
e can be provided for at moderate cost of locomotives and distribution
'Stems. The chief disadvant.ige of the direct-current system has been the
latively high cost of feeder copper and substations and their low efiiciency
it this has been largely overcome by the adoption of higher voltages and

1445
Sec. 16-277 ELECTRIC RAILWAYS

the advent of the automatic substation. The advantages of this systen

include simplicity, low cost and high efficiency of the locomotives, the optioi
of trolley or third-rail distribution, the benefits of bi-polar gearless-nioto
construction, and the use of balanced three-phase power supply of any fre
quency and entaiUng no serious telephone or telegraph interference.
Large direct-current locomotives are in service upon the following main
line electrifications.

New York Terminal

P. R. R. 600
volts
B.& O. Tunnel Railway 600
volts
New York Central Railway 600
volts
Detroit Tunnel Railway 600
volts
Butte, Anaconda & Pacifio Railway 2,400 volts
Canadian Northern Railway 2,400 volts
Chicago, Milwaukee & St. Paul Railway. 3,000 volts

DISTBIBUTINa SYSTEMS
277. Train diagrams represent in graphic form the movement of al
frains over a given division during the 24 hr. of operation. Such diagram
are usually plotted with distance as ordinates and elapsed time as abscissas
and they are of the greatest value in determining the average and maximuE
sustained demands upon the distributing and generating systems.
The average train input for a given service is determined according t
methods outlined in Par. 77 to 117, so that a train diagram is useful fo
indicating the local demand upon any part of the distributing system durin
any period of 24 hr. The train diagram also furnishes means of obtainin
the total average load upon the entire division covered by the diagram, b!
plotting in curve form the total average kilowatts demanded by the several
train movements intersecting equally spaced ordinates. Thus, referring t'
Fig. 88, representing a typical train diagram wherein is depicted the pejj
|6 i

12 3 6 9 12 3 G 9
A.M. P.M.
Fig. 88. —Typical train sheet (suburban service)

tormance of both local and express trains, the ordinate, a —

h, intersects tl
graphs of five trains. Assume that the various trains demand the followii
average input:
Local passenger 100 kw.
Express passenger 130 kw.
Freight 210 kw.
The line, a — h, intersecting the various train movements, therefore, cal
for a station output at 3:15 p.m. as follows:
Three local passenger trains 300 kw.
One express passenger train 130 kw.
One freight train 210 kw.

640 kw.
278. Calculated load curve. By erecting other ordinates upon the 2,
hr. performance sheet it becomes possible to plot a detailed generating-8tati<,
load curve for the 24 hr. with the train movements as predetermined. Tl
train load curve does not show momentary fluctuations, and these must al
be considered in determining the character of the distribution sysUi

1446
 ELECTRIC RAILWAYS Sec. 16-279

especially in suburban and other systems where the train units are large and
i
operate at infrequent intervals.
'{
279. Classification of service. As affecting the distributing system,
[railway service may be divided into two broad classes as follows: (a) fre-
quent or conge-sted service; ^b) infrequent operation. Under class (a) are
?rouped all city systems, underground or elevated roads and certain sub-
urban roads where the headway between train units is small. Under class
.b) are grouped all inter- ,
iirban and most suburban
oads, in fact, all classes of
lervice where the interval
setween trains is fairly
^
w
^ 600
\i Wi
arge, as 10 min. or more,
nd where the train unit
)perates at a high maximum
a
S
§
^'^
i\
\ m
peed and thus demands con-
iderable input. The treat-
*^

§ 200 EH
tnent of classes (a) and (b)
ervice as affecting the dis-
^
^
n
ribution system must be
q
omewhat different as in ] 2 3 6 9 12 3 6
lass (.a) momentary fluctua- A.M. **
P.M.
ions due to starting of cars
ave little effect upon the Fia. 89. —Typical load diagram.
iifie of conductor determined
.pen for feeders, or location and capacity of substations if these are used.
In class (b) the momentary input demanded during acceleration is often
jie determining factor in selecting the amount of feeder conductor and
^betation capacity required.
S80. Classification of distribution systems. Distribution systems
yiay be divided in general into two classes, which are secondary systems
.^ar. 281), and primary systems (Par. 293).

281. Secondary systems consist of the trolley wire, third rail or other
)nducting medium, extending from the generating station or substation
id the feeders connected thereto; also the track return with its feeders and
)osters, if used. The conductivity and physical characteristics of the
condary distributing system are determined partly by the momentary
;mand of each train unit and partly by the average input required by an
Igregation of such units, where the interval between trains is short. For
stance, in suburban service a high speed car may be equipped with motors
igregating 300 h.p. to the car, and the conditions of service may demand
'.
input, during acceleration, of 400 kw., while the average input to the car
eluding acceleration, coasting, braking and standing still during stops,
ly not be much greater than 100 kw. per car. As the train interval is so
eat that possibly not more than two cars receive power from a substation
one time, it becomes necessary to determine carefully the amount of over-
id during starting as influencing the conductivity of the distributing cir-
iitand the substation capacity. On the other hand in city service, asub-
|Uion or generating station may feed fifty or more cars, and individual
jiders may carry the load of perhaps fifteen cars, thus, making the momen-
ry demand of any one car a matter of small importance. In such cases
13 determination of conductivity and substation capacity would rest upon

iS sum of the average load of all the cars.

Jtt. The permissible drop in voltage of the conducting system between

i" and bus bar with a specified load, determines its conductivity. This
I'missible drop varies under different conditions of operation and types of
Iparatus used. Following are approximate percentages of allowable voltage
>p:
jy systems. 8 per cent, average 12 per cent, maximum
purban direct-current sya- 10 per cent, average 20 per cent, maximum
jcrurban direct-current sys- 12 per cent, average 25 per cent, maximum
aas
lerurban alternating-current 5 per cent, average 10 per cent, maximum
liStems
fee-phase induction-motor 5 per cent, average 10 per cent, maximum
stems
li^ 1447
 . I

Sec. 16-283 tlLECTRIC RAILWAYS

283. The conductance of the circuit between motors and bus bars.j
is seldom determined by its proper relation with interest on first cost of the I

conducting system and the cost of energy lost, as the first cost of the distribu-j
tion conductors so determined is considerably in excess of current practice m
this respect. In city systems the average and momentary maximum drofl
are practically the same owing to the small effect of the starting current o^
any one of the large number of cars controlled by one feeder. In interurbanj
systems, where generally but two cars are controlled by one feeder, th^
maximum fluctuation is much in excess of the average drop.
284. Relation of trolley wire and feeders. Feeders are different
grouped according to the demands of the service and the physical arrangem^
. of the trolley sections. The simplest conducting system to the car upon t
track consists in that shown in Fig. 90, wherein the trolley is connect
through circuit-breakers directly to the positive bus bar with no auxiha

I I I I I

Fia. 90. — No feeders. Fio. 91. — Single feeder.

P
Fia. 92. — Multiple feeders. Fra. 93. — Sectionalized trolley
feeders, and the negative bus connected to the track return. The tro|
is
is generally sectioned at the station and each section controlled by an ill
pendent feeder panel.
Where the trolley conductor itself has not a sufficiently high conducts
it isreinforced with auxiliary feeders connected to it at frequent inten
See Fig. 91. The result of such feeder reinforcement is simply to inci '

the conductivity of the trolley circuit, and corresponds to an enlargenit

the cross-section of the trolley conductor itself. This grouping is best I

for feeding a small number of units, and is more useful in the operaticn
suburban or interurban systems than in city work.
285. The most economical copper distribution for feeding: a If^i'S
number of train units would consist in a separate feeder to each truin ^^

proportioned that the drop in all feeders would be equal to the maxinun
drop permissible. As this would be impossible without too great a inuli
plicity of feeders, the arrangement in Fig. 92 is adopted. A better arrunr^
ment of the same feeder connection is shown in Fig. 93 which is identical t

that in Fig. 92, except that the trolley itself is sectioned so that each finl'
independently controls a single section of trolley and the cars drawii
energy from that section (Par. 286 and 287)
286. Lengrth of trolley wire sections. Trolley sections may be fro
a few hundred yards to 2 miles or more in length in city service, depiinlii
upon the lay-out of the streets and the importance of sectionalizing dill in i

streets or sections of the same street in such manner as to occasion the li i

possible interruption to general traffic in case of failure of any one trulli

section or its feeder.
287. Segregated trolley-wire sections. The trolley wire may be si.

throughout as shown in Fig. 92, or preferably sectionalized as shown in I'l

94, in which case the different sections are entirely independent and vw
feeder and each trolley section is calculated to give the limiting IR drop w li'

feeding the maximum group of cars drawing energy from that section of t

trolley. Thedirect-current feeder distribution shown in Fig. 93, appli

more especially to city systems and may be elaborated to any extent ret|uii
by the complexity of a large-city trolley system. Sectionalizing the troll
is desirable from the standpoint of localizing the effect of trolley breaks

144S
 ELECTRIC RAILWAYS SeC. 16-288

;roui)ds, and is necessary in large-city systems supplying a contiderable

lumber of car units traveling over different routes. Thus, with the scction-
[
Jized system, the failure of the trolley on one section will not affect the oper-
tion of cars on a different route. The ends of trolley sections should be
oined at adjacent ends by a switch or circuit-breaker which normally remains
pen. This switch may be closed if such procedure be desirable, as in the
ase of possible failure of an individual trolley feeder. The.se trolley-pole
witches may be operated manually, or they may be controlled electrically
rom the supply station if they are located at very important points not
onvenient of access.
Feeder copper calculations depends upon the character of the
388.
;rvice, trolley potential and permissible drop. In and about cities, 600-
olt equipment is universally used, while for suburban and interurban service
oth 600-volt and 1,200-volt systems are in operation. Still higher dircct-
irrent potentials are being proposed, but the 1,200-600- volt combination
orks out so conveniently in practice that the use of higher voltages will
robably be restricted to special locomotive installations.
The use of 1,200 volts direct-current or higher makes it possible to install
rect-current generators of this potential and feed direct to the trolley, pro-
ded the generating station can be centrally located on a road not over 35
>40 miles long. One such installation is in operation, and a high efficiency
suits from the elimination of step-up and step-down transformers, trans-
ission line and synchronous converters.
289. Perraanent and booster feeders. City service demands a feeder
stribution capable of taking care of rush daily loads without prohibitive
op. In addition a properly proportioned
stem should easily carry infrequent heavy
on certain sections such as those due to
ids
lusement parks, race courses, etc. The
ily rush loacf justifies the expense of
tider conductor permanently installed, but ^^q^ y4 Use of booster.
J'requent loads are best taken care of by
fiders arranged for use with series or shunt boosters in the power house.
'
other words, the infrequent load occurs so seldom that it does not justify
3 expense of a large amount of feeder conductor, which may be inoperative
ring the greater portion of the year. With the pyramidal feeder system,
jSi 92 and 93, it is entirely possible to use the outside feeder as a booster
"«er in case the infrequent heavy load should occasion a prohibitive drop.
190. Factors determining sectional layout. A city feeder system
)uld be so designed that the voltage of no part of the trolley to ground will
more than 100 volts lower than that at the switchboard when momentary
ituations due to starting cars are eUminated. This 100-volt average drop
-luld apply to the rush load occurring in daily operation. The laying out
a city direct-current network consists in establishing the limits of the
ritory controlled by each substation (or generating station if separate
{tions be used); sectionalizing the district according to routes and streets,
sermining the average load upon each section as obtained from the average
iut demanded by the several cars on this section; and determining the
iss-section of the conductor required for feeder sufficient to limit the IR
kp including track return, to 100 volts. In crowded city districts the
Mey will be cut up into such short sections that the additional IR drop
tuning therein will not materially add to the combined return track and
tier drop of 100 volts. For the outlying districts less feeder drop must be
,uired, in order to allow for the larger drop occurring in the longer trolley
lions. Trolley sections will vary in length, depending upon the density
«rvice, street intersections, etc.. ranging from one quarter of a mile up
l! miles or more in the suburbs.

91. Components of a city distribution system.

i) Trolley, consisting of a grooved copper conductor upheld by so-called
luspension approximately 20 ft. to 22 ft. over the centre of the track.
olley conductor is sectionalized according to local requirements into
of from one quarter of a mile to 2 miles or more.
1

feeder system, consisting of copper conductors extending from the

trolley sections to the supply station. The feeder may be under-
in conduits in the congested sections and carried overhead on poles
luburbs, or in small towns.

1449
 • ,

Sec. 16-292 ELECTRIC RAILWAYS

(o) Booster in the supply station, which can be connected in series witl
any feeder extending to a temporarily overloaded section for the purpose 6,
supplying the added voltage required to compensate for the excessive feede,
and trolley drop.
(d) Track return, consisting of the track rails, bonded at the joints. _ ,

(e) Track return feeders, consisting of copper conductors reinforcin

the track at points of greatest drop or at points where the track is negativ|
to the neighboring pipes.
(f) Pressure wires extending to important points on both trolley, trac'
and pipes, and serving to indicate at all times the potential of the sever{j
parts of the distribution system.
Such large city systems are a matter of growth and not of calculation, s|
the practice giving good results in one city may not be directly applicable ti
the different conditions obtaining in another city. j

292. Feeders for underground trolley or conduit systems. Suoj

systems are described in Par. 334. The trolley conductors are two in numbei
and are located underground between the two rails. These conductors av
of opposite polarity, and there is no track return circuit. The arrangemeUii
therefore, neoesisitates double the number of feeders required with the seij
tionalized overhead trolley used with track return. As both positive an
negative rails are insulated from ground, the conduit systems practicallf
eliminate any stray currents and electrolysis. Conduit systems are installf?
to avoid the unsightliness of the overhead trolley, and can only be considorc
in the largest cities owing to the enormous expense of their installation.
293. Primary distribution comprises the location of substations and tl
high-tension overhead transmission lines or underground cables connectii
the substations to the generating-station bus bars. Primary transmissic:
systems invariably employ alternating-current, and where synchrono'
converters or motor-generator sets are used, this primary current is of t/
threa-phase type transmitted over three wires or in multiples of three;
duplicate circuits are provided. Owing to the novelty of single-phase ra
way-motor distribution systems and the close interconnection of seconda
and primary distribution systems when applied to alternating-current mot
operation, this subject will be considered later (Par. 296). ji

294. Methods of serving direct-current substations. Substatioij

for direct-current systems are located at strategic points along the Hne ,,

travel best suited for secondary distribution. These substations may

fed from a common trunk line to which all substations are connected; tl
is common practice in suburban and interurban railways operated by dire
current motors. In such cases the trunk line preferably consists of two inc
pendent circuits, each of which may be used alone, providing, thereby, 1.

continuity of service in case of the accidental grounding of one set of lin ,.

It is also common practice to interrupt the transmission line at each si,'

station, providing both incoming and outgoing line panels at each substati »!

in order that the transmission-line troubles may be localized between t'lj

adjacent subs rather than that a whole trunk line be put out of commissin:
due to the fault of any i)ortion thereof.
In city systems or m .

interurban systems where the traffic is very hea

and where freedom from interruption of service is of greatest importan «
it is good practice to connect each substation to the gencrating-stat;'!
bus bars through its own individual transmission line or underground calji! -

In fact, if the substation is very large, this divisibility of the transmiss

circuit is sometimes carried to the extreme of providing each substat
with several cables connected either to individual synchronous convert-
or to different bus-bar sections. If this bus-bar segregation is resorted'
each section is allowed to control two or more synchronous convert'.
It is evident that this multiplicity of high-tension transmission lines or cat
i

can be made use of only in very large and important cities, or in interurl >

systems taking care of a very congested traffic.

296. Single-phase generation and transmission. Alternati
current single-phase railway-motor systems are best energized by sirir
phase generation and transmission, owing' to the simplicity of single-ph)
connections throughout the system. The method of connecting the varU
alternating-current substations to the generating station consists usui'
in tying all substations to a single trunk line through circuit-break
designed to open on short-circuit only. Individual transmission lines)

1450
 ELECTRIC RAILWAYS Sec. 16-296

each substation may be preferable under certain conditions, but multiplicity

of transmission circuits is generally to be discouraged owing to the consider-
able increase in cost over a single or duplicate trunk line.
296. Single-phase generation with three-phase alternators.
Owing to the enormous aggregate kilowatt capacity of three-phase 25-cycIo
^nerators already in operation for electric railway work, and due to the
act that single-phase railway installations are often an extension of existing
direct-current systems, it becomes necessary to consider the different systems
of primary distribution for alternating-current roads operating from three-
phase generators. The simplest means is to use one leg of the three-phase
system for the alternating-current railway distribution, that is, to treat the
'generator as a single-phase machine and carry out the transmission scheme
tnd substation connections in all respects as though the other two legs of
die three-phase generator did not exist. In this case the connections will
M as described in Par. 296 for single-phase generators. The objection
'a this method of connections is the reduction of generator capacity re-
sulting when a three-phase alternator is operated single-phase. For the
lame heating, the single-phase output of a three-phase generator will approxi-
mate two-thirds of its three-phase output on balanced load. Although
ingle-phase distribution is simplest, the resulting reduction in generator
MHjacity may be so serious in certain installations as to necessitate the
ionsideration of three-phase distribution to the transformer substations
Par. 297).
297. Three-phase transmission "legged" to sectionalized trolley,
here the road is of extended length, the secondary distribution or trolley
r- r

pSajOSaq pJBl/pflfiq ^flflnrtta^

Fig. 98. —Three-phase to

single-phase.
Sec. 16-299 ELECTRIC RAILWAYS

in employing the three-phase two-phase connection of substation trans-

former, feeding the two-phases to adjacent trolley sections, so that corre-
sponding phases will be fed to a given trolley section from the transformer sub-
station at its terminals. This system of connections will not provide perfect
balance upon the three-phase side of the transformers unless the loads are
balanced upon the several trolley sections. Sufficient balancing, however
may be obtained in the majority of cases, and this system of connection ii
in quite extended use.
299. Two-phase generation and single-phase distribution. Two-
phase generators may be used to supply single-phase railway distributioi
systems by sending out transmission lines from the two phases in difforeni
directions, thus amounting in principle to two separate single-phase tranS'
mission systems. This method of connection is open to the objection thai
unless the loads are perfectly balanced upon the two phases, the voltagf
regulation will be very poor, and in cases of generators having poor inhereni
regulation, it may reach such proportions as to endanger the lamps anc
the general operation of the equipments.
300. General considerations in design of a new single-pha8<
motor system. In general a new railway system, favorable for the opera
tion of single-phase motors, operates to best advantage with the single
phase system of generation and transmission, provided the contemplatec
road has no future connections with neighboring systems and is free fron
entanglements, such as power distribution, operation of synchronous con
verters, etc., requiring multiphase generation and distribution. When
it is advisable to provide for the future utilization of three-phase power
three-phase generators may be installed, operating either on one leg as single
phase generators, or using all three legs in connection with three-phasi
two-phase transformer connections in the substations in order to provid'
for reasonably good balancing of the three-phase primary distribution.
301. Three-phase, induction-motor systems may employ the sam
method of substation connections and primary distribution as outline"'
under the head of synchronous converter substations for direct-curren
motor systems. Owing to the fact, however, that transformer substationj
of all kinds may be operated without attendance, such substations are besf
connected to a main trunk line through circuit breakers operated by relay
designed to open only on short-circuit. Where the control of the sub'
station is extremely important, attendance should be supplied, or each in!
dividual substation should be connected to the generating station b,"]
separate transmission lines having automatic control at the generating en
only. In all cases the trolley or secondary connection to the transformel
substation should be safeguarded by automatic switches designed t
oppn on short-circuit. 1

302. Resistance of trolley wire circuits is dependent upon the weight rl

trolley copper and track rail, and also upon the composition and bondin'
of the latter. Trolley conductors arc cither 000, or 0000 A.W.G., th'
smallest size being seldom u.sed owing to its lack of strength and the
culty of clamping its small diameter.
303. Trolley wire and track resistance

Ohms per mile

Weight Copper*
of rail equivalent No.
\}h. per (cir. mils) Two 3^g^ I Ohms, Two 4/Ot
yd.) rails total rails
trolley trolley

50 500,000 0.056 0.34 0.396 0.056 0.27

60 600,000 0.047 0.34 0.387 0.047 0.27
70 700,000 0.040 0.34 0.380 0.040 0.27
80 800,000 0.035 0.34 0.375 0.035 0.27
90 900,000 0.031 0.34 0.371 0.031 0.27
100 1,000,000 0.028 . 34 0.308 0.028 0.27
no 1,100,000 0.025 0.34 .365 0.025 0.27
• Copper equivalent based on steel weighing 490 lb. per cu. ft. and I)

a resistance 12.5 times the resistance of an equivalent section of copr

t Resistance for hard-drawn copper.

1452
 ELECTRIC RAILWAYS SeC. 16-304

304. Impedance. The use of alternating current in the trolley and rail-
ircuit necessitates some modification in the above values, as the effective
asistance is increased by reason of the inductive reactance of both trolley
nd rail, and also due to eddy currents set up in the rail itself.
305. Kail impedance. The impedance of a rail depends in a considerable
agree upon its chemical composition, a reduction in permeability also
"iduoing the internal losses. In general the action is a skin effect, and the
npedance and resistance are inversely proportional to the perimeter of the
lil and are proportional to the square root of the frequency. This pro-
jrtion assumes an unbroken rail, and the introduction of short lengths of
dl bonded together calls for modifications. Thus at 25 cycles the imped-
ice of track rail of standard outline and composition is approximately eight
iraes the ohmic resistance offered to the passage of direct current; at 15
f'ck-3 a ratio of 6.2 obtains, etc. The power-factor at either frequency is
)proximately 80 per cent. Considering a track circuit with bonding,
perimental results show an impedance at 25 cycles of 6.6 times the ohmic
sistance.
Under the following conditions the measured impedance of rail of various
1

is given below: height of trolley above track, approximately 20 ft.;

nghts
ge of track standard, 4 ft. 8.5 in.; power-factor of circuit, 80 per cent.;
erage power-factor of load 80 per cent.; ratio of impedance to ohmic
ifiistance, 6.6 to 1.0; frequency, 25 cycles per sec.

V^eight of rail, lb. per| 60

yd. I

impedance ohms per; 0.291

Hiinile 2 rails.

^06. Trolley-wire impedance. In addition to the increased impedance

the rail itself, the impedance of the overhead trolley conductor is also
reased by reason of its reactance when carrying alternating current. Tests
de upon 000 and 0000 conductors indicate an increase in impedance
the ohmic resistance. The conditions under which the following values
•e obtained were, with the exception of the impedance ratio, the same
those given in Par. 306. Impedance per mile of 000 trolley = 0.495
08. Ratio of impedance to ohmic resistance, 1.5. Impedance per mile
JOOO trolley = 0.390 ohms. Ratio of impedance to ohmic resistance, 1.5.
07. The height of trolley- wire above rail can be varied somewhat
fn the 20 ft. .issumed without introducing an appreciable error. The
'er-f actor of 80 per cent, assumed for the load is somewhat lower than
fid be experienced in a well-proportioned alternating-current railway
dilation, but the small error of 4 or 5 per cent, introduced by assum-
full impedance drop of the trolley and rail circuit is justifiable in making
timinary estimates where the character of load cannot be very closely
Tmined.
)8. Classification of trolley construction.
(a) Span construction (.Par. 309).
Bracket construction (Par. 311).
(b)
••. Span constructioncomprises poles on either side of the track con-
led by cable from which is suspended the trolley conductor. The trolley
«be hung directly from the span wire through an intermediary insulated
;er or may be suspended from a galvanized steel catenary (Par. 312)
ihin turn is supported by the span wire. Span construction may be used
"rovide a support for the trolley wires over any number of tracks. With
* than two tracks it is preferable that the side poles shall be aelf-aup-
Jag steel towers joined by very heavy catenary construction, the whole
>ination being thoroughly anchored to withstand stresses, or else the
owers should be joined by a light steel truss, forming a bridge construc-
this latter being used in steam-railroad electrification where the num-
jf tracks exceeds two.

Trolley wires generally have a cross-section equal to No. 3/0 or No.

and are drawn in three sections; round, figure 8, and grooved,
Irv.W.G.,
hise of round wire is objectionable owing to the difficulty of securely

i.
 :

Sec. 16-311 ELECTRIC RAILWAYS

clipping it to the hangers without forming a projection on the wire its*

which will tend to throw off the current collector in high-speed operation.

Fia. 100. —Cross suspension. Fio. 101. —Bracket suspensionj

The use of figure 8 wire is open to the objection that owing to its unsy
metrical cross-section it is very difficult to handle during installation, althou
it affords a ready means of fastening and loaves a cle:
unbroken under-surface suitable for high-speed opcratifl
The grooved trolley wire (Fig. 102) is in greatest i;
and consists of a round wire grooved on opposite Bi(
sufficiently deep to permit gripping by adjustable clairi
or hangers. Owing to its round cross-section, it
readily unreeled and installed, and presents all the li
vantages of a smooth under surface. j

311. Bracket construction comprises a self-suppoj

irig pole having a projecting arm or bracket extend;
over the track and supporting the trolley wire eitl
Fig. 102.— directly or\by means of a steel catenary cable. The f i

Trolley clamp. is generally of wood, and the best construction provil

for anchoring each pole to guard against lateral strajj
due to wind and the unbalanced weight of the overhung trolley. ij

Fio. 103. — Two-track bracket construction. Fio. 104. —Combination i

1404
 ELECTRIC RAILWAYS Sec. 16-312

The trolley is usually not attached directly to the projecting arm or

bracket, but to a flexible cable attached thereto, whose office is to provide
for the needed amount of flexibility. Span construction is more flexible
than bracket construction, but by use of the flexible bracket cable, the
latter can be made sufficiently cushioned to permit the operation of trolley
wheels up to 60 miles per hr.
312. Catenary construction (Par. 309) has been brought into promi-
nence with the development of the alternating-current motor, but its applica-
tion is not confined to alternating-current motor installation as its excellent
mechanical qualities are of equal benefit in the case of high-speed direct-
current motor installations. Catenary construction comprises either a
span or bracket-supporting structure over which is hung a stranded gal-
vanized steel cable loosely suspended with 20 in. or more drop between
supports, thus giving rise to the term catenary. From this catenary or
messenger cable is suspended the grooved trolley wire by means of hangers
A different lengths. The number of these hangers varies from a minimum
jf three between supports to a maximum of a hanger every 10 ft., the
abject being to secure a practically flat trolley wire of equal height at all
points above the track.
313. Twin trolley construction consisting of two trolley wires hung
lide by side and alternately suspended from the same messenger was first
ised on the Chicago, Milwaukee and St. Paul electrification. On account
i)f the fact that there are two trolley wires the current-carrying capacity of

he combination is greater than with a single trolley wire and on account

){ the uniform flexibility of the arrangement there are no hard spots causing

he collector to leave the wire and cause arcing. This type of construction
s suitable for both high-speed operation and heavy-current collection with
>antograph collector.

Fia. 106. — Three-point catenary suspension, curve.

S14. Advantages of catenary construction. The flexible suspension
I
a catenary-hung trolley and the flat surface which it presents to the trolley
>llector makes it admirably suited for the operation of high-speed equip-
ments whether these be of the alternating-current, or direct-current type,
jhis form of construction is furthermore especially adapted to withstand
I'.e high-voltage stress of the trolley voltages employed in alternating-
jtnent, secondary distribution systems, owing to the fact that the catenary
f! generally suspended from porcelain insulators of the high-potential
fansmission type, forming both a strong mechanical structure and having
gh-presaure resisting qualities.
ith catenary construction it is possible to adopt a greater spacing

1455
Sec. 16-315 ELECTRIC RAILWAYS

between supports than is customary with the self-supporting trolley wire

construction.
316. Distance between trolley-wire supports on tang^enta
Self-supporting trolley 110 ft.
Catenary wooden-pole bracket construction 150 ft.
Catenary steel-pole bracket construction 200 ft.
Catenary steel-bi-idge construction 300 ft.

The only limit placed upon the distance between supports in catenarj
construction on tangent track is the likelihood that long spans will have con-
siderable lateral sway. This is corrected in part by suspending the troUej
from a double catenary construction, thus forming a triangular tru.ss ol
considerable rigidity.
316. Pole guying. With wooden-pole bracket construction it is cus-
tomary to anchor the poles on curves, often on tangents.
317. Duplication of primary circuits. Primary transmission circuits
may be carried upon the same poles that serve as a support for the trolley
The transmission line so supported may be supplemented by a separatt
transmission line hung on independent poles, in order to provide greater as-
surance for continuity of service.
318. Standard trolley potentials in use are as follows: COO, 1,200
1,500, 2,400 and 3,000 volts direct-current, 3,300, 0,600 and 11,000 volts
alternating-current.
An alternating-current trolley potential of 3,300 volts has been u.sed ii
several installations but is being superseded by 6,600 volta in the smaller, and
11,000 volts in the larger installations.
319. Overhead collecting devices for use with trolley may be divided
into three classes: wheel (Par. 320), roller (Par. 321), and slidiug-bow
(Par. 326).
320. The trolley wheel consists of a grooved wheel of composition metal
ranging from 3.5 in. to 6 in. in diameter, depending upon whether the
service is low or high speed. Wheels are carried on a self-lubricating bearinj
and press against the trolley at pressures from 15 to 40 lb. depending upon the
maximum speed of the equipment, this pressure being maintained throughout
a wide range in height of trolley wire in order to provide for reduction in
standard height of 22 ft. made necessary when going beneath bridges,
culverts, etc.
321. Approximate life of trolley wheels
City service 25 miles per hr. maximum 11,000 miles
Suburban service 35 miles per hr. maximum 0,000 miles
Interurban service 50 miles per hr. maximum 3, .500 miles
High-speed service 00 miles per hr. m.aximum 2,000 miles
322. The current capacity of the trolley wheel is determined by it«
speed and the pressure of contact between wheel and wire, the higher the
speed the greater the pressure necessary to maintain contact without ariingj
High speed also demands a very nicely balanced wheel and the maximum speet,
at which trolley wheels are used, corresponds to a car speed of 60 miles per hr
Following are the current-carrying capacities of trolley wheels at various
speeds.

Speed in miles per hr 5 j

10 20 30 40 50 00
Current capacity in amperes.! 1,000 850 6,50 550 400 300 200

This table is compiled on the basis of maximum current-carrying capacitjj

at the different speeds with trolley and wheel in good condition. The wheeij
isbalanced for the higher speeds and the contact pressure varies from 20 U]
40 lb. between trolley and trolley wheels. '

323. Flexible trolley- wire suspension for the higher speeds

the higher speeds it is absolutely necessary that the trolley suspciisi
very flexible, preferably hung from a catenary and with the clip fa.-^t' :

the trolley wire of as light weight as possible in order to minimize the blow o
the trolley wheel striking it. f

1456
 ELECTRIC RAILWAYS Sec. 16-324

S24. Trolley rollers are sometimes used in place of trolley wheels where it
desired to make use of a reversible collecting construction or where the
rolley potential is so high as to make it desirable that all control of the
rolley collecting devices shall be automatic and not manual with cord. RoU-
\e contacts consist of a brass or composition roller about 5 in. in diameter
mi 30 in. long, supplemented by stationary wings to provide for greater
ff-centre displacement of the trolley than can be taken care of by the roller.
toller trolleys are beirig used for high-voltage direct-current locomotives
ith success, and improvements in design have made it possible to collect
ay current required for main-line freight or passenger trains with direct-
lurrent 2,400-volt supply.

Fig. 107.— No. 12 fork; No. 17 wheel.

Fig. 108. — Pantograph roller.

lU. Sliding shoe trolleys are in very general use at moderate speeds,
Tying currents of moderate value, and the development of high po-
tial alternating-current trolley collectors has brought this form of con-
uction into prominence. In many alternating-current roads the use of
Uey wheels operated by means of insulated linen cord is still adhered to,
; tne majority of such roads are adopting some form of roller or sliding-
V contact. As the application of the sliding-bow trolley to high speed
oration calls for certain modifications in its construction as hitherto made,
complete operating data are extant in regard to its carrying capacity or its
\. For speeds between 50 and 60 miles per hr., the sliding contact has an
ireciably less life than either the trolley wheel or roller, but continued use
.he sliding bow at these speeds is resulting in the selection of metals and
jfls of construction which will provide for a reasonably long life. A double-
|e trolley has lately been developed for collecting heavy currents which will
iHoubtedly supersede the roller. It is much lighter and will collect much
vier currents, not only at low but at high speeds.
SS. Sliding-bow construction may be supported either by a trolley
.5 mounted upon a spring base along the lines of standard trolley-wheel
i|struction, or the bow or scraper may be held in a horizontal position at

W57
Sec. 16-327 ELECTRIC RAILWAYS

all heights by means of the so-called pantograph construction. Because o

the parallel motion introduced, it does not interfere with trolley construction
327. Third-rail construction may be divided into two broad classes
o, overrunning contact (Par. 328); h, underrunning contact (Par. 334).
Third-rail voltages of 600 and 1,200 volts (Central California Traction
are in operation and still higher potentials are being proposed. The liniitini

Fia. 109. — Sliding bow. Fio. 110. — Pantograph bow.

third-rail voltage has not yet been reached, and it is probable that the d<
velopment of improved forms of construction will result in the use of highe
voltages for steam-road electrifications. Bonding of the third-rail
treated in Par. 349.
328. Overrunning-contact third rails were the first introduced and a^
in more general use. The construction consists essentially in supporting!
steel rail, of either standard track or special composition, upon insulatoi
placed every 10 ft. These insulators rest on supports carried upc
projecting ties. Rails are joined loosely by fish plates, are bonded, and \
intervals are thoroughly anchored to prevent creepage. Contact is mac
with the collecting surface of the rail by means of a third-rail shoe suspendc
from the trucks of the car or locomotive.

111. — Unprotected third-rail.

JL
Fig. 112. — Protected third-rail.

329. Protected third-rail construction is a modification of the above, a^

consists in providing a wooden or metal shield over the rail in or(^
protect it from snow and sleet or accidental contact, the rest of the con
tion being identical with that outlined above. The wood or iron constrt
is supported by uprights placed every 10 ft. or more, and such proteo
of a man midway
'''
usually substantial enough to bear the weight
supports. J

1458
 ..

ELECTRIC RAILWAYS Sec. 16-330

u A H .
T
? jL!tr
Type T Type B
Fig. 113.
330. Third-rail roads giving: location of third-rail
Inches on Fig. 113
Name of road Type*
A B

vlbany & Hudson R.R. Co U.T. 26.25 6.00

..urora, Elgin and Chicago R.R. Co U.T. 20.25 6.25
Baltimore & R.R. Co
Oiiio P.T.i 30.35 3.50
ierlin Elevated and Underground 14.375 7.05
loston Elevated Ry. Co P.T.» 20.407 5.94
irooklyn Rapid Transit U.T. 20.50 6.00
lentral London ....._ Centre 1.50
Central Calif., Traction Co P.B. ad. 50 3.00
rand Rapids, Grand Haven & Muskegon U.T. 19.00 6.00
Ry. Co.
iterboro Rapid Transit Co.
Manhattan Elevated P.T.« 20.75 I 7.50
Subway, East side, Viaduct & West Farms U.T. 20.75 I
7.50
Subway, all excepting above division. . . P.T.« 26.00 I 4.00
[ackawanna & Wyoming Valley Rapid 1

LFransit Co U.T. 20.344 !

3.00
[iverpool Overhead Railway Centre i 1.60
ong Island R.R. Co P.T. 27.50 i
3.50
Cersey Railway
'

22.00 4.50
Metropolitan & District 16.00 3.00
jletropolitan West Side Elevated Ry. Co. . . U.T. 20.50 I 11.25
liichigan United Rys. Co U.T. 21.50 i
6.00
Hilan-Gallarate 26.625 7.60
few York Central & Hudson River R.R. . . P.B. 28.25 I
2.75
Northern Electric Co U.T. 25.50 I
5.562
fcrtheastern 19.25 ,
3.25
nris-Orleans 25.625 ;
7.125
nQadelphia Rapid Transit Co P.B. 27.00 i

•liladelphia & Western Ry. Co P.B.» 27.50 :

5.75
iget Sound Elec. Ry. Co U.T. 21.22 i
7.125
doto Valley TractionCo U.T. 28.00 i
6.00
mth Side Elevated Ry. Co U.T. 20.125 I

11.662
pion Elevated R.R U.T. 20.125 I 6.187
aterloo City 28.25
est Jersey &, Seashore U.T. 27.344 3.50
est Shore 32.00 2.75
ilkesbarre & Hazleton Ry. Co P.T. 28.00 .5.00

* Note.
P.B.
—=U.T. = unprotected top running; P.T. =« protected top run-
ig; bottom running.
protected
ttl. The location of the thixd-rail is determined by physical character-
08 of the rail and by the character of the rolling stock passing over it, that
nifficient clearance must be provided to allow the passage of low-pressure
amotive cylinders, hopper cars, etc., and also the third rail must be laid
Two side guards and slotted covering through stations.
•One side guard on outside 6.25 in. distant, extending 6.5 in. above too of

Ipne side guard on outside.

nke that shown in Fig. 113 "Protected."
Farhan System.

1459
Sec. 16-332 ELECTRIC RAILWAYS

to provide sufficient clearance through tunnels, etc. The distance froi

track gage line to centre of third-rail varies from 20 in. to 28 in. an
the height above track is from zero inches to nearly 8 in. The snialh
distances apply to elevated and subway roads operating only one class (
rolling stock, and the greater distances apply to iuterurban lines or ele(
trifled steam lines where provision must be made for the ijassago of a
classes of freight cars and possible steam locomotives.
332. Third-rail jumpers are used to connect the third rail severed i
crossings and consist of copper cables bonded to the rajl and extcndiu
through underground conduits. Jumper cables are heavily insulated, ai
lead covered, and enter the ground through solidly-constructed coucrel
structures.
333. Third-rail insulators consist either of impregnated wooden block
reconstructed granite or porcelain insulators designed to be held in chaii
fastened to elongated ties and forming a loose support for the third rai
In order to provide for elongation of third rail caused by extremes in ten
perature there is no solid fastening between the third rail and its insulatin
support, and jumpers must be of sufficient length to allow for creepage.

Fig. 114. — Underrunning third-rail.

334. Underrunning third-rails of the protected type, first install?

on the New York Central U.K., offer some advantage over the overrunnii
type in regard to better protection against accidental contact and again.st sle
and snow. The contact surface being the under side, is self cleaning, ar
this form of third rail has successfully operated through heavy snov
completely covering the third-rail structure. The Central California Trai
tion Co. operates an underrunning third-rail at 1,200 volts. i

335. Leakage from third-rail is extremely small and may be neglect*

unless the road bed should be deeply impregnated with salt. Even thoutj
the third-rail be covered with snow it is found that the leakage is too smij
to constitute a noticeable item of expense.

Neutral Position of 8Im»

A- Sii" For Lowoal ir<riionUlPosltioil
A- V'i" for Highest UorizoDtel Petition

Fig. 115. -8hoe for standard and inverted rail.

336. Third-rail shoes (Par. 337) are of two general types: those acquir
their pressure by gravity and those actuated by means of springs. 1
unprotected overrunning third rail was Hrst used in conjunction with gnM
shoes, and in many installations this form of shoe is still in operation. WW
rails are protected it ia necessary to provide a form of shoe which will operj
 .

ELECTRIC RAILWAYfi Sec. 16-337

I the limited space between rail and protection, and such shoes are hinged
ad actuated by springs in order to provide the necessary pressure.
337. Current capacity of third-rail shoes is much in excess of that of
ay form of overhead current collector, especially in regard to current
'ipacity at high .speeds. Tests have been made which indicate that elec-
icity may be collected at the rate of 2,000 amp. from a single shoe at a
!>eed of 35 miles per hr., and 500 amperes at a speed of 70 miles per hr.
.wing to the considerable wearing surface of a cast-iron shoe its life may be
ken as exceeding 25,000 miles.
338. Conductivity of the third rail depends upon its composition,
id it is sometimes the practice to roll third rails of special composition in
^der to increase their conductivity. The specific resistance of steel has
:«n found to be proportional to the per cent, of manganese and carbon which
i
contains. Of these two elements mangane-se is the most objectionable,
the standard track rail contains from 0.40 to 0.50 per cent, carbon and
high as 0.70 per cent, manganese, which gives it a specific resistance
nging from ten to twelve times that of pure copper. For samples of special
nstruction see Par. 339.
339. Composition of special third rails

Albany
Material
Manhattan New York and
railway subway Hudson

Per cent. Per cent. Per cent.

larbon 0.073 0.10 0.090
f anganese 0.340 0.60 0.440
ulphur 0.073 0.05 0.08
hosphorus 0.069 0.10 0.088
Alio of resistance compared
to copper 7.7 8.0 7.25

340. Suggested third-rail composition specification

llarbon not to exceed 0.12 per cent.
:»Ianganese not to exceed 0.40 per cent.
Sulphur not to exceed .05 per cent.
'hosphorus not to exceed 0.10 per cent.
'he resistance ofa third-rail of composition given above will be approxi-
sdy seven and three-quarters times that of commercial copper,
ncluding bonds, the table given in Par. 341 is representative of third-rail
ed according to these specifications for special rail, having 7.75 times the
stance of copper and of track rail having 12.5 times the resistance of
per.
341. Resistance of rails including bonds

eight of rail lb. per

d . . . . . 40 50 60 70 80 90 100 110
lird-rail resistance
hms per mile 0.093 0.074 0.062 0.053 0.046 0.042 0.038j0.034
TO track rails, resist-
nce ohms per mile. . 0.070 0.050 0.047 0.0400.035 0.031 0.0280.025

his table is based upon the use of 9-in. bonds having a carrying capacity
J to one-half that of the rail.
A, Third-rail maintenance is a very small item, as tests have shown
rail to wear an extremely small amount, even in very heavy service,
s taken show tha,t the passage of 2,000,000 third-rail shoes resulted in
ing away O.OOG in. of special soft rail. The maintenance of a third-
includes such items of expense as maintaining the bonding, alignment,
insulators in good condition together with the upkeep of jumpers and
sables. This expen.se has been found in practice to be very small and
low maintenance charge of third-rails together with the possibility

1461
Sec. 16-343 ELECTRIC railways

which such a system offers for handling unlimited current values at ai

spaed constitute the strongest arguments in favor of its adoption.
343. Protection of third rail against sleet and snow is affect
directly by the various forms of protected third rail, and it has been foui
that especially the undorrunning type can operate in snow entirely surroun
iag the third rail without difficulty, owing to the fact that the under conta
surface of the rail is self cleaning. With the various forms of exposed ov<
running rail it has been found that the accumulation of sleet may be pi
vented by the use of calcium chloride mixed with water in the proportion
I lb. to 5 gal. and sprayed upon the rail at intervals of not more than 2 ]
during the continuance of the storm.
344. Underground trolley or conduit systems are in use only in t
very largest cities owing to the enormous expense of their installatic
Such systems consist in the location of two third-rails or conductors plac
in a conduit located between the track rails, contact being established 1

means of a plough extending through a slot opening of -the conduit. .

the plough carries both the positive and negative contacts, there is no tra
return and hence the conductivity of the track as a return feeder is lost.
Underground trolley systems are installed in city streets where the co
gestion of travel is sufficiently heavy to warrant the large expense and whe
the use of overhead wires is objectionable. As conduit systems are esse
tially double-trolley systems, the feeder network is double that required f
an overhead trolley with track return. Both conductor rails are control!
by separate feeders and are divided into sections as previously indicat
for city trolley systems. Each section, with its_ feeders, is controlled 1

double-throw switches so that it may be made either positive or negati

at will. With this arrangement of double-throw switches it becomes pc
sible to throw all temporarily grounded sections on a bus of the sar
polarity and thus prevent possible short-circuits due to simultaneous groun
ing of a positive and a negative conduit conductor.
346. Double-trolley systems are installed to a very limited extent
city streets in order to prevent any liability to electrolysis possible with t
single-trolley track-return system (Par. 460). Such systems call for doul
_

collectors and double-trolley construction, which becomes complicated ai

expensive to maintain in city streets. One trolley is positive and the oth
negative, so that the track is not utilized for return and hence need not
bonded.
346. Three-i>liase double-trolley systems or double third-rail sj
terns are sometimes used in conjunction with three-phase induction mot
equipments requiring three conductors, in which case the track acts as t
third leg of the triangle. Such systems usually carry several thousa
volts upon the trolley wires, employ the catenary overhead construotic
and are as yet in very limited use.
347. Three-wire systems comprise two overhead trolleys having ,

Fotential difference of 1,200 volts between them and 600 volts each to groui*
n this case the car equipment consists of two separate 600-volt roof
equipments including control, connection being estaolished with the tra^
as a neutral. Such systems can therefore operate either as 600-volt fr<i
either or both trolleys, or as a straight 1,200-volt system troUey-to-troUi
with the track acting as a neutral and carrying practically no curro"
Where there is no restriction placed upon the voltage drop in track :

such systems suffer in comparative first cost with the singlo-trolley

848. Track return. It is almost the universal custom in elect i

way systems to utiliza one or both rails of the tracks as a return ci i

the generating station. It was early found that the ground itself
adjacent bodies of water constituted a return circuit of such high tv-^'
as to be of little practical use, hence the necessity for a carefully bam
track-return circuit, reinforced by feeders where necessary. Data on 0(3
ductivity and the resistance of standard rails is given in Par. 338 and 341,
349. Rail bonding (Par. 360 to 364) consists in establishing contact, a
to rail, in order to utilize to the fullest extent the conductivity of the rail n
return circuit or as a third-rail. The contact resistance of fish plates IM
great as to amount practically to an open circuit, hence the need of a bona
joint of good conductivity. The question of bonding has largely resol'l^
1402
 I

ELECTRIC RAILWAYS See. 16-350

,tself into the mechanical maintaining a low resistance contact

problem of
1hat will withstand the constant pounding and extreme changes in tempera-
>jre to which the joint is subjected under operating conditions.
i 360. Types of bonds may be listed as follows: a, expanded-terminal
i.onds (Par. 361); b, soldered, brazed or welded bonds (Par. 3621; c, amalgam
> onds (Par. 360) d, cast welding (Par. 362) e, electric welding (Par. 364)
; ; ;

[ thermit welding (Par. 363).

I 351. Expanded-terminal bonds comprise all those which depend upon

• cpanding a soft copper core into contact with the rail through a hole in the

'eb or flange. The size of hole in the rail varies with the capacity and type
'
bond used, ranging from } of an in. to 1 in, in diameter. There are two
!neral tyf>es of expanded terminal bonds.
The Steel-core bond comprises a soft steel centre inserted in a copper
ad and so designed that when placed in the rail and pressure applied, the
pansion of the steel core centre will force the copper head into close con-
ct with the rail. This type of bond has been largely superseded by the
1-copper bond.
Tlie second type of expanded-terminal bond comprises two solid copper
ads or terminals into which is forged a laminated copper conductor joining
etwo. When the bond is in place and pressure applied, the soft copper
, ad is expanded into close contact with the rail.
I Bonds of the expanded-terminal type are designed for use either beneath
I e fish plate or under the flange of the rail, or are made of sufficient length to
I
an the fish plate. Where the conductor joining the terminals is of con-
lerable length as in cross bonding, it is sometimes made of solid copper wire,
t a .stranded or laminated conductor is absolutely necessary where the bond
short and must conform to rail deflection at the joint.
352. Soldered boiuls have been introduced successfully in some cases.
lese comprise a laminated copper conductor terminating in two solid heads
ned to the rail by soldering, brazing or welding. The bond is attached
[
the head of the rail on the outside, or to the flange of the rail. In either
' 36 it is exposed to view, which facilitates inspection and renewals but also
iders the bond liable to theft. It is difficult to obtain a contact by soldering
It will withstand constant vibration, but brazed and welded bonds
uear to be freer from this objection. Where good contact can be secured
accessibility and cheapness of this method of bonding recommends it.
;

353. Comparisonof soldered and expanded-terminal bonds.

ih the expanded terminal and soldered bonds are universally used for
idiiig the track and third-rail of city and interurban electric-railway
teiiis. While the soldered bond is cheaper and has many qualities
ommending its adoption, its use on T-rails laid on surface ties is open to
•
iibjection that it is relatively easy of removal which renders it liable to
ft. Hence the expanded terminal bond, placed beneath the fish plate is
ferable when the rail is exposed.
154. The selection of bonding for a given road depends both upon
rent capacity and contact resistance desired, and is determined by the
' S3of service involved.
156. The contact resistance of a singrle 9-in. 4/0 bond of the ez-
1 idcd-terminal type in good condition, is approximately 0.00003 ohms.
1'! the relative resistance of bonded joints and track itself is approximately
.ven in Par. 356.
56. Comparison of track resistance with bond resistance.
'•
[ile 70-lb. track (2 rails) of 12.5 times resistance of copper = 0.0400 ohms
''§l6 bonding 176 joints at 0.000015 ohms (2 rails) = 0.0026 ohms
.al per mile of bonded track = 0426 ohms. .

t is evident that the joint resistance of a well-bonded rail is relatively

I
compared with the total resistance of the rail itself, but the propor-
I holds only when the bonding is installed and maintained in first class
< dition.
57. Double bonding is resorted to in many instances in order to insure
hof good conductivity in case of failure of a single bond. Where
icbonding is not required to provide additional current capacity in order
^ eep temperature rise within reasonable limits, it is better engineering to

1463
Sec. 16-358 electric railways

install a single bond of sufficient capacity from a temperature rise staa

point and maintain this bonding in good condition. Double bonding is op<
to the objection that one of the two bonds may give imperfect contact at
be practically useless, and such a method of installation usually results
the operation of the road with practically single bonding throughout.
368. Single bonding 'or suburban roads where the service is infr
quent and current demands do not momentarily exceed 1,000 amp., is tol
recommended provided rails are frequently cross bonded and all bond<
joints are regularly inspected and maintained in their original good conditio
369. The heating of bonds will determine the size and number of bom
to be used on roads over which there is a large volume of traffic, and whe
the moving units demand a large kilowatt input, such as trains hauled I
locomotives, etc. Following are given values of temperature rise at ditfere;
current strengths:

Current amperes
Temperature rise deg. cent
 ELECTRIC RAILWAYS SeC. 16-367

almost universal for supply frequencies of both 25 cycles and CO cycles.

The location and capacity of railway substations depends upon the character
of the service and local considerations, but the type of apparatus used is
similar whether the substations are located in the city to supply many small-
car units, or on interurban lines ta supply perhaps but one or two high-speed
oars or trains of several such cars. Synchronous converters are designed
^o operate both three-phase and six-phase, depending upon the capacity
i»nd the frequency of supply. Also see Sec. 9.
367. Field of application of the compound converter. The use of
;he compound synchronous converter with series field is restricted more
especially to those systems in which the station output is very fluctuating,
iiueh as would be experienced in substations feeding suburban and inter-
irban railway systems, or city systems in which heavy trains accelerate at
1 rapid rate. The compound winding of converters is generally adjusted
or fiat compouiuling at GOO volts throughout the range in load, and this is
Jest secured in conjunction with inductive coils placed in .series with the
'ransformer secondaries. Artificial inductive reactance is introduced in
iOm))ouud converter substations both in order to secure flat potential on
he direct-current side on all loads and unity power-factor on the alternating
urrent side at all loads.
368. The shunt-wound converter may be used to advantage in sub-
tations supplying city service lines.
'
369. Starting of synchronous converters is accomphshed by one of
liree methods, whicli are as follows; first, direct-current starting through
eostat; second, alternating-current starting by induction motor; third,
Iternating-current starting from transformer taps. Starting synchronous
Dnverters from the alternating-current side with a reduced potential
btained from transformer taps is the recognized method of starting in uni-
ersal use. The advantages of alternating-current starting are cheapness
I installation and a minimum amount of time required to throw the con-
prter into se^^"i(•e, no synchronizing being necessary (see Sec. 9).
370. Equipment of synchronous converter substations is generally
i follows: (a) Incoming primary feeder, provided with disconnecting switches
id lightning arresters: (b) high-tension oil switch and current transfornier;
:) stop-down transformer; (d) synchronous converter; (e) control panels of the
ind or automatic type.
871. Ratio of conversion of synchronous converters varies somewhat
th the construction of the machine, being in general as follows: three-
lase converters, 370 volts alternating-current to 600 volts direct-ciurent;
t-phase converters, 430 volts alternating-current to GOO volts direct-
jrent. Machines having long pole arcs have a somewhat higher ratio of
aversion than those of shorter pole arcs. In order to provide for the dif-
Cnces in types of machines and also for the varying drops in the primary
jtribution .syst to which rotary converter substations are connected,
is customary to provide five primary taps of 2.5 per cent., each in the step-
''wn transformers.
872. Step-down transformers are of several types, as follows: air-bl st,
|f-cooled, oil-cooled and water-cooled. Each of these several types of step-
m transformers can be built three-phase or single-phase; in the latter
6 three transformers are required for either "Y" or delta connection with
:h converter.

73. Comparison of transformer cooling methods. Air-blast trans-

mers, when used, require the construction of an air chamber over which
!y are placed and from which they receive air at a pressure of from J2 oz.
1 oz. per sq. in. Air is supplied by a duplicate motor-driven fan feeding
lO the air chamber. This type of transformer is not designed for poten-
k above 33,000 volts. For higher potentials and for small transformer
ts oil is resorted to for cooling by a variety of means.
The design of the small self-cooled (oil) transformer is especially adapted
the smaller sizes, owing to its cheapness. For larger sizes it becomes
essary to cool the oil, either by means of a cooling coil placed in the trans-
ner and through which water is circulated, or by providing means of
ulating the oil itself through an outside pipe coil, in order to reduce its
perature. In general, oil-cooled transformers in all sizes and at all
tials are preferred to the air-blast type.

1465
 1

Sec. 16-374 electric railways

374. The general arrangement of substation apparatus is somowiot

similar in all cases, as such buildings are usually designed for the pui
In general the wiring scheme consists in providing tlie shortest and
direct path from the incoming primary lines to the outgoing direct-cu!.. i.!
feeders, and the interior wiring scheme is carried out with the object ii
view of preventing any crossing of circuits or doubling back upon themselves
375. Duplicate apparatus in a substation may or may not be installed
depending upon local reiiuirements and is generally omitted from portabh
and automatic substations. The manufacture of synchronous converters
transformers, and general substation apparatus, has been so far perfectec
that failures in such apparatus are very infrequent. It is, therefore, quitr
customary to install substations containing but a single converter and se'i
of transformers. This practice is largely influenced by local requirements o
absolute continuity of service, and also by the development of the so-calleci
portable substation, wliich is now furnished in units as large as 1,060 kw. j

376. Portable substations, so-called, comprise a synchronous converter

step-down transformer, and switch-board apparatus, mounted in a box ca
and intended to be moved from place to place, as occasion demands, thu
serving as a reserve to be used in case of failure, or overload of any substaj
tion in the system. A compact arrangement of the apparatus involved ha;
been perfected, so that portable units of 1,000 kw. capacity can be com
structed. The complement of apparatus is identical with that in the stand
ard substation, and the arrangement provides sufficient room for the opera
tor. As such substations are not intended for any fixed location, they ar
designed to be connected to an unbroken primary circuit. The convertei
may be compound-wound and provided with an equalizing switch, so tha
a portable substation may serve as an auxiliary to a stationary substatio
in case of extreme sustained overload. Portable substations are often aut<
matically controlled.
377. The automatically controlled substation may be defined j

one in which the function of starting and connecting the machines to tl

line whenever there is a demand for power, and finally shutting them dow
as the demand for power has been satisfied, are all performed in their propi
sequence without the assistance of an operator, either locally or from adj;
cent stations. The automatic equipment does not require a separate alte
nating-current feeder to each substation and is, therefore, essentially di
ferent from a remotely controlled system with separate feeder to
machine, and in which the operation, both of starting and stoppii
machines, is performed by an attendant in the station from which the i

is supplied. Since attendants are eliminated and the light load losses save
it is practical to use a relatively large number of substations with consequei i

improvement in the voltage regulation. Daily visits, supplemented by

careful inspection once a week, or once every two weeks, are recommendeij
The control has been developed for units as large as 5,000 kw. j
378. Wiring diagrams of automatic substations of 1,000-kw. capa j

ity, of both Westinghouse and General Electric design are given below
Fig. 116 and Fig. 117 respectively.
379. Operation of automatic substations. Substations wi<li
attendants may be made to start automatically in a number of wii.\
pending upon conditions to be met, but for the most part they fui
through the agency of some form of remote control, or automation
means of a voltage relay, which closes its contacts at some predetn
value of reduced trolley voltage. This scheme is followed by the M t

house Electric & Manufacturing Co. for starting their automatic sub.'^t^
(see Fig. 116). Circuits thus set up cau.se other control relays to fun.ii
in such a way as to close the oil circuit breaker, the normal field switcti
n

the alternating-current starting switch. Synchronism and polarity

indicated by a polarized motor relay which, in case of reverse polarity, cau: ,

the polarity of the machine to be corrected by field reversal accomplish j

by normal and reverse field switches which open and close automatical j
The control for the field switches consists of a small direct-current magi, t
switch energized from the direct-current end of the converter through C(\i
tacts made on a small drum switch driven in a counter clock-wise (hrecti I
by the polarized motor. The field of the polarized motor relay is fixed 1
means of a permanent magnet, while the polarity of the relay armature 1,

1466 I
 ELECTRIC RAILWAYS Sec. ie-379

loomea that of the machine, for the reason that, during starting, it is directly
connected across the direct-current terminals of the converter. It is thus
I
obvious that the relay armature will not rotate until the machine has pulled
into step, since prior to synchronism it is receiving alternating current of a

*/W«y^*^ a

^^^pwrv\^Jlr**-^g-Y^^'^^lf^'^fl^^i^^
^('-/•Itoqt DC ^•ay
Sec. 16-379 ELECTRIC RAILWAYS

of themachine is definitely and instantly fixed by means of a small exciter

The converter is cushioned on the hne tiirough load-limiting resistances
This resistance is also used for overload protection. High-speed oircuii
breakers may be provided for feeder control. A motor mechanism is pro-

vided to raise and lower the br\ishes on interpole converters, as required. |

5-kw. transformer is used to supply energy for operating the control and t
oil circuit breakers. A suijcrvisory and remote s(;lective control of the seve^
converters and feeders may be provided, giving the load despatcher infltaj
14C8
 ELECTRIC RAILWAYS Sec. 16-380

'j^ntrol ofthe machines, and an answer back to indicate the condition. This
trol is operated over the usual telephone line. Then through interlocks,
are closed in proper sequence, the brushes are lowered to the com-
,ch
lutator by a motor-driven device and the direct-current switches close.
his connects the machine to load through current-limiting resistance which
then shunted in steps by switches closed through the functioning of accel-
ating relays. The machine remains in operation until cut out of service
y the light load control.
580. Protective features of automatic substations. Protection is
•ovided by induction type, single and polyphase relays which prevent the
ation from starting under any abnormal conditions of alternating-current
ae voltage, such as low voltage, open phase or reverse phase. This same
"pe of relay causes the station to shut down on unbalanced phase conditions;
the trouble is inside of the station, a lockout relay prevents restarting,
Idle if the unbalanced phase condition is outside of the substation, the auto-
atic equipment will function to bring the apparatus into service as soon
the line is restored to normal. Bearings are equipped with thermostats
:

hich, in the case of a hot bearing, lock the machine out of service until the
ntacts of the thermostat device have been reset by hand. A thermal relay
otects the machine from overheating on overload. A direct-current
verse current relay, an overspeed device, induction type alternating-cur-
Qjt overload relays, a thermostat to prevent overheating of the direct-
Trent current-Umiting resistance, and a lockout relay which locks the
uipment out of service in case of failure of any part of the apparatus are
her protective features.
581. Advantages of automatic substations. The use of automati-
Ihr controlled substations extends the economic limits of direct-current
stems of distribution. The voltage regulation, the efficiency and capacity
a distributing system can be improved by automatically controlled units

\
400 600 800 1000 I20O
1400 1600 1800 20OO
Size of Units
in Kw.
Fio. 118. —Cost of substations for electric railways.

Hsrspaced between existing hand-operated substations. Reserve apparatus

land-operated stations can be equipped with automatic control and used
threat advantage when relocated in these interspaced substations. The
a antages claimed for automatic substations are as follows: (1) Reliability;
saving of light-load losses; (3) saving in wages of attendants; (4) increase
_(

iiioth normal and overload capacity. Relatively small machines will not
bnjured when exposed to severe overloads, and this is of importance to
etric railways since any number of trains may be blocked near a small
;.Bistation and started without injury to the apparatus. (5) They permit
gl voltage regulation with only a small amount of feeder copper; (6) a
n inising means of electrolysis mitigation; (7) as the number of substations
reased, the chance of an interruption in service caused by the shutdown
-ingle station is greatly lessened and the need of spare apparatus is also
I'd; (8) quick starting in case of load demand. The standard time
arting and taking load is 35 seconds. Quick restarting in case of shut-
due to the interruption of high-tension lines. (9) Relatively small
inexpensive buildings, since no provision need be made for the operator.
f relative cost of
automatic and manually-operated substations is shown
"ilg. 118.
fllir 1469
 '

Sec. 16-382 electric RAILWAYS

RAILWAY SIGNALING
B7 AZEL AMES, S.B.
Engineer, Keriie Insulated Wire and Cable Co. Associate, American Inslitii
o/ Electrical Engineers

GENERAL I

382. Introduction. The development of this art has been and is '

rapid that space does not permit either its historical treatment nor coj
sideration of details of design of apparatus or circuits. Little relating J
working data or costs is given in this discussion as these change almost frci
day to day, but only such material as will assist the otherwise well-qualifii
electrical engineer who may have to do with signaling, to understand son
of the principles and practices involved (for further details see Bibhograpfc
Par. 427 to 429). i

383. The salient features of present-day signaling practice are i

recognition of the electric track circuit as the only adequate means of sigr
control, the rapid increase in the use of alternating-current apparatus, Jt
the attention being given to automatic train control. ;

Interlocking is treated at some length in subsequent paragraphs, becai;

of the lack of information thereon in the publications commonly read
'

electric railway men, and the increasing electrification of steam roads havi
yards or junctions requiring its use.
384. Railway signaling maybe defined as the art of regulating railw
train movements by means of the indications displayed by visual signals
fixed location placed along the roadway. Its practice requires a knowle*
of railway operating methods and rules, of train acceleration, running c*
ditions and braking (Par. 203) and a thorough understanding of the relati^
of track to traffic. Its function is to prevent loss of life or property fri
collision or derailment and to save time and money by minimising congesti
and assuring the use of trackage to maximum capacity. Its prolaW
include the proper layout and subdivision of tracks to handle an existiof
assumed traffic with the greatest safety and least delay; the determinat
of the extent to which visual signal indications shall supersede written oO
munication in the regulation of train movements; the design, construct
and installation of the necessary signal apparatus; the training of engine l
train crews in the understanding and observance of signals; and the org
ization and training of the necessary personnel for the maintenance (
operation of the various installations. t

385. Capitulation of railway operation. The tracks of a railr

bear two distinct relations to the trains or cars running thereon, they se
as channels of traffic and they also serve as structures for carrying rolling 10
on flanged wheels. In order to define the relations of train movementi
each other and to the definite channels of traffic provided by the main tea
and sidings of a railway, rules are established, special instructions issued
time-tables containing train schedules are prepared. These written insti
tions are supplemented by train orders, communicated from the tram
i

patcher by telegraph or telephone. As the density and particularly the ap.

of traffic increase to a point where either danger or delay result
from
multiplicity of train orders required, it becomes necessary to supply
needed directions for train movement by means less cumbersome and I

liable to error. The means usually employed comprise the visual indicfttl
of fixed signals (Par. 387 and 388).
'

, ^ .. :i
The conditions of the track as a structure, namely, whether the raiu
intact and the switches so set that a continuous path for wheels is provl
over a given route, can hardly be indicated by rules or written orders i

may be readily denoted by signal indications. |

386. Classification of railway signaling. Isolated signals are ?«'

times used to protect particular points such as curves, stations or switl
where the view is poor. Train-order signals at stations indicate to tij
whether or not there are orders to be delivered. Aside from the.s6 two t1
of installation, signalling naturally divides itself into two classes, nam
interlocking (Par. 404 to 420) and block signalling (Par. 421 to 426).

1470
 ELECTRIC RAILWAYS Sec. 16-387

TYPES OF FIXED SIGNALS

387. Targets and lamp signals. In American practice, targets of
arious forma are generally used to show the positions of switches except
here the latter are operated from interlocking plants. The signals generally
'sed in interlocking practice, as well as for train-order signals and block
gnals, are of the semaphore type, in which an arm, composed of a casting
a which are mounted colored glasses called roundels ancf a wooden blade,
pivoted about a horizontal axis so that it may be moved either manually
by power, from a horizontal posi-
on to an inclined or vertical position
order to indicate the various condi-
ons affecting the movement of trains.
11 fixed signals, in addition to their
ivy indications, are provided at night

th lights of prescribed colors. With

maphore signals, one light is pro- 8IsiuU Tr&nsmisslon Line
ded for each signal arm and is so
iced that as the arm moves to its
rious positions, the different colored
isses will move in front of the lamp
show red, yellow, green, white or
rple light as desired. For block
naling, signals of the enclosed-disc
je are used to some extent, although
! semaphore affords more distinc-
e indications.
Light signals," consisting of electric
?ip8 placed behind suitably colored
•sea and so shaded as to permit
it colors to be distinguished by
^ have been introduced to some
fent on electric railways, and have
recently developed to consider-
efficiency.
?he American Electric Railway As-
Committee on block signals
iation's
recommended as the preferred
of signals for electric roads, a
aphore moving in the upper left-
d quadrant as viewed from an ap-
iclung train; the arm in the hori-
position indicating "Stop;" in
|tal
inclined position, 45 deg. upward,
m^
eating "Caution;" and pointing
Jcally upward, indicating "Pro-
—
Fig. 119. Standard location of
signal (right of track)
It is considered that less inter-
nee with the view of signals by pole lines adjacent to the track will thus
It than if the steam railroad practice of displaying the blade to the right
le mast, as seen from an approaching train, is followed. This is based on
American practice of locating signals to the right of the track which they
im (Fig. 119).
18. The usual type of automatic signal is the electric-motor
Aphore. The arm comprising the blade and the casting carrying the
red glass roundels is pivoted near the top of the post, the shaft to which
connected carrying a crank or arm connected to the "up and down" rod
ed inside of the tubular iron signal post. The lower end of this rod is
jected to the mechanism proper which consists of an electric motor and
mg whereby the motor transmits motion to the up and down rod. A
ce called a " slot" which comprises a magnet and latch is so arranged that
,e magnet is energized the motion of the motor is
transmitted to the
^ arm, but if the magnet is de-energized, mechanically disconnects
fnotor from the up and down rod allowing the signal to go to the stop
ion by gravity. Signal mechanisms of the "top-post" type have the
^)r mounted adjacent to the semaphore-arm shaft
at the top of the post,
le "slot" mechanism is generally provided with two windings in multiple,
)f low resistance being in series with the motor while the latter
is clearing

1471
 1

Sec. 16-389 electric railways

the signal. A circuit controller actuated by the signal arm when the lati
has moved to the clear position, opens the circuit of the motor and li
resistance winding, leaving the high-resistance coil energized in order to h(
the latch carried by its armature. This latch, by connecting the driving a
driven members of the "slot," holds the signal in the clear position. The hi
resistance of the holding coil reduces the current required for holding t
signal clear, to a fraction of that required to clear the arm using the mol
and the low-resistance coil in series with it. Motor-driven signal niecha
isms are of many types and are designed for either upper-quadrant or low<
quadrant movement of the arm; for operating in three positions; or (
operating, by selection, one of two or three arms on a post. Motor-driv
signal mechanisms are used for operating either black or interlocking signi
with direct or alternating current at from 10 to 110 volts.

TROLLEY-OPERATED SIGNAL SYSTEMS

389. Operation and reliability of various systems. On many elect
railways the volume of traffic is not sufficient to warrant the expense
employing signalmen to operate manual or controlled-manual block signs
Hence signal systems have been developed which are partly manual a
gartly automatic. In such systems the manual operations are performi
y the motormen or conductors of cars or trains, and the automatic ope)
tions are performed by the action of the trolley upon circuit controllers, i

tuated by the passage of the trolley wheel. A very large variety of sigi
installations of this character have been made, varying from exccodinc
simple ones to those involving a greater complication of apparatus a
circuits than are necessary in complete automatic blocking. Many of th<
are very crude and of decided limitations both as to safety and the r
tent to which they facilitate traffic. Many of them depend upon step-l
step devices which count the number of oars that enter a block and coi
them out at the other end of the block. A number of these systems hi,
been quite highly developed as regards their apparatus. The relays a,
magnets as a rule require no separate source of energy for their operation 1
use the trolley current. None of them can be considered as ofiering a deg j

of safety or reliability approaching systems employing the track ciici

which is the only means so far known in signaling whereby a train is i

tinuously active in maintaining its own protection (Par. 892).

390. Relative value. By strict obedience to the prescribed rules
their observance, without which no signal system is of value, trolley-opers)
signals afford a very considerable degree of protection and facility to trsi
Their relatively low cost makes them available where other systems ooi
not be installed on account of the expense involved.
391. Tendency toward abandonment. The development of
light signal to a point where its day indication can be observed at distaD|
sufficient for stopping high-speed cars, enables it to be substituted for >

electric-motor semaphore, resulting in a material reduction in the cost

automatic block-signal systems employing the continuous track circuit,
additional apparatus and line wires which it has been found necessary to i

to the trolley-operated signal systems to make them furnish the s^

information as that given by track-circuit signal has, on the other hs'
tended to increase their cost. The costs of the two systems are thus rapi
approaching each other, and the tendency toward the adoption of tra
circuit signaling for electric railways is increasing to such an extent thati
latter bids fair to supersede the trolley-operated signal at no distant date.|

THE TRACK CIRCUIT .

392. "A track circuit may be defined as a metallic path for an eleC
current formed primarily by both rails of a pre-determined length of tn!
the terminating rails of which are electrically separated from adjacent r^
a source of electric energy for maintaining a difference of potential betwi
the rails; and one or more devices (relays) so connected in the circuit ft
respond to variations in the potential difference between the rails produ
by train action upon them" (J. P. Coleman). This invention, than wlj
none other has contributed more toward safety and despatch in rail]
transportation, is to-day the only medium recognized as fundaments
safe by experts in railway signaling, whereby a train or any vehicle tl»e|

1472
 ELECTRIC RAILWAYS Sec. 16-393

may retain continuous and direct control of a signal while occupying any
portion of the track protected by the signal. •
393. The function of the closed' track circuit is to maintain a relay
Jiormally in an energized state; the influence of the train upon the rails is to
ie-energize this relay by shunting or short-circuiting the generator, a process
'IS effectively accomplished by a single car as by a train of considerable length.

Dn account of the low insulation resistance between the rails, due to the
ionductivity of the ties and ballast, track circuits are susceptible to influence
rom excessive leakage of current from rail to rail. This leakage may ap-
jroach, in its effect, the value of current conducted by the wheels and axles
if a train. Obviously a failure of the source of energy or a break in the
ircuit, whether in the rails themselves or in the wires connecting the battery
ir the relay to the rails, produce the same effect upon the relay sis if a train

fere running or standing on the rails. The contacts carried by the armature
4 the track relay (Fig. 120), which are closed only when the relay is energized,
re included in the circuits which control the signals themselves. These
lircuits must be closed in order that the signals may indicate "proceed."
:'hus the track circuit conforms to the principle demanded by sound practice,
iwnely, that the signals shall invariably display the "stop" indication when
aeir operating or controlling energies cease to be active from any cause.

R
Sec. 16-396 electric railways

the road-bed and relay when the track section is unoccupied, as well as 1

avoid extravagant discharge through the train axles when the section
occupied. Where the common gravity battery is the source of energy, tl
general custom on steam roads, its internal resistance is sufficient and i
external resistance need be provided. On account of the variation in intern
resistance with gravity batteries, however, it is more general in present stea:
railroad practice to use storage batteries with a fixed resistance in seri
therewith.
896. Track relays. In common steam-railroad practice relays of fro
4 to 9 ohms resistance are employed on track circuits varying in lengt
from about 60 ft. as a minimum, to about 6,000 ft. as a maximum. A ce
tain minimum air-gap between the relay armature and its pole pieces mu
exist in order to prevent undesirable effects from residual magnetism. J
this air-gap is increased when the armature falls away under the action <

gravity, to permit the contacts carried by it to open, it is evident that mo:

current through the relay will be required to lift the armature than to ho^
it in position against the pole pieces, once it has been raised. The usu
4-ohm track relay requires about 70-mil amperes through its coils to pick i
the armature; it will drop away when the relay is shunted sufficiently to redui
this current flow to about 35 mil-amperes.
While much included in the foregoing paragraphs is only applicable
direct-current track circuits for steam roads, it may be considered importa:
as indicating the principles upon which the track circuit has been develope
These principles should be thoroughly understood by the electrical engine
as a preparation to the consideration of track circuits for electric railwai
(Par. 397). -|
TRACK CIRCUITS FOR ELECTRIC RAILWAYS 1

397. Effect of bonding. Wherever, as isthe case in most electric raj

ways, adjacent rails of the track are bonded together to form the b(!
possible conductor for the return propulsion current, it is obviously imprt
ticable to divide these rails into sections. electrically separated from ea
other by insulated joints, as is done where track circuits are used for signali;
on steam railroads, unless means can be provided for the return of the pi
pulsion current without affecting the action of the track-circuit re&i
In case the track is laid upon a metallic structure one rail can be bonded'
the structure. Other considerations may render one rail of each tra
sufficient for the return of the propulsion current. One of the rails m-
therefore be left electrically continuous to serve as a return for the prop
sion current, while the other is cut into sections of proper length for thr ci
trol of the signals. It is evident, if generators and relays are conncot
across the rails at opposite ends of each track section, that in the event
the conductance of the power rail becoming reduced as a result of defect
bonding, the return current would divide so that a sufficient amount o)
might flow through the signal relays to energize them even when a eon-
erable shunting effect was produced upon them by a train in the bio
furthermore, the drop in potential, due to the return of power current o
the considerable length of rail included within the limits of the block, mv,
be sufficient to energize the track relay illicitly.
398. To prevent improper operation of track relays by diff<
of potential between the track rails produced by the propulsion n
itself, the track relays for electric roads are designed to be immune
effects of the propulsion current. This may be accomplished eitl
protecting them against excessive flow of current with series resistanr.
in some cases, providing a shunt path around the relay for the proji
current, or by so designing them that they will respond only to the
of alternating current. Where alternating current is used for proiM
the relays are made to respond only to an alternating current of a dir
frequency than that used for propulsion.
399. Field of single-rail track-circuit system. Whenever,
yards or terminals, the number of tracks that can be bonded togetlu *

sufficient to afford an adequate return for the propulsion current, one ra [

each track being assigned to signaling, the single rail track circuit is
'

Fig. 126 shows a single-rail

*

for the return of the propulsion current.

circuit as installed at an interlocking plant, with a desirable arrangenn
the apparatus.
1474
 ...

ELECTRIC RAILWAYS Sec. 16-400

400. Impedances and power-factors per 1000 ft. of track

(Union Switch and Signal Co.)

Total capacity
2 No. 6 copper. .

1 No. 8 iron
1 No. 6 copper
2 No. 6 C.C.-40
per cent.
2 No. 6 C.C.-30
per cent.
2 No. 8 iron
Total capacity.
2 No. 6 copper. .

1 No. 8 iron
1No. 6 copper
2 No. 6 monnot-
40 per cent.
2 No. 6 monnot-
30 per cent.
2 No. 8 iron.. . .

Total capacity . .

2 No. 6 copper.
1 No. 8 iron
1 No. 6 copper
2 No. 6 monnot-
40 per cent.
2 No. 6 nionnot-
30 per cent.
2 No. 8 iron . . . .

Total capacity.
2 No. 6 copper. .

1 No. 8 iron
1 No. 6 copper
2 No. 6 monnot-
40 per cent.
2 No. 6 monnot-
30 per cent.
2 No. 8 iron . . . .

Total capacity.
2 No. 6 copper.
1 No. 8 iron
1 No. 6 copi^er
2 No. 6 monnot-
40 per cent.
2 No. 6 monnot-
30 per cent.
2 No. 8 iron

Resistance of bond wires

J
No. 6 copper
.No. 6 coppyer and 1 No.
firpn.
Jo. 6 nionnot-40 per cent
6 monnot-30 per cent
8 iron
Sec. 16-401 ELECTRIC RAILWAYS

401. Two-rail track-circuit system. Where it ia not practicable to

give up one of the track raila for signaling purposes, the conditions existing
in the single-rail track circuit not only apply, but means must also be provided
whereby both rails are electrically continuous for the return of tlie propulsion
current, but are electrically separated from adjacent rails at the ends of each
track section in so far as the signaling track-circuit current is concerned.
This is accomplished through the means of impedance bonds which
consist of a few turns of heavy copper wound about and insulated from a
laminated-iron core. The connections of impedance bonds to the rails is
so made that the traction current has no magnetic effect on the bond,
grovided an equal amount of current is flowing in each of the rails. If,
owever, more current is flowing in one rail than in the other, there will be
a tendency to saturate the iron core and thereby reduce the impedance of
the bond. This effect, which is called "unbalancing," is hmited by intro-
ducing an air-gap into the magnetic circuit, the bonds ordinarily being
designed to stand 20 per cent, unbalancing without a decrease of more
than 10 per cent, in impedance. The size of the bond to be installed ig.
dependent upon the amount of current it will be obliged to carry, the
impedance for which it must be wound (this being more or less dependent
upon the length of the track circuit) and the amount of unbalancing to be
cared for. Where good traction bonding can be maintained, unbalancing
can be assumed less, hence a smaller size of bond can be employed.
402. Energy supply for signal system. Power for the operation of the*
track circuits and signals on an electric railroad may be taken from trans-
formers connected directly to the propulsion-power transmission system.
More frequently a signal-power line is provided to furnish this current at a
reduced voltage, the necessary apparatus being located in the substations :

For the track circuits, the potentials of the transformer secondaries range i

from 2 to 8 volts, and for the operation of the signals and line circuiti ;

generally from 55 to 110 volts. For any installation it is necessary to con- :

struct a power diagram. The current consumption of the track circuits

relays, alternating-current signal motors, indicators, lights, etc., will vary ii
each installation and will be affected to some extent by the volume of traffii
which governs the number of switch and signal movements per day. Thi
energy consumption data for each piece of apparatus is furnished by th'
maker.
403. Track-circuit constants. The data in Par. 400 show the im
pedance in ohms per 1,000 ft. of track and the power-factor of steft
rail of various weights and lengths for frequencies of 24 and 60 cycles and wit"
various types of bonding. In all electric-railway practice the current:
carrying capacity of the bonds provided would be assumed equal to that <
the rail itself. The data given for the other types of bonds apply to singk
rail circuits for electric roads or to steam-railroad conditions.

INTERLOCKING
404. Definition and field of application. Interlocking plants ai
assemblages of switches, switch-operating and switch-locking devices, an
signals so interconnected that their movements must succeed one anoth)
in a predetermined order. They are used at crossings or junctions of on
line with another, at drawbridges, at cross-overs, or in yards where tl t
number of switches or the frequency of their movement is so great that hni
operation would not be sufficiently rapid nor safe. At railroad cro-ssin
or drawbridges, signals are frequently interlocked with derailing devices, tl
protection being required by the laws of several states provided trains ;i

permitted to pass over without stopping.

406. Classification. Interlocking plants are either mechanical
power-operated. In those of the former type, pipes or wires connect t
switches, locks, signals, or other operated units with the levers that openi
them. In the latter type, pneumatic cyUnders or electric motors are rr
nected to suitable "lock and switch movements" or signal mechanic
Electric circuits controlled by the levers in the interlocking machine regu
the operation of these .switch and signal mechanisms.
406. Mechanical processes involved in interlocking. In all uit'
locking macliines the desired sequence of operations is secured by means of t

1476
 8

ELECTRIC RAILWAYS Sec. 16-407

dogs, bars, or tappets which constitute the mechanical locking. These parts
are so interrelated that if any lever in the machine is reversed (that is,
moved from its normal position), the act of the signalman in unlatching this
lever will cause parts of the locking so to operate that no other lever in the
frame can be moved which would allow a train movement conflicting with
the train movement controlled by the first lever. The mechanical lock-
ing between the levers of the machine also provides for the movement
of the levers in proper sequence when the route for a train is being set
1' up, by assuring that the switches must first be properly set and must then
be locked in the proper position before the signal governing the route can
be cleared.
1^ 407. Prevention of switch operation while train is passing. Long
i
bars of steel, called detector bars, are held by clips along the outside of the
head of the rail at switches. They are of a length greater than the maximum
distances between any of the adjacent wheels of a train, and are so mounted
that they must move upward above the level of the top of the rail before the
switch may be unlocked. They generally are mechanically connected to and
operated simultaneously with the lock plungers which pass through holes or
notches in the lock rods of switches to lock them in proper position. This
method of proteofion may prove unsatisfactory owing to the increasing width
of rail heads, and, especially on electric roads, the relatively narrow wheel
treads of which may fail to engage the top of the detector bar while the vehicle
13 jiassing over it. Electric track circuits controlling electric locks mounted on
the levers of the interlocking machine itself, are becoming quite generally
u.sed as a substitute for detector bars in the prevention of switch movement
while trains are passing.

Machine
It t.«Ten for 12 Si^&lfl
Interlocking Plan i •• .• 1 Svitch Eud ; DcnlU
• 8 F.P.Le.
and 2- WoTlting LeTen
2 S pare Spaces 7,1
Locking Sheet £4 Lever Fnme

E«v*rM
Sec. 16-409 ELECTRIC RAILWAYS

ft. from the crossing. On the single-track interurban line the derails would
be located in accordance with legal requirements or the necessities of the
locality. The derail in the siding is placed at fouling distance from the
main track. The single switch and each of the derails is locked with a
facing-point lock and provided with a detector bar. At the crossing itself
a detector bar might also be used to prevent the clearing of signals for a
movement on one line while an engine or a detached car was standing on the
crossing.
The "home" signals, governing through movement, and the "dwarf"
signals, governing reverse movement and the movement from the siding, are
located about 50 ft. from the points of the der.ails. One home signal in the
single-track Une has two arms: the upper governing the through or high-speed
movement, while the lower governs the low-spieed diverging movement on to
the siding. Distant signals, used to regulate the approach to the home sig-
nals, are placed from 1,.500 to 4,000 ft. in rear thereof.
The mechanical interlocking mochine has a 24-lever frame, the assignment
of the various levers being shown in a table. A locking sheet is also given, in
which a circle drawn around any lever number indicates it to be in the re-
versed position. Levers, the numbers of which are not within a circle, are in .

their normal position. ,

i

409. Power interlocking. In mechanical interlocking (Par. 408) the \

rigidity and mechanical continuity of the connections between any switch,

lock, or signal, and the lever
Interlocking StatlunJUmitfl that must be thrown
r order to move it, is depended
High Yoltagf upon to accomplish the de-
sired motion of the unit. It
Primary
is assumed, in other words, if
Transformer BbleMinK Impedanoe

n kA/V| the lever operating a facing-

I
^
(Indicating)
point lock on a switch la
moved through its full stroke,
that the lock
its full stroke.
is also moved
It is further
assumed that the movement
of the lock lever may be de-
I— Multipie Condaotor
Bonded to ali Common
pended upon to
mechanical locking
release the
in the
Eelum Rails interlocking machine and
Cermit the proper lever to
e moved that will clear the
\ Oommon Return Rmil Bonded to desired signal and permit a
all other Common Return Kails train to pass over the switch,
Fig. 122. — Single-rail track
plant.
circuit at an which is locked by the fac-
ing-point lock previously
interlocking
mentioned.
410. Return indication. In power-operated interlockingnxachines
where the only physical connections between the operated units and the
levers in the machine consists of 'insulated conductors which carry small
currents, there is no direct assurance, when a switch lever is operated, that;
the switch itself has moved at all. To insure that it is moved properly and
will be locked in a position corresponding to that of the lever, all power-r
interlocking systems provide for what is called a return indication. When the
lever in the interlocking machine is moved to cause a switch or signal to be,
thrown, it cannot at first be moved through its complete stroke nor through'
sufficient length of stroke to release the mechanical locking between itseli:
and conflicting levers. The lever can only be moved far enough to closei
the circuit which will cause the desired motion of the switch that is to be
operated.
The switch mechanism itself must complete the throwing of the switch
must completely lock it in the proper position, and must then close contacU:
that will cause current to flow back to the lever in the tower and energize f
magnet to release a dog, which has heretofore limited the motion of the lever-
After this dog has been released the operator is permitted to complete thd
stroke of the lever, which will in turn release the mechanical locking betweei
the switch lever and others in the frame, allowing movement of the latter to b(
made in proper sequence.
1478
 ELECTRIC RAILWAYS SeC. 16-411

411. The Electric-Pneumatic Interlocking System of the Union

Switch and Signal Company. This system is so named because com-
pressed air is employed to shift the switches and signals, while electricity
18 used to control or direct the admission and discharge of pressure to
and from the cylinders by which the shifting is performed. The sys-
tem is comprised of the following elements: an air compressor (prefer-
ably in duplicate for reserve) which, especially in terminal station plants,
is often used for many other duties; a main air pipe extending through-
out the interlocking system with branch pipes connecting it with each switch
and signal to be operated; a double-acting cylinder at each switch which,
through a motion plate, operates and mechanically locks the switch in its
two positions by movement of the piston; a slide valve for each switch
cylinder used to direct the pressure to cither side of the piston in order to
effect the movement of the latter (Par. 412); a single-acting cylinder, operat-
ing the signal (Par. 414); a source of energy (Par. 416).
412. Arrangement and operation of the switch- cylinder slide valve
(Par. 411). There are two miniature cylinders employed for shifting
the slide valve; two pin valves, operated by electromagnets, control the
movement of the pistons in these cylinders. Mounted over the slide valve
8 a third small cyUnder, also under the control of a magnet and pin valve.
The piston of this small cylinder engages with and locks the slide-valve against
'movement save when the magnet is energized and the pin-valve is actuated
\jO permit the pressure to withdraw the lock.

I
By energizing and de-energizing the magnets in proper sequence, the slide
/alve is unlocked, shifted, and again locked by the operating and indicating
jitrokes of the lever. During this process each movement of the valve is
iccompanied by a corresponding unlocking, shifting, and relocking of the
witch through the resulting operation of the switch enforced by the piston
if its own cylinder. The three magnets are directly connected with contacts
hat are actuated by one of the levers in the interlocking machine, a separate
.ire being used for each magnet.

413. Indicating system (Par. 411). In the latest development of this

ystem, a circuit controller is employed which is actuated by each switch
movement. When the switch is in one of its extreme positions and locked
here, this controller allows a current of given polarity to traverse two wires
''hich connect it with a polarized relay in the tower. Conversely, when
ae switch is moved to and locked in its opposite position, a current of the
,^Terse polarity is sent through the relay. During transit of the switch, and,
I fact, when the switch is in any position and unlocked, the controller
.itablishes a shunt or short circuit between these two wires. This short
rcuit renders the apparatus immune, at such times, to the effects of any
'.ray current which might energize the relay. The circuit controller or
ile changer, the relay in the tower, and the two wires joining them consti-
ite the fundamental elements of the indication system of this type of power
•terlocking.
! The polarized relay frees one or the other of two electrit; locks which,
•evious to this action, has been arresting the complete movement of the
.itch lever in the tower. This incomplete movement of the lever from
dl " normal " or full "reverse " involves about two-thirds of its total move-
lent. After the partial movement has been made, the complete lever move-
Sent, can be consummated only in the avent of one of the two locks which
eviously restricted the lever's movements becoming energized. The
ergiiiation of this lock can occur only when the indicating relay has shifted
armature in response to a reversal of current in the two indicating wires,
1

.ch reversal is only possible when the switch has fully moved and become
:ked in response to the incomplete lever movement. After the lever has
en released, its movement may be completed. Following the processes
reived in a final execution of the lever stroke, the mechanical interlocking
tween switch and signal levers permits the shifting of the proper signal
er for train movements over the switch. The current supply to each and
;ry signal leading over the switch is carried through other contacts of
indicating relay, so that unless the relay is energized in the proper polarity
the lever and the switch correspond precisely in position, no signal what?-
1

r can be given over that switch. Conversely, should a signal be properly

ired for train movement over a switch, by reason of switch and lever

1479
 -

Sec. 16-414 ELECTRIC RAILWAYS

corresponding in position, any interference causing a partial or full reversal

of either lever or switch would immediately cause the signal to move to the
"stop" position. This, the most necessary feature of modern power inter-
locking practice, gives protection against careless, ignorant, or maliciouB
shifting of a switch by improper means from the position to which it wat
properly moved by the lever.
414. A single-acting cylinder operates the signal (Par. 411), the
signal being held at and returned to the stop position by gravity. Cora-
pressed air is admitted to and discharged from this cylinder by means of a
pin valve operated by an electromagnet, as in the slide-valve cylinder of the
switch mechanism. When energized, this magnet causes the pressure to
depress the piston, thereby clearing the signal. When the magnet is de-ener-
gized, the air escapes from the cyUnder and the signals move to the "stop'
position by gravity. Failure of the signal so to move, from any cause, pre-
vents the signal lever from being restored to normal. This incomplete level
stroke prevents the mechanical release of all levers operating switches wliicb
lie within the route governed by the signal.
To restore a signal to normal in regular operation the signal lever is moved
partly toward normal, where the lock arrests its further movement unti
the latter becomes energized by the closing of the circuit when the signai
assumes the stop position.
416. The source of electric energ^y (Par. 411) for supplying the curreni
required for the operation of the pin-valves and locks of the system, consisti
usually of a storage battery of 7 cells in duplicate. This battery has a lov
ampere-hour capacity and may be charged from any local lighting or powe:
circuit. If direct-current service is obtainable, a resistance is conncoiet
in series in order to obtain the desired charging voltage. Charging may b'
accomplished from an alternating-current line by use of a converter (See
9), a motor-generator set, or a rectifier (Sec. 6). Magnets of 130 ohm-
resistance will operate pin valves controlling air at from 60 to 100 lb. pressur
and are supplied with energy from a 12-volt battery. Two magnets ar
converted in serie.s. Alternating-current magnets may be substituted fo
direct-current magnets in the operation of pin valves, and the system oper
ated without batteries. Cylinders of areas and strokes appropriate fo
the work to be done, are used in various arrangenxents of switches and frogs
A constant current rate of 5 amp. at 12 volts being sufficient for a larg
terminal plant. *

416. Electric interlocking system of the Union Switch & Signal Cc'
In this system of interlocking known as the Type "F" the machine f"i ;

control of the switches and signals is very similar to that used in the ol
pneumatic system. The switches and signals are driven in this c:i>i
electric motors or solenoid magnets working through suitable gears and r:uii
For the control and indication of a signal, the circuit is similar to that use
in connection with the electropneumatic interlocking (Par. 411), excej,
that instead of a magnet actuating a pin valve, there is a relay or othi
electromagnetic device controlling either an electric motor or a solenoid ar
suitable holding magnet at the signal. The function of the motor or solono
is to move the signal arm from the "stop" to the "clear" position. Win
the arm comes into the "clear" position it is cut out of the circuit nit
matically, and the holding coil is energized in order to maintain the sit'inl
the clear position so long as the circuit is complete. When the cin
opened the signal moves to the "stop" position through the action ot
ity. The signal-indication circuit is in all respects the same as in cK
pneumatic interlocking.
For the movement of a switch, current is supplied by a stroke of the 1<m
to an electromagnetic controlling device at the switch. Here the controlln
device consists essentially of an electrically operated circuit control'-
arranged that with the lever in one position the controlling dcvi(
establish a circuit to operate the switch motor in one direction; wherens
the lever in the other position, the connections will be reversed, so t)i:
motor will run in the opposite direction. At the end of the stroke -^
switch in either direction, a circuit controller is actuated in such a m
as to cut the motor o>it of circuit, and partly establish connections S<>' •

opyeration of the switch in the opposite direction when the proper lever mo^
ment is subsequently made.

1480
 ELECTRIC RAILWAYS Sec. 16-417

The switch-indication circuit is in all respects the same as in the electro-

pneumatic system. A polarized relay controlled by a pole-changer at the
switch used.
ia The pole-changer is so arranged that in any position except
the extreme ends of stroke, when the switch is locked, the wires feeding the
polarized indication relay are short-circuited and disconnected from the
source of energy.
Direct-current at a potential of 110 volts is suppUed to the switches and
dgnals through heavy mains running from the storage battery in the tower.
Current from these mains is fed to the motors through the electrically oper-
jted circuit controllers as already explained. These controllers are ener-
^zed by current from the same battery at the same potential. The resist-
mcc of the various pieces of apparatus is such, however, that the current
lowing in these control circuits is very small. Consequently the wires from
the interlocking-machine levers to the units need never be of larger size than
s required for mechanical strength. For the indication circuits, the poten-
tial is cut down by resistances, one at each switch or in series with each
signal indication circuit, therefore the indication wires may also be small,
rhe selection of signals and their control by the various switches in a route
8 accomplished through the polarized indication relays and combination
contacts in the same manner as in electropneumatic interlocking.
417. The electric-dynamic indication interlocking^ system of the
Seneral Railway Signal Co. (see Par. 418 to 420). The source of power
lonsists of a storage battery
vith its charging unit, which LunpCmae
urnishes current at 110 volts
^r the operation of the switch
;.nd signal motors. Power-
ontrol apparatus is intro-
luced betweem the battery
,nd the interlocking machine,
li'he interlocking machine
proper is provided with levers, Bafetj Magnet
5f the sliding type, built gen-
ially in units so that any lever
•ith its safety and indication
•lagnets, accessories and hous-
,ig may be removed from the
•ame without disturbing adja-
,;nt levers. The mechanical Looking Phitei
the vertical type,
'icking is of
le tappet bars being moved
ertically by the horizontal
.otion of the levers through
'le medium of a cam slot in
ich lever. Fig. 123 shows a
oss-section of a unit-lever
pe electric interlocking ma-
line, and Fig. 124 shows
Fig. 123. —Electric interlocking machine.
pical circuits for this interlocking system.
Alternate levers have their handles turned upward and downward. Beside
e interlocking machine, the system comprises the switch and signal
schanisms with their operating and indicating circuits and means for the
evention of unauthorized movement of any unit. Each switch or derail is
rown and locked by a switch and lock movement driven by a series-wound
ect-current motor. Two wires are used for this control, one for the
rmal and the other for the reverse operation. These same wires are used
indicating purposes, the normal control wire being used for the reverse
lication and the reverse control wire for the normal indication. The
cuit is connected to the main common-return wire at each switch.
The control circuit for each switch and signal is broken through the proper
ck and line relay contacts, also through the proper lever, switch and sig-
circuit controller contacts, so as to insure that conditions are safe and
iper for the movement of the respective switch or signal. In small plants
breaking or selecting of the control circuits is done at each unit; in large
1 nts it is usually the practice to do all selecting of circuits at the control
'tion, by means of repeater relays, which affords greater simplicity and a
iiimum amount of wire.

1481
 n '

Sec. 16-418 ELECTRIC RAILWAYS

418. Indication locking (Par. 417). The distinctive feature of the elec-
tric-dynamic system is in its method of "indication locking," which is of th<
so-called dynamic type, in that the source of energy used to supply curreni
for the operation of the switches and signals is not used to supply curreni
for energizing the indication magnets in the interlocking machine. Ii
this system, whenever a switch has completed its movement and has beei
locked through the operation of the motor which drives it, the completion o:
its operation disconnects the motor from its load, permitting the former t<
operate as a generator under the momentum which has been acquired by th«
armature in operating the switch and lock. The current generated by thii
motor acting as a generator, is transmitted back to the interlocking machmi

Fia. 124. — Circuits for electric interlocking system.

where itactuates the indication magnet and permits the completion of tb'
lever stroke. In the case of signals, no return indication is necessary when
signal is operated to give the "proceed" indication. In this system, tb
signals are so connected that they return to the "stop" position by gravit;
The counterweight, which has been raised during the operation of clearing tt
signal, overhauls the motor armature in being restored by gravity to i
normal position; this causes the armature to generate the indication curren
The indication current in this system being generated by the momentum ',

the motor, can only be secured after the operation of the unit driven by tj
motor. As the energy for the indication is developed at one end of tl'
circuit and the indication magnet is located at the other, a cross betwet
wires tends to prevent indication. When the momentum of the motor hi
sufficiently diminished, the indication current ceases. The generation
indication current serves also to retard the motor which renders unnccessai'
the use of buffers or other special means for stopping the movement of tl
apparatus without shock. Protection against the operation of the motors t

foreign current is furnished by the indication circuit which forms a lo

resistance path around the motor.
419. Protection against the effect of crossed wires (Par. 41?
In this system, protection is provided for the prevention of the unauthoni
movement of any switch or signal resulting from the improper application
energy to its circuit by a cross between wires. This protection is secund
cutting off current from the unit itself in the event of a cross. A small polar..
relay is connected in each switch or signal circuit through which all opera
and indicating currents must pass in such a direction as to maintain the n 1

contact closed. Conversely, currents from un.authorized sources siich

crosses are compelled to pass in the opposite direction, thus openmK
'

on
All these relay contacts are in series and control the
<

polarized relay.
of the retaining magnet of a circuit breaker on the operating switchbo.i

1482
 ELECTRIC RAILWAYS Sec. 16-420

This circuit breaker controls the supply of current from the storage-battery to
the interlocking machine. A check on the integrity of the cross-protection
jsystem is secured by having all necessary contacts and connections either on
jclosed circuit or used in each process of operation and indication so that
failure of any individual member would prevent operation and indication and
would be promptly detected. A necessary feature in this system as in other
electric interlockings, is the prevention of indication current from reaching
any lever, while the unit normally under the control of that lever is being
operated due to crossed wires from other units which may be indicating at the
moment. This protection is secured by means of a safety magnet located
,^low the indication magnet on each lever, Fig. 123. The windings of this
safety magnet are included in the operating circuit of the lever, and its mag-
netic properties are so proportioned to those of the indication magnet, that
f both were energized at the same instant, the safety magnet would over-
lowcr the indication magnet and prevent the latter from lifting its armature
o trip the indication latch in the lever. Normally, the armature of the indi-
;ation magnet rests upon the poles of the safety magnet. As a further safe-
juard, an indication selector is provided with its magnet coils in series with
he safety magnet and in the control circuit. The function of this selector
s to prevent possible receipt of an improper indication during the interval
)etween the time that a lever is moved to the opposite position from that
»hieh it previously occupied, and the time the movement of the switch
aechanisin itself is complete.
420. Operation in reverse direction ( Par. 417) . The last portion of the
troke of the locking plunger at the switch mechanism operates the pole-
;
hanger which cuts off the operating current and puts the circuits into action
)r an operation in the opposite direction. The breaking of this circuit de-
nergizes the safety magnet, permitting the indication magnet to be energized
y the current generated in the revolving motor armature. The operating
rciiits are so designed that the magnetic control of the pole-changer insures a
jrrespondence in position between the lever in the machine and the operated
ait outside.

THE BLOCK SYSTEM

til. Classification of block signaling systems. The block system
royides for the division of the railroad into lengths of track of defined
mits, over which railway trafBc is controlled by block signals. Block
gnals and block-signaling systems may be classified as follows: a (Par. 432),
Amtal, in which the signals are operated by hand on orders or information
^ved by telegraph or telephone; b (Par. 423), controlled manual, in which
>me means (generally electrical) are employed to necessitate the cooperation
the signalmen at both ends of a block in order to clear the signal admitting
^rain on the block; c (Par. 424), automatic, in which the signals are power-
>»ated and are controlled by the trains themselves through the action of
ieir wheels upon electric circuits constituted by the rails of the track.
Ich signals indicate the presence of a train or single car or engine in the block
fd also such conditions as the presence of a broken rail, an open switch
' a car standing upon a siding within fouling distance of the main track.
4SS. In the manual block system, when a train has passed into any
|pck, the signalman sets his signal to the "stop" position behind it, and noti-
I the signalman at the entrance to the next block of the approach of the

ia. This second signalman in turn consults his record to see if the signal-
|lua controlling the entrance of the third block has reported the passing of all

«Ub out of the second into the third block which previously have been
lotted to the second block. If such is the case, the signalman at the
pance of the second block will set his signal to indicate "proceed" and
jtmit the approaching train to enter the second block. Such a system
jeessitates the use of very carefully prepared rules and is dependent for
jwfe and successful performance entirely upon the watchfulness of the
nttlmen and the precision with which they perform the duties prescribed
I
them by the rules. On single-track railroads, this system necessarily
>eives the protection of trains against opposing movements, and is in
^ral supplemented by the issuance of train orders from the despatcher,
ma provide for the meeting of trains at other times or stations than those
^ofied in the time-table.

148S
Sec. 16-423 ELECTRIC RAILWAYS

i23. In the controlled-xnanual block system, the levers by which

the signals are operated are provided with electric locks. The solenoids oi
these locks must be energized to release the levers before the signals may be
cleared for the passage of trains. Circuit controllers, called "block instru-
ments," are placed in each block station and are so interconnected elec-
trically as to require that a definite sequence of operations be performed by
the signalmen at both ends of each block before the signal at the entrance oi
a block may be cleared. Signal bells and keys are provided for the trans-
mission of code signals between adjacent signal stations. Adjuncts such at
indicators and electric track circuits may also be installed, whereby th€
presence of a train in the block may effect the electric locks in such rnannei
as to insure its own protection. The variety of apparatus and circuits
necessary to afford varying degrees of protection are too diverse to b«
herein enumerated.
424. The automatic block system, which is continually coming intc
more extended use, has its foundation in the electric track circuit. Its cost
of construction and maintenance is relatively high. Its operating cost ii
low as compared with any system requiring the constant presence of signal-
men on duty, as would be necessary with manual or controlled-manua
systems. The principles of the electric track circuit are considered at somi
length in Par. 392 to 403 incl.
Seldom can automatic block signals be controlled by track circuits alone
Such conditions as the existence of a number of track circuits in one bloc)
and where the position of one signal arm must be made to determine the posi
tion of another, require the use of line-wire circuits, each of which is provide"
with its own source of energy and one or more relays for direct control c
the local signal circuits themselves. These line circuits include contact
carried on the armatures of the track-circuit relays; the latter thus indirectl
control the signals through the medium of the line circuits.
The line circuits frequently pass through circuit controllers actuated b
the switches in the tracks, so that the opening of any switch in the bloc
will directly open the signal line circuit. Line circuits for the control (
signals are always so designed that the source of energy is located at one 63
treme end of the circuit and the relay at the other extreme end of the circui
any controlling devices are being located between these extremes. This i

important in order to prevent the possibility of false "clear" indicatidr,

from the supply of energy to the line relay in case crosses or grounds occn
on the circuit.
SlgnarPower nne

Fia. 125. — Simple field circuits. A. c. automatic block. Steam propulsio

426. Typical application of automatic block signalling. Fig. 1;

shows diagrammatically in simplified form, an application of line-circir
control to an automatic block signal. The track is paralleled by a po\»
line feeding transformers which step the voltage down for the
track circu
and the line circuits. The line circuit begins at one side of the transtoriij
control
secondary; is carried thence through a contact operated by a circuit ;nc
on the side track switch; thence through a contact of a track relay bio(
through the contact of the track relay of the other section of the
from this point to the coils of the line relay located in the mechamsm ci

1484
 ELECTRIC RAILWAYS Sec. 16-426

)f the signal; and thence back over a common wire to the other side of the
ransformer secondary.
Fig. 125 also indicates how a portion of one of the track rails on the siding
s insulated from adjacent rails and bonded to the opposite main track rail.
if a train or car on the siding moves to within fouling distance of the main

rack, it will thus shunt the relay of the track section in which the switch is
seated.
426. Automatic block siRnalling applied to electric railways.
'ig. 126 shows a simplified form of automatic block signal circuit for one
rack of a double-track railway using direct-current propulsion and two-rail
Iternating-current track circuits, the signals themselves being operated by
irect current from batteries. Alternating-current track relays are gener-
Uy of the vane, galvanometer or induction-motor type. In the first named,
•a aluminum sector revolves between the poles of a C-shaped laminated core,
1 which the winding is placed. This winding is connected across the rails
•
the track circuit and receives current through the rails from tiie traosfonner

Trolley or Third Rail

^.C. Signal Mains

A.C. Signal
Generator
Fig. 126. — Typical circuits. Power supply for a.c. track circuits.

the other end of the track circuit. The galvanometer type of relay has a
of fixed coils energized from a local source, and a movable coil energized
m the track circuit. In the induction-motor type of relay both the track
I the local windings are fixed, and the rotor is made to revolve by phase

ilacement in the current of the two windings. In all types the moving
oaber carries or actuates contacts through which are controlled the circuits
trolling the operation of the signals themselves.
'he transformers which supply energy to the track circuit also supply
rgy to the local windings of motor-type track relays together with any
or secondary relays necessary in the circuits; in addition they supply
llsr for the operation of the signal mechanisms proper. The transformer
«dary windings supplying current to the track rails are generally pro-
id with a number of taps, so that the voltage impressed on the track may
begulated to suit the length or characteristics of the track circuit. The
siadaries are naturally provided with series resistances which limit the
c ent output when the secondary
is short-circuited by the presence of a
c iu the block.

BIBLIOGRAPHY— RAILWAY SIGNALINQ

!7. Association reports. Comparatively few books have been written
Oi he subject of railway signaling, most of the available data being found
iBeriodical technical literature, in publications of engineering societies,
*> in the bulletins and catalogues issued by the manufacturers of signal
iliratus. The last mentioned source is voluminous, as such publications
JIM frequently issued and contain much valuable technical information.

1485
 '

1
Sec. 16-428 ELECTRIC RAILWAYS

The following associations regularly publish committee reports on signalin

Publications are listed below their names as follows:
American Electric Railway Association, 29 West 39th St., New York, N.
Proceedings, Standard Rules.
American Railway Engineering Association, 900 So. Michigan Avi
Chicago, 111. Bulletins, Manual of Approved Practice. (This applies most
to steam railroad signaling.)
American Railroad Association, Signal Division, 75 Church St., Ne
York, N. Y. Journal (Quarterly), Manual (Standard plans and specific
tions). Index to Signal Literature.
The rule book of the American Railroad Association, containing the stan
ard code of train rules, block-signal rules and interlocking rules, is the bai
from which almost all other rule books have been developed. The School
Railway Signaling, Utica, N. Y., publishes text books and corresponden
courses of study in railway signaling.
428. Periodicals. The following are the principal periodicals which de
with signaling: Electric Railway Journal, 239 West 39th St. (weekly). Ra
way Age, Woolworth Bldg., New York, N. Y. (weekly). Railway Sign
Engineer, Transportation Bldg., Chicago, 111. (monthly).
429. Dictionaries and published bibliographies. The most impc
tant compilation of information on signaling is the signal dictionai
second edition, 1911, Railway Age Gazette (now Railway Age), Woolwor
Building, New York, N. Y. By far the most complete bibliographies of si
naling are the following:
Index to Signal Literature, Vol.I, October, 1910, Railway Signal Associ
tion,Bethlehem, Pa. (now American Railway Association, Signal Seetio
75 Church St., New York, N. Y.).
Bibliography on Block Signals for Electric Railways, pages 227 to 2£
Proceedings of the American Electric Railway Association, 1913.

ELECTROLYSIS OF UNDERGROUND STRUCTURES

BY ALBERT F. OANZ
Late Professor of Electrical Engineering, Stevens Institute of Technology, Fello
American Institute of Electrical Engineers

REVISED BY ALBERT S. RICHEY

Consulting Engineer, Fellow of American Ijistitute of Electrical Enginee
Professor of Electric Railway Engineering, Worcester Polytechnio Institute

NATURE AND CAUSES

430.Oeneral cause of electrolysis. Electrolysis is defined as chemi
decomposition by an electric current. If the anode by which an elect
current enters an electrolyte consists of a metal which ran combine chemics
with the anions set free by the electrolytic action, then this anode will
decomposed or corroded. This electrolytic corrosion of an anode is w
willbe referred to as electrolysis in this discussion.
431. Stray or vagabond currents. Stray or vagabond currents
electric currents which have leaked from grounded electrical distribut
systems and flow through earth. These stray currents in their path throi
earth may reach underground metallic structures, such as piping syste
and the lead sheathing of cable systems.
432. Stray currents from direct-current electric railways.
the simplest arrangement of electric railways using the tracks as return c,
ductors, the rails are connected to the negative terminal of the generate;-
the power station or substation, and the current returns to tho.>jf:ili
through the rails. Where these rails are in contact with ground, i

this current will shunt through the earth and through undergroum!
lie structures, as is illustrated in Fig. 127. Current will leave the r;u.-
enter the earth at distant points, and will return to the rails m the ncv
borhood of the power station or negative feeder taps. 1

1480 I
 ELECTRIC RAILWAYS Sec. 16-433

433. Electrical properties of soil. Soil when dry has such a high re-
sistivity practically, it does not conduct electric current.
that, Under
ordinary conditions, however, soils contain considerable water with various
salts in solution, making them electrolytic conductors. An electric current
iherefore passes through soil by electrolytic conduction. The resistivity of
ioils varies within very wide limits, depending upon the amount of moisture
ind salts present. Most values lie between 300 and 30,000 ohms per centi-
neter cube, with the average soil within the more narrow limits of 1,000 to
,>,000 ohms per centimeter cube.
434. Distribution of potentials in rails and earth. For the simple
irrangement illustrated in Fig. 127, the distribution of potentials is shown
n Fig. 128. The following assumptions are made in the development
f these curves: (a) the negative bus bar is connected to the rails at the
iiower station by an insulated cable, with no other ground connections;
b) the line extends in one direction only; (c) the load is uniformly distributed
,ver the line; (d) a pipe of uniform resistance lies in the earth parallel to
'hese rails: (e) the resistance between the rails and pipe is everywhere the
',»me. With these assumptions, the current in the rails will increase uniformly
-om zero at the end of the Une to its greatest or total load value at the power
tation O. Taking the negative bus bar and this point O as the datum or lero
f potential, the potential of the rails is represented by the parabola OI.
'he voltage OD is the total rail drop. There will be a neutral point A' in
;
=ie rails at a distance 0.42 of the total length of the line from the power
1
nation where these rails are at the ground potential. Between the power
;
ation and N, the rails are negative with respect to ground, and current
;
-nds to flow from ground to the rails; while from A'' to the end of the Une E,
I
le rails are oositive with respect to ground, and current tends to flow from
|ie rails to the ground.

^
jBBBBBaf,

' /^ ^/^.^/^^
Fig. 127. —Conditions contributing to electrolysis.

Distance Iroio Power Station

Fig. 128. — Distribution of potentials.
Jhe pipe of Fig. 127 will have a potential shown by the curve A-H
in
128. Between O and N the pipe is positive, and this, therefore, con-
Btes a positive region. Conversely, between A' and E
the pipe is negative
this is a negative region. The current flow between pipe and rails is
SBTtional to their potential difference. The total current flowing from
 ;

Sec. 16-435 electric railways

rails to pipe, shown by the shaded area N-I-H, is equal to iW total curhil
flowing from pipe to rails, shown by the shaded area 0-A-N. The currei
on the pipe will be a maximum at the neutral point jV, and will be zero at th
power station and at the end of the line. The greatest negative potential C-;
of the pipe, with reference to the rails, will be at the end of the Hne; and tb
greatest positive potential 0-A of the pipe will be at the power statioi
For the case assumed, the greatest positive potential will be twice the greatei
negative potential. The total rail drop 0-D is equal to the sum of the thr«
voltages, the greatest positive pipe potential 0-A, the greatest negative pip
potential C-D, and the voltage drop on the pipe A-C. This voltage drop o
the pipe is a measure of the current flowing on it, and is therefore a measui
of the danger from electrolysis to which the pipe is subjected. If no cu:
rent flows on the pipe there will be no voltage drop on it, and the pit
potential curve A-N-H will coincide with the horizontal line B-G. Tt
gositive and negative potentials of the pipe referred to the rails will howevt
e increased, which shows quite clearly that the magnitude of the voltaj
between pipe and rails is not a measure of the danger from electrolysis.
Where there are rail networks and underground piping networks, tl
potential distribution curves are correspondingly altered, but follow tx,
general trend of those given in Fig. 128. !

435. Where electrolysis occurs. Wherever electric current leaves

1

metal to flow to soil, corrosion from electrolysis is produced. In positii

regions stray currents generally flow from underground structures and co
rode these structures by electrolysis. The greatest density of current lea
ing will generally occur where the positive potential is highest, namely,
the neighborhood of the power station; here the destruction by electrolys
is usually most severe. Underground structures may also be damaged I
electrolysis in regions where they are negative to the rails, and far away froi
any return feeder connections, because of currents shunting from one set
underground conductors to an adjacent set. A case frequently met in pra.
tice is where underground gas or water service pipes cross near lead cab
sheaths to which they are positive, and where current flows from the servi
pipes through soil to the cable sheaths, damaging the. pipes by electroly.',!
even though they are negative to adjacent trolley rails. If there are higij
resistance joints in a pipe line carrying stray electric current, current
mi:
shunt around these joints and produce corrosion on the positive side of ti "

joint.
436. Nature of corrosion of cast iron by electrolysis. When ci.
iron is corroded by electrolysis, the oxides of iron mixed with graphite usuaJj
remain in place, leaving the outward appearance of the pipe unchanged. 11(:
material resulting from electrolysis of cast iron usually has the consistency -fc

hard graphite and possesses little mechanical strength. The oxide of ir 1

together with the surrounding soil frequently prevent noticeable leakage of e i

metal
or water, even when corrosion has extended entirely through the j

the pipe. In such cases a physical examination with a test hammer iii

required to establish definitely whether the pipe has been damaged by elif
trolysis Current generally leaves iron pipes for soil from localized are:
In the case of cast iron corrod'
resulting in localized corrosion of the metal.
electrolysis, the graphitic residue usually can be dug out with
a km
by
exposing pits in the pipe.
437. Nature of corrosion of wrought Iron and steel by electrolys
Where electric current leaves a wrought-iron or steel pipe for soil, i

oxide of iron resulting from electrolysis is diffused through the soil. I

action is also generally localized, resulting in pits which eventually
may
entirely through the wall of the pipe.
438. Belative danger from electrolysis to cast-iron and wrougl
th
Iron or steel pipes. For a given current leaving an iron pipe for soil,
is practically no difference in the rate of corrosion
by electrolysis am(
The electrical resistivity of cast iron
cast iron, wrought iron and steel.
anrt
however, about ten times as great as that of wrought iron or steel,
usual lead joints in cast-iron pipes have a resistance which is
many tii
screw-coupling joints usual with wrought-iron and ^
greater than the
pipes. For these reasons a given voltage drop through earth will, in k
much smaller current to flow on a cast-iron pipe than o
eral, cause a
wrought-iron or steel pipe, thus practically making cast-iron pipes
mucn i

1488
 ELECTRIC RAILWAYS SeC. 16-439

abject to electrolysis than wrought-iron or steel pipes with screw-coupling

:)ints. With ordinary conditions of soil, and with current densities of less
lan 5 amp. per sq. ft. (about 5 milliamperes per sq. cm.), as ordinarily
mnd with stray railway currents leaving underground piping for surround-
lig soil, iron is oxidized by electrolysis at the rate of approximately 20 lb.
i kg.) per year for every ampere leaving the pipe. Under some conditions,
articularly with very small current densities, the corrosion may be as much
< 40 per cent, greater, although usually not to exceed 10 per cent, greater
lan the theoretical rate, while with larger current densities than the above
te corrosion may be as low as 20 per cent, of the theoretical rate. The
nount of corrosion produced by electrolysis is independent of the applied
}ltage, except in so far as this voltage determines the amount of current
*wing.
4X9. Corrosion of lead and tin. Where electric current leaves lead or
'»d alloyed with a small percentage of tin to flow to surrounding soil, the
tetal isoxidized by the electrolytic action, forming white or yellow salts.
le theoretical rate of oxidation of lead by electrolysis is approximately
lb. (34 kg.) for every ampere leaving the lead in one year. The actual
^y vary from the theoretical rate, as in the case of iron. Where lead-
eathed cables are drawn in clay conduits, stray current may flow from the
We sheaths to water in the conduit or to the damp conduit itself. In
ph cases pittings are usually produced at the lower surfaces of the cable
eaths. Owing to the thin walls usual with lead cable sheaths, together
^k the high electrochemical equivalent of lead, such cable sheaths are
maged by electrolysis far more easily than are iron pipes.
ELECTROLYSIS SURVEYS
'

H40. Nature of survey. The principal measurements generally made in

'electrolysis survey of an underground pipe or cable system are as follows:
voltage measurements between the pipes or cable sheaths and the rails (Par.
',); b, voltage measurements between the pipes or cable sheaths and other
ierground metallic structures (Par. 441); c, measurements of current
iving on the pipes or cable sheaths (Par. 442). In order to be able to com-
tely judge the electrolytic condition of an underground metallic system
1to be able to decide upon remedial measures, it is necessary in addition
uake measurements of rail drop and of the resistivity of the soil in various
1 ts of the system.

41. Potential survey. To make a potential survey, potential differ-

es between the underground structures and rails are measured at a num-
I
t of points along every street where these structures and electric railway
t;ks are located. With lead cable sheaths contact is made directly on
tse sheaths in manholes. With underground pipes contact may be made
I means of service pipes, hydrants
or drip connections. The connections
I i for the potential measurements
may be tested for continuity by means of
simmeter momentarily connected between the contacts with a dry cell in
»es if necessary. Where there are a number of underground metallic
Bictures which may be affected by electrolysis, it is desirable to make
8 ultaneous measurements of potential difference between the rails and each
hese structures, and from these results to compute the potential differ-
e !3 between each pair of structures.

.**• Current survey. To determine the current on a pipe or cable

8 ith, the drop between two points on a continuous length of
pipe or sheath
isieasured by means of a miUivoltmeter. From tables of pipe and cable
81 .th resistances, the strength of current
may be computed by Ohm's law.
''^^sonable accuracy is required, the resistance of a pipe or cable
llT should
Wth be measured instead of computed from its dimensions. In
II case of lead cable
sheaths, the drop measurements usually can be made
inianholes where the cables are exposed. In the case of iron pipes, the
m voltmeter leads must be connected directly to the metal of the pipe on
w,h current is to be measured; and no joint must be
included between the
I' contacts. Service pipe connections cannot be used for such current
«rminations. Temporary contacts are conveniently made by means of
a irpened piece of steel
rod, fastened in a wooden handle, with connecting
«*i soldered to the rod inside of the
handle. For permanent connections
"' a can be used at any time for measuring
drop on the pipe without again

1489
 .

Sec. 16-443 ELECTRIC RAILWAYS

exposing the pipe, rubber-insulated wires may be soldered to brass plui

and these screwed into the pipe; the wires are then brought to the stre^
surface, preferably inside of the curb, and the free ends left in drip or servii
boxes. It should be noted that small potential differences, such as 0.1 mil
volt or less, may be caused by local galvanic or thermal action, and ca
should therefore be taken that such observations do not lead to erroneoi
conclusions.
Current measurements on pipes or cable sheaths frequently are made ;

two or more stations simultaneously in order to determine whether there

a gain or a loss of current between the stations. This is the most rcliafa
method of determining localities where current is leaving the structure ai
where corrosion may be taking place.
443. Instruments. Milli voltmeters for measuring drop on pipes >

cable sheaths should have as low a millivolt range and as high a resistance i

practicable. Moving-coil permanent-magnet instruments of the WesU

type having zero in the centre of the scale are the most suitable for this wor
The millivoltmeter can be conveniently combined in one instrument with
voltmeter for the potential measurements. These instruments may 1

obtained with resistances of 600 ohms per volt and even higher where nece
sary. Convenient ranges for such a combination instrument are 5, 50 ai
500 millivolts, and 5 and 50 volts. Ordinary shunts adjusted for 50 mil
volts drop can also be used with this instrument. Convenient ranges f
such shunts are 5, 50 and 500 amperes. Recording instruments having tl
same ranges as above noted can also be used for obtaining 24-hr. records, I
means of which the characteristic variations of a potential difference or ol
current may be obtained. Such recording instruments with 1-hr. clocks a
useful also for recording potential differences and current in cases whei
due to infrequent service, it is necessary to take readings for periods of fro
} hr. to 1 hr.
444. Measurement of earth potential. It is possible to trace t.
path of stray current through earth by measuring potential differenq
between points in the earth. When iron rods are used as electrodes 1

making contact with earth an error may be introduced, where the volta
measured is small, due to a possible difference in the polarization volta^
at the two electrodes. This polarization voltage may be eliminated
using a non-polarizable electrode, developed by Dr. Haber. With this elj
trode electrolytic contact is made with soil by means of a zinc sulphi,,
solution contained in a porous cup; the potential lead is connected to a ttt
rod dipping in the solution. With this electrode the contact resistance is v<;
high, so that a zero method and not an indicating voltmeter should be uf;
for the potential measurement. This makes the method very troublesome
ordinary electrolysis testing, where the voltages to be measured genera,
fluctuate constantly. For this reason this electrode is useful only in vi*
special cases. For description of the non-polarizable electrode see the pajt
by Haber and Goldschmidt listed in the bibliography. I

446. Measurement of earth current. It is often desirable also:

measure directly the flow of stray current through earth. This can
done by means of the Haber earth ammeter, which consists of a wooden fra"
supporting ^wo copper sheets insulated from each other by a plate of mica
glass. Insulated copper wires connect the two copper sheets with .

ammeter. To use the frame, the two copper plates are coated with a pa^
made of copper sulphate and a 20 per cent, sulphuric-acid solution for i

purpo.se of equalizing polarization voltages. A wetted piece of parchm»

paper is then laid over the paste, and the remainder of the frame is filled »'
If the frame be buried in the earth with its plane normal to the di:
•

soil.
tion of the current flow, the ammeter wiU indicate the current which in
i.s

cepted by the buried frame. This earth ammeter is well suited for mensm ;

current flow between a pipe and earth. For this purpose the fr /
buried in the earth near and parallel to the pipe. By using a ri
instrument in connection with the earth ammeter, the characteristn
tions of the current leaving a pipe can also be dctorminrd, and in this ^.^

identity of the current can often be established. For description of tin

ammeter see the paper by Haber and Goldschmidt listed in the bibliog: ,

446. Physical examination. From a study of the results of a go" '

electrolysis survey, it is possible to determine in what regions curreDi

1490
 ELECTRIC RAILWAYS Sec. 16-447

aving an underground system. Excavations then may be made where

toent is leaving, and the exposed structures may be tested with a hammer
^effects of electrolytic corrosion.

PREVENTION OF ELECTROLYSIS
447. General description of different methods. The methods which
»ve been used to minimize electrolysis from stray railway currents may be
vided into three classes: a, the insulation method (Par. 460 to 462),
Mch is intended to increase the resistance of the path of the current through
irth; b, the drainSige nxethod (Par. 463 to 466), which removes the cur-
at from structures by metallic connections or bonds between these struc-
res and the railway return circuit; and c, the return- feeder method
'ar. 456 to 468) which reduces the voltage drop in the grounded rails.

448. Brief description of double-trolley systems and where used.

ouble-trolley railways may be provided with positive and negative over-
ad trolley wires as used for example in Cincinnati andHavana; with posi-
'e and negative conductors in underground conduits, as used on the sur-
!e lines on Manhattan Island and in Washington, D. C; or with separate
lulated third and fourth rails for the positive and negative conductors,
used on the Metropolitan District Railway in London. Where both sides
such circuits are insulated from ground, there can be no stray earth cur-
its and no electrolysis.

449. Objections to double-trolley systems. The principal objection

thf underground double-trolley system is the very high cost of installa-
n, which makes this method practicable only in densely populated dis-
ts. The principal objections to the double-overhead-trolley system are
high cost of installation and the complication resulting from two over-
id trolley wires, especially at crossings and where several lines meet and
. on common tracks.
Insulation of rails. Where a road operates on a private right-of-
ISO.
the rails can be practically insulated from ground, and the escape
y,
Kurrent from the rails substantially prevented. For surface or subway
I I'.a this can be accomplished by placing the rails on wooden ties above
i lund and using broken stone for ballast. For lines operating on elevated
! rictures substantial insulation may be secured by fastening the rails on
jden ties and keeping them out of metallic contact with the structure.
'

he leakage resistance of street railway road beds varies greatly with the
I struction. Tests by the Bureau of Standards indicate resistances per
1)0 ft. of track, as follows:
olid concrete ballast and non-porous pavement, 0.2 to 0.5 ohm for single
t k, or 0.15 to 0.35 ohm for double track; clean crushed stone foundation
V er a concrete paving base, 0.6 to 1.5 ohms for single track, or 0.4 to 1.0
c for double track; full crushed stone ballast, with tarvia finish, 2 to 5
1

c is; ties embedded in earth road bed, 1 to 1.5 ohms; open construction,
Ito 15 ohms in very dry weather, dropping to 3 to 5 ohms when wet;
e;pt where specified, the above figures are for single track, and unless
o;rwise stated, the resistance of double track is practically one-half that
ingle track.
iac chloride and other chemical salts, used as preservatives, render ti'cs
n ily conductive, and greatly increase leakage currents. Creosote has
y- little effect on the resistance of wood ties, but a treating material con-
sing of 75 per cent, gas oil and 25 per cent, creosote appears to increase
tlr resistance materially.
•_ Insulation of pipes. Attempts have been made to insulate pipes
il.
Ki earth by paints, dips and insulating coverings. It is doubtful whether
t'e is any instance on record where damage by electrolysis has been effec-
'ily prevented in this way if the voltage conditions were at aU severe. On
tl contrary, there have been cases where efforts to prevent electrolysis of
pis by this means have undoubtedly done actual harm. In general, this
W be said to be due to peculiarities of the coatings used, which cause them
tOiil in spots and thus allow greatly aggravated cases of local damage to
"5 r, in place of the more distributed trouble which would take place if
" lipes were not coated," assuming the voltage conditions to be the same
•n th cases.
Coatings of the thickness commonly used for covering service

1491

ii
Sec. 16-452 ELECTRIC RAILWAYS

pipes and similar structures can hardly be expected to last more than a f<
years, their useful life probably not exceeding a year in the majority
cases. A careful study of the conditions under which the failure of insuiati
coatings under electric stress takes place shows that it is due to the coinbin
action of the moisture and electric stress. The manner in which these coi
ings usually fail under electric stress shows that they may under certa
circumstances increase the trouble from electrolysis. Breaking down-
they do at isolated points, the discharge of current from the pipes is conce
trated at those points and the pitting is likely to be more serious than if t
coating were not used at all.
452. Insulating joints in pipes or cable sheaths. Current flow
pipes or cable sheaths can be practically prevented by using a sufficient nu
ber of insulating joints. A pipe line laid entirely with insulating joints,
uniformly high-resistance joints, has such a high resistance that it is pn
tically free from electrolytic danger. It is sometimes possible to use co
paratively few insulating joints to break up the electrical continuity ot
pipe line, and so to protect the line from electrolysis. Such joints, howev
must be installed only after careful tests have shown that the current is i*

likely to shunt through earth around them and thus produce a conditi
worse than the previous one. This effect depends largely upon the potent
gradient through earth, and also upon the electrical resistivity of the s
In general, the drop across an insulating joint in a cast-iron main she
not exceed 0.1 to 0.4 volt, while in wrought iron pipes the drop should *
exceed one-third of these values; in either case the lower hmit applies
joints located in low, wet places, and having short-leakage paths.
For wrought-iron or steel pipes of small size, the Macallen, the Hamn-
and the Dresser insulating joints are largely used. For large sizes, a flanii
insulating joint as shown in Fig. 129 is often used. For gas or oil pipes, I

fibre has been found a satisfactory insulating material, while for water ptij

Dlscof Issulating Washer of Insulating

Material Material

Bushing of Insulatiug'
Material

Fto. 129. — Insulating pipe coupling. ^

soft sheet rubber is preferred. Where such flanged insulating joiiits arSJ
be used in cast-iron mains, the flanges may be cast as part of the pipe «
water mains various forms of insulating joints employing white pim
for the insulating material have also been successfully used. simiA
of this joint for cast-iron water mains with bell and spigot joints, is im •

placing a short wooden ring between the inside of the bell and the end oi *
spigot to prevent metallic contact between the pipe lengths, and then txX
the joint with wooden staves of clear white-pine wood sliaped to fit the ctr
ture of the pipe. The spigot end of the pipe should have the bead removf
be cast without a bead. Any leaks that develop are stopped with white-
wedges. These joints have been found satisfactory for pressures up to aj
7') lb. per sq. in. (5.27 kg. per sq. cm.). Higher pressures sometimeM
moderate leakage through the pores of the wood; this has been overootaj
dipping the inner ends of the staves in red lend. The staves may a»
reinforced by an iron band clamped sround the spigot end of the pipe. I

ment joints in cast-iron pipes as ordinarily made do not produce mt]

1491a I
 ELECTRIC RAILWAYS See. 16-463

'onnection between the adjoining pipes and may practically be classed with
isulating joints. Metallic contact may be positively prevented by inserting
ring of any cheap insulating material between the end of the spigot and the
iterior of the belJ.
i
453. Drainage method. Since stray currents cause damage only where
J
ley leave metallic structures and flow to surrounding soil, the current may
ie removed by connecting or bonding these structures, by metallic conduct-
fcs, to the rails or to the negatiye return circuit or directly to the negative
[us bar. This is known as the drainage method. The lead sheaths of
.aderground cables form continuous and uniform metallic conductors, and
is possible to protect such cable sheaths again.st electrolysis by bonding
leni to the railway return circuit. Through such bond connections bow-
er only enough current should be drained from the cable sheaths to render
em at the same potential or slightly negative with respect to neighboring
ructures. The effectiveness of drainage as a protective measure depends
)oii the uniformity of the conductor to be protected. The method is
erefore not generally applicable to underground piping systems, because
ese do not form continuous electrical conductors, but are more or less dis-
ntiiiuous networks. While lead-calked joints usually have a relatively
V irsistance, they may develop such high resistances as to make trouble
luited below.
454. Possible dangers from drainage connections. Drainage con-
ctions considerably reduce the resi.stance of the path of stray currents,
Tf liy increasing the total amount of stray current through earth and on
round structures. The danger of local electrolysis damage due to
anting of current around high resistance joints is thereby increased.
r, unless all underground metallic structures are bonded together in

way that where different structures come into proximity, all are main-
at the same potential, damage may result from a flow of current
:

11 the earth from one such structure to another. Also, where, for
•e, drainage is applied to water mains and not to parallel gas mains,
ly large stray currents may flow through buildings by way of the
•

pipes where such pipes are in metallic contact, such as through

leaters; accidental contact between such service pipes within build-
ay also cause arcing, with possible danger from gas leakage or fire.
i.inage connections to underground structures, therefore, should be
id with caution, and in general designed so that only small amounts of
.'ly currents will flow over such connections. Drainage connections to
I
riTound cable sheaths are generally necessary to protect the lead cover-
!'

linst electroly.sis. In the case of pipe systems, however, such drain-

nnections should not be used except in special cases, such as a final
.;re to remove relatively small currents.

55. Reverse-current switches for drainage connections. Cases

E where the polarity of underground structures reverses at times with
•'

t rence to the railway return circuit. Consequently, where these structures

8 provided with metallic connection to the railway return circuit, current
'ild be made to flow to these structures when these are negative in poten-
t To prevent this, automatic reverse-current switches may be used in
with such drainage connections. The action of these switches is to
k this circuit open while the structures are of negative potential, and
while they are of positive potential. Such reverse-current switches
luently used in connection with drainage connections from telephone
'

i6. Insulated return feeder system. Since the drop in potential in

g luled rails is the cause of the flow of stray curreht through the earth,
"'
currents will be reduced in the proportion that the drop in the rails is
'1. It is therefore desirable to use heavy rails of high electrical con-
ity, and to maintain these rails well bonded, so that they form con-
is low-resistance conductors. The next important consideration is to
'': the distance from the supply station to which it delivers direct-current
PCr, so that current is not returned through an excessive length of track;
thnay be accomplished by the use of a number of distributed substations.
I'lly, the current may be removed from the rails by means of insulated
'6 n feeders connected to the rails. These feeders draw current from the
'^- t such
points as are necessary to avoid an excessive potential gradient

14916
^1
Sec. 16-456 ELECTRIC RAILWAYS

in the tracks and an excessive total voltage drop in the tracks. When
is necessary to bring current back from a distant point in the tracks, ii
sonaetimes more economical to employ a negative booster in series witl
return feeder of small cross-section than to make this feeder of cross-sect
large enough to drain the required current from the tracks at the disfc
point. It also may be necessary to install resistances in short feeders. W
such insulated track return feeders, part of the voltage drop is removed fr
the rails and is transferred to the insulated return feeders, from which c

PoaitiTc Feeders >. » k

! t X
-Positive Bus Bars
Power House Generator
Negative Bus Ear-assu med Zero Potential
Negative Booster
Negative Feeders

Fig. 130. — Insulated track-return feeder system.

rent cannot leak to ground. With this arrangement of insulated ret
feeders, the rails may be utilized as return conductors to the extent that
potential gradients and total track drops do not exceed safe limiting vali
A diagrammatic sketch of an insulated track return feeder system proj
tinned for equal drop is shown in Fig. 130. In this illustration it is assui
that the negative bus bar is at zero potential, and that the return-fet
20
 I

ELECTRIC RAILWAYS Sec. 16-457

ated. The reducing stray currents by means of properly

possibilities of
jportioned insulated return feeders as illustrated in Fig 134 was clearly
)wii in a paper by Mr. George I. Rhodes (see bibliography).
The diagram
I IK. 131 is reproduced from that paper.
This shows the relative leakage
-rents with negative bus bar insulated and with various
numbers of insu-
ed return feeders proportioned for equal drop and connected
to symmet-
x[ points in the track. The points halfway between integral abscissas in
131, correspond to a connection between the negative busbar and
;.
the
Is .^t the power station, with a
resistance in the connection proportioned
maintain this point in the rails at the same potential as the other
return-
ier connection points. The unit of leakage current is a.ssumed as the
ount which flows when the negative bus bar is grounded through
:

a negli-
le resistance, the rails being connected to
:
the negative bus bar only at the
1
ver station. In practice each return feeder would actually be connected to
I umber of points in the rails in the immediate neighborhood of the connec-
I points shown. See also Bureau of Standards Technologic Paper No. 52.
57 Examples of installations of insulated return feeder
stems are in common use in Germany and in Great Britain,
V
systems
-ivcn most satisfactory results.
and
In America a considerable number
tsuri systems have also been installed, the most
prominent reported
«mpie being on the subway system of the Interborough
Rapid Transit
^ ""^ ^i"!*^ ^^AL- Description of insulated return feeder systems
; ''^^^X^''^ Springfield,
1 ailed in Ohio, and in St. Louis, Mo., are given in Bureau
o.tandards Technologic Papers No. 27, No. 32 and No. 64.
58. Advantages of the insiilated return
feeder system. This
s em IS intended to reheve the
tracks of current by insulated conductors.
a thus tends to prevent the
escape of current into earth. With a pron^
e kud out return feeder system
and properly bonded tracks, it is possible
a practicable to reduce stray
currents tlirough earth and therefore stray
c ents on underground piping
and cable systems to any desired minimum
V e.s and such currents may be
made so small as to be neghgible.
IICTROLYSIS FROM GROUNDED ELECTRICAL DISTRIBUTION
SYSTEMS
i9. Grounded neutrals in three-wire direct-current systems.
^"^«h t*^^ distribution is on the
oLlhrp^^Hr "^^*''^'i"conductor
''i"°'l'^^-'"^.^'^'*'^"'"
^}a'with
^-^r"^ ^hlarge grounded, are, in Ameri-
Itr^MkrtTl
practice provided such neutral conductors of copper that only
.Kible stray currents are produced from
such systems. T¥is grounding
'^'' intended to serve only as a safety measure, and is not for thf
A L^^"f
pi ose of using the earth to carry current.

i»l!iv«^^®^*'"?^^i**^
^1°^ alternating currents. A large number of
atory tests have been made to determine whether electrolysTis pro-
^
Sr ™nT
t'^f
1^ pl^nfSf- *''"''*'"
"'^^'"^ current flows between a metal and an efectrolyte.
* P'P^ ''l^ surrounding soil. These indicate that
h 1 , of ?^y \% produced; this effect is generally less
*i ""/."r."?^'"!?
t^'^V'"''*''' ^-""Id be produced by a corresponding dire^
u nt^ wfJV.U
current however, electrolytic corrosion is
ufat h^ h .wf.^*'"^ pro-
d--^ --nt.
corroLn electrolytic
oeloli,J1?t|'lS°ft?^'e:S,or'^
... Grounded transformer secondaries. The secondaries
of trans-
grounded for the purpose of preventing a h gh' and
tZul\%1Tf^''
la .rous voltage fr9m e.xisting between
the secondary circuit and ground
"°"nd connections however do not produce flow of currenrto
fround!
rom
^^"^ ""*' ^''°'''i*"«« therefore does not cause
ere"ctrofys°is.

ELECTROLYSIS IN CONCRETE
^°"<''"eje ^^en damp is an electrolytic
»le a
|Wg a^r^e^tt.Viffnf tK same order as damp
resistivity of the conductor
soi When iron is embedded
.

an electric current flo^v^ from the iron to

IfcP^^^I"^*''
Hy
^"-^
Z?.^*' "'''^if^ Vv.*^^
re is produced which in time
theToncrete
electrolytic action. The oxides o iron Sd
may crack the concrete. An exhaustive
1491d
 «
}

Sec. 16-463 ELECTRIC railways

investigation of the effect of electrolysis on iron embedded in concrete

been made at the Bureau of Standards in Washington, and the results of
investigation are published in Technologic Paper No. 18 of the Bureai
Standards. This investigation appears to show that when no chlorides
present, the iron is practically nassive at temperatures below 45 dcg. o
but becomes active at higher temperatures. With large current densities,
heating effect of the current will destroy the passivity of the i ron. W
chlorides, even in very small amounts, are present, however, the iron is aci
at all current densities. These investigations also show that when curi
flows from the concrete to iron a softening of the concrete is produced ('109
the iron, which eventually destroys the bond between the two. Aside fi
slight and usually negligible heating, the only effect which an electric <
rent has on unreinforced concrete is to cause a migration of the water solv
elements. Non-reinforced concrete structures are therefore immune fl
electrolysis trouble.
463. Reinforced-concrete structures. In order that a reinforced-c
Crete structure may be damaged by electrolysis, it is necessary that an e
trie current flow between the reinforcing steel and the surrounding concr
Such current may be leakage current from a direct-current lighting system
stray railway current brought into the building by means of service pij
The conditions required for producing electrolysis of steel embedded
concrete are such, however, that this can result only in extreme cases;
example, where a direct contact is established between the reinforcing g
and one side of a direct-current lighting system, or where stray railway (

rent of sufficient magnitude is brought by way of service pipes into cont

with the reinforcing steel. It is therefore a safe precaution to install ii
lating joints in all pipes and lead-covered cables which lead to reinfor
concrete structures from earth. It has been proposed to protect reinforc
concrete by making the reinforcing steel continuous throughout, and c
necting it to the negative terminal of a low-voltage generator. While
'

would prevent corrosion of the steel, it might result, however, in grei

danger, on account of the possible destruction of the bond between the r
forcing steel and the concrete.
464. Structural foundations. Where steel foundations are embed
in concrete, it is important to guard against stray electric current read
the steel from external sources and then flowing from the steel to the concr
because corrosion of the foundation steel and cracking of the concrete i
result.

MUNICIPAL AND STATE REGULATIONS

466. General. Municipal and state regulations, designed to minir
the escape of electric currents from electric railways using a grounded rei
circuit, generally attempt to limit the total allowable voltage drop and
allowable potential gradient in the grounded return circuit or grounded r
Additional requirements limiting the total allowable current escaping t
the system are included in some regulations. A few brief references to r
lations which are at present in force, are given in Par. 466 to 469. r,

466. British Board of Trade" regulations. The two most importftirf

these regiilations are Regulations No. 7 and No. 8. The former limitsj
allowable difference of potential between any two points in the unmsul;
return circuit to 7 volts, and requires that continuous records be kept b) i

railway company, of the difference of potential between certain points oi

i

uninsulated return circuit. Regulation No. 8 limits the allowable cuH

density in the rails to 9 amp. per sq. in. of cross-section (1.4 amperes
i

sq cm ), which with ordinary steel is equivalent to an allowable pote

I

gradient of approximately 0.8 volt per 1,000 ft. (0.305 km.) of rail.
467. German electrolysis regulations. In Germany a joint com'^
tee, representing the German Society of Gas and Water Engineers,
the So' i
of German Electrical Engineers, and the Society of German Street Rai ^
and Little Railway Managers, adopted in 1910 regulations for the prote."
of underground structures against electrolysis. The track network is an
into an inner district and an o\iter or suburban district. In interurban «
the parts near villages are designated as suburban districts. The P"^^
difference between any two points on the track must not exceed 2.5 J
under average load conditions in the inner district, and on a bordering"!

1491e
 ELECTRIC RAILWAYS SeC. 16-468

I
km. (6,562 ft.) wide; outside this zone in the suburban districts, the
drop must not exceed 1 volt per kilometer (3,281 ft.).
oltage
468. American municipal ordinances. Some American cities have
nacted ordinances designed to prevent damage by electrolysis. In 1912
jie City of Chicago enacted an electrolysis ordinance, the most important
lature of which is the voltage requirement, limiting the permissible dif-
Irence of potential between any two points on the uninsulated return circuit
I 12 volts, and limiting the potential gradient in the rails within 1-mile radius

( the City Hall to 1 volt per 1,000 ft. (0.305 km.), and outside of this 1-mile
dius to 1 volt in 700 ft. (0.213 km.). In 1913 the City of Chicago enacted
aat is known as the Unification Ordinance, which also contains clauses
Isting to electrolysis. These divide the city into three zones, and prescribe
fferent voltage limitations for each zone. The Board of Supervising Engi-
is, however, authorized to modify these voltage requirements in the
ifrd or outer zone. The above ordinances although not entirely in accord
e.both in effect in Chicago.
iln a number of cities in Ohio electrolysis ordinances have been enacted
which the most important features are track voltage requirements. In
^e ordinances the average potential difference during any 10 consecutive
ntites between any two points 1,000 ft. (0.305 km.) apart on the uninsu-
ed return circuit must not exceed 1 volt, and the average potential
*~^ence during any 10 consecutive minutes between any two points more
1,000 ft. (0.305 km.) apart on the uninsulated return circuit within the
of the municipality must not exceed 7 volts.
Legal status of liability for electrolytic damage. There has
tai^on.siderable litigation at various times with reference to damage from
Dtrolysis. It has been held by various courts that no one utility can claim
exclusive right to use the earth as a return circuit, and that priority
luch use is of no importance to either side of the controversy.
Vn. Peoria decision. In the celebrated Peoria case which was finally
ided after having been in the courts for over 10 years, the railway com-
ly was enjoined and restrained from injuring the property of the water
apany by electric current escaping from the rails or structures of the rail-
r company. No particular method for preventing escape of current is
Bcribed in the decree, because the court in its decision states that a court
not have the power to prescribe by injunction any specific system, and
tthis power resides only with legislative bodies. The decree also requires
water cornpany to co-operate with the railway company to the extent of
ng the railway company access to its piping system for the purpose of
isuring flow of current upon its system and of determining whether injury
n electrolysis is being continued, in order that the railway company may
irmine whether it is complying with the terms of the decree.

ItUOaBAPHY— ELECTROLYSIS OF UNDERGBOUND STBUC-

TUSES
[Tl. References to literature on electrolysis:
—
iBRiCAN Committee on Electrolysis. Preliminary Report, October,

BEAU OF Standards Technologic Papers:

No. —
15. "Surface Insulation of Pipes as a Means of Preventing Elec-
Utrolysis." January, 1914.
No. 18. — "Electrolysis in Concrete." March, 1913.
No. 25.— "Electrolytic Corrosion of Iron in Soils." June, 1913.
No. 26.— "Earth Resistance and Its Relation to Electrolysis of Under-
d'ground Structures." December, 1915.
—
|No. 27. "Special Studies in Electrolysis Mitigation." June, 1913.
1. A Preliminary Study of Conditions in Springfield, Ohio, with

No. — "Methods Making

Recommendations
28.
Mitigation.
for
of Electrolysis Surveys." August, 1916.
No. — "Special
32.
'.'1913.
Studies in Electrolysis Mitigation." December,
Electrolysis from Electric Railway Currents and
2. Pre- Its
vention — an Experimental Test on a System Insulated Negative
of
'Feeders in St. Louis.
No. 52. — '^Electrolysis and Its Mitigation." December, 1915.
jNo. 54. — "Special Studies in Electrolysis Mitigation." February,

i 1491/
 '
'

Sec. 16-472 ELECTRIC RAILWAYS

1916. 3. A Report of Conditions in Springfield, Ohio, with In

lated Feeder System Installed.
No.55. —
"Special Studies in Electrolysis Mitigation." January, 19
4. A Preliminary Report on Electrolysis Mitigation in Elyria, 01
with Recommendations for Mitigation.
No. 62.— "Modern Practice in the Construction and Maintenance
Rail Joints and Bonds in Electric Railways." March, 1916.
No. 63.
No. 72.
—
"Leakage of Currents from Electric Railways." March, 19
—
"Influence of Frequency of Alternating or Infrequently 1
versed Current on Electrolytic Corrosion." August, 1916.
No. 75.
No. 127.
—
"Data on Electric Railway Track Leakage." August, 19
—
"Leakage Resistance of Street Railway Roadbed and
—
Relation to Electrolysis of Underground Structures." October, 19
CuNLiFFE, J. G., AND CuNLiFFE, R. G. "Electric Traction Vagabond C
rents." Journal of the Institution of Electrical Engineers, London, \
XLIII, p. 449, 1909.
Deiser, George F. —
"The Law Relating to Conflicting Uses of Electric
and Electrolysis." T. & J. W. Johnson Co., Philadelphia, Pa., 1911.
—
Ganz, Albert F. "Electrolysis from Stray Electric Currents." Proe. A
Water Works Ass'n., p. 159, 1912. Also Proc. New England Associatioii
Gas Engineers, Year 1913-1914, p. 19.
—
German Electrolysis Regulations. Adopted by Electrolysis Commit
Representing the German Society of Gas and Water Engineers, the Soci
of German Electrical Engineers, and the Society of German Street Railv
and Little Railway Managers. Electrotechnische Zeitschrift, May 25, 19
Berlin.
—
Haber, F. and Goldschmidt, F. "Dor Anodische Angrifl des Eisens Du
Vagabundierende Strome im Erdreich und die Passivitat des Eisens ('
Corrosion of Iron by Stray Currents in the Earth and the Passivity of Iroi'
—
Zeitschrift Jiir Elektrochemie, JanunTy 2&, 190G. Breslau.
Hayden, J. L. R. "Alternating-Current Electrolysis." Trans. A. I.E.
XXVI,
Vol.
—p. 201, 1907.
Hering, Carl. "Measuring Stray Currents in Underground Pip'
I

Vol. XXXL
M. — "Alternating-current Electrolysis."
Trans. A. E.
I. E., 1449, 1912.
p.
Kintner, S. Journal,
Electric

MiCHALKE, Carl. —"Stray Currents from Electric Railways." Trans);:

II, p.668, 1905.

and edited by Otis Allen Kenyon, McGraw Publishing Co., New York C
Rhodes, George — "Some Theoretical Notes on the Reduction Eil
1906.
I. of
Currents from Electric Railway Systems by Means of Negative Feedf
Trans. A. I. E. E., Vol. XXVI, p. 247, 1907.
RicHEY, Albert S. —
"Electric Railway Handbook." Section on E*
trolysis, p. 704.
Sever, George F.
1915.
—
"Electrolysis of Underground Conductors." Tri,
International Electrical Congress, St. Louis, Vol. Ill, p. 666, 1904.

BIBLIOGRAPHY—ELECTRIC TRACTION
472. Selected List of Reference Literature.
Transactions International Electrical Congress; St. Louis, 1904.
—
Harding, C. F. " Electric Railway Engineering." McGraw-Hill Ik
Company, Inc., New York, 1911
—
BuRCH, E. P. "Electric Traction for Railway Trains." McGraw 'I'
Book Company, Inc., New York, 1911.
—
Ashe, S. W. and Keiley, J. D. "Electric Railways Theoretica!
Practically Treated." D. Van Nostrand Co., New York, 1907,
—
Austin, Edwin. "Single Phase Electric Railways." D. Van Nu>
New York,
Co.,
Dawson, P. —
1913.
"Electric Traction on Railways." D. Van Nostraml >•

New York. 1909.

—
Herrick, a. B. and Boynton, D. C. "American Electric Railwa
tice." McGraw-Hill Book Company, Inc., New York, 1907.
" Report of the Electric Railway Test Commission to the Presideni
Louisiana Purchase Exposition." McGraw-Hill Book Company, Im
York, 1906.

1491(7
 ELECTRIC RAILWAYS SeC. 16-472

——
HoBART, H. M. " Electric Trains." Harper and Bros., New York, 1910.
GoTSHALL, W. C. " Notea on Electric Railway Economics and Prelimi-
ary Engineering." McGraw-Hill Book Company ,Inc., New York, 1903.
—
GoNZENBACH, Ernest. "Engineering Preliminaries f or Interurban Elec-
ic Railways." McGraw-Hill Book Company, Inc., New York, 1903,
,
—
Parshall, H. F. and Hobart,H. M. " Electric Railway Engineering."
Van Nostrand Co., New York, 1907.
1
'.

—
Arnold, B. J. " Chicago Transportation Problem." McGraw-Hill Book
ompany. Inc., New York, 1902.
Sheldon, Samuel and Hausmann, Erick. "Electric Traction and —
iransmission Engineering." D. Van Nostrand Co., New York, 1911.
—
RicHBT, Alberts. "Electric Railway Handbook." McGraw-Hill Book
pmpany, Inc., New York, 1915.
The most recent and important literature on Electric Traction will be
,

und in the Proceedings ot Trans actions oi the following societies: A. I. E. E.,

S. C. E., A. E. R. A., A. R. E. A. and I. E. E.
Allen, E. W. and Taylor, Edward. —
"Automatically Controlled Sub-
itions." A. I. E. E. Proc, September, 1915.
"Automatic Substations Permit Large Savings in Des Moines." Electric
.ilway Journal, January 13, 1917.
Wenslet, R. J.
,bstations."
—
"Some Experiences in the Development of Automatic
Electric Railway Journal, November 15, 1919.
Wensley, R. J.
I. E.
—
"Automatic Stations for Heavy City Service." Journal,
E., April,
1920.
C. — "Automatic Substations at Des Moines."
,

Ceu.mber8, F. Electric
ilway Journal, April 1920.
10,
Jones, C. H. — "Checking Up on Automatic Substation." ElectricRail-
:y Journal, March 1921.
26,
ToHNSON, E. — "Aurora, Elgin & Chicago Automatic Substation Experi-
S.
;e." Railway Journal, March
Electric 1921.
26,
(ones, C. H. — "Advantages Automatic Railway Substations."
of Electric
ilway Journal, January 22, 1921.

1491A
I
 KOI'^A0i'?122AJ:) .lA^lAnO

SECTION 17

ELECTRIC VEHICLES
BY JOHN G. CAKKOLL
' Engineer, Walker Vehicle Co.; Member American Institute of Electrical
Engineers and Society of Automotive Engineers

CONTENTS
{Numbers refer to Paragraphs)
';
leneral Classification 1 Vehicle Control 108
i
'aasenger Cars 6 Storage Batteries 124
/Ommercial Trucks and Trac- Battery Charging 133
tors 20 Battery Charging Equipment 160
ndustrial Trucks and Tractors 51 BibUography 209
chicle Motors 87

1^8
 ^,

SECTION 17

ELECTRIC VEHICLES
OENERAL CLASSIFICATION
1. Theelectric vehicle art prior to 1910 exhibited relatively little
progress, due partly to tlie poor design of the earlier types of vehicles and
partly to the comparatively heavy unsuited batteries. The art began to
show considerable activity in 1910 and for the following four years the devel-
opment of the passenger car progressed more rapidly than that of the com-
mercial truck. However, the progress in the design and development of the
gasoline passenger car, with its electrical starting and lighting system,
higher speeds and practically unlimited radius of action, resulted in the diver-
sion of popular attention from the electric passenger car to the gasoline
passenger car. For this reason the number of manufacturers decreased
steadily, until in the beginning of 1921 there were only two prominent
makers of electric passenger cars.

^ 2. Progress in commercial and industrial vehicles. The electric

commercial and industrial trucks and tractors have progressed steadilj
since 1910 and have proved their economic worth in their particular fields
in the transportation of merchandise.
3. Classification. Electric vehicles may be subdivided into three gen-
eral classes according to character of service:
(1) Passenger cars.
(2) Commercial trucks and tractors.
(3) Industrial trucks and tractors.
The source of energy supply permits another classification, namely storage
battery vehicles and the so-called trackless trolley which is a motor-propene(
vehicle receiving its energy from an overhead trolley system. The storage
battery vehicle is by far the more important at the present time, as the high
way trolley vehicle has not yet come into extended use in this countr;
although it is employed to a limited extent abroad.
4. Scope of presentation. Due to the broad scope of design, the sur
ject of electric vehicle engineering can be presented in the brief space aval;!
able in an engineering handbook only with difficulty. An attempt has bee^
made in this section to embody merely the fundamentals of the subje('
based on modern practice and so far as possible describe the most reprjj

type„ -- ,^ . - - ,

and baggage transfer, cable pulling, crane tractors, pole hau

i

as passenger
ing, dumping, baggage trucks, fire apparatus, etc., but practically all 3
these applications are specific and no attempt has been made to inclu<<
them. *
J

6. Features emphasized. It is particularly desired to point out th;|

where descriptions of machines and accessories of various makes have be^'
omitted, such omissions are due to the fact that limitations of space haii
confined the subject matter to those types which have gained prominen j

in industry or whose designs embody characteristics of particular intere|-

to the engineer.
PASSENGER CARS
,

6. Qeneral features. The passenger vehicle involves no engineeri

features which do not conform to the fundamentals of vehicle engineeri.
and their applications to commercial trucks as discussed under that captic
7. Chassis and body. All cars are comprised of two principal elemen
the chassis and the body. In general, the chassis comprises the frarij
front and rear axles, complete with wheels, springs, steering gear, mot
power-transmission members, controller and battery. The plan view o
typical electric passenger-car chassis is shown in Fig. 1.
 ELECTRIC VEHICLES Sec. 17-8

8. chassis frame is usually of pressed steel channel sections of

The
liberal depth, with cross members for supporting the motor, battery com-
partment and other equipment forming a part of the vehicle.
9. The front axle is of drop-forged I-beam construction,
providing
maximum carrying capacity with minimum weight. The steering knucUea
ire, in general, drop-forged from alloy steel and heat treated.

Fig. 1. — Plan view of Detroit electric chassis.

10.Power-transmission systems have in the past embodied various

nbinations of chain, spur and bevel gear, and worm drive. In the present-
V designs,the rear axle is generally of the three-quarter floating type
ling either spiral bevel gears, with an approximate reduction of 5 to 1, or
rm gearing with an approximate reduction of Q^i to 1. Power is usually
'
ivered from the motor to the rear axle through a propeller shaft having
dust-proof universal joints. The rear-axle torque is usually carried
)

I
ough a pressed steel member, pivotedly supported, to the chassis frame.
1. Two separate sets of brakes are usually provided, operating inde-
lidently. The two sets are usually of one of the following combinations:
External contracting and internal expanding type mounted on the rear
(

*5els and operated by foot pedals; (6) internal expanding type mounted
tthe rear wheels, operated by a foot pedal, and external contracting type
I mted on the front end of the motor, fitted onto the armature or propeller

s ft and operated by a backward movement of the controller lever or by a

f pedal. In some designs the application of the service brakes simul-
t :'ously interrupts the power circuit regardless of the position of the con-

t ler lever, making

it impossible to start the car again until the controller
" r has been returned to its neutral position.
'ynamic and regenerative braking have been tried in the past, but
D her is in general use at present due to the complications that are intro-
\id into the control system.
The springs are generally of chrome- vanadium heat-treated steel,
pat being of the semi-elliptic type and the rear either the three-quarter
K.p or cantilever type.
The wheel base on cars of present-day design is usually 100 to 105

1496
 Sec. 17-14 ELECTRIC VEHICLES

14. The wheels are usually quick-detachable wood or wire type, designe<
for approximately 32 X
4J^ in. cord pneumatic tires.
15. Batteries. Two prominent manufacturers specify their standari
battery equipment to provide for 40 to 42 cells of 13 to 15 plate lead-aci(
battery. Vehicle batteries are discussed more fully in Par. 128.
16. The motor is usually a 4-pole series-wound machine, liberally de
signed to insure efficiency and abiUty to withstand overloads encountere<
under all operating conditions. The armature bearings of the motor an
of the ball type. The motor is usually supported from cross members o
the chassis frame. See Par. 87.
17. The controller is usually of the drum, continuous-torque type pro
viding approximately five or six speeds forward and three or more reverse
The controller is generally supported from the chassis frame and actuate<
by a lever mounted beside the steering lever. The controller is discusse<
more fully in Par. 108.
18. The operating levers for steering and control are usually mounte<
at the side of the seat, in parallel position one above the other. The steerini
lever, usually the longer, is operated by the right hand and the controUe:
lever, usually the shorter, by the left hand.
19. The radius of operation is usually from 60 to 90 miles per chargi
of battery, depending on topography, road conditions and the speed a
which the car is operated.

^ COMMERCIAL TRUCKS AND TRACTORS

20. Classification. Commercial trucks may be divided broadly int(
four classes:
. (1) Those having electric propulsion, the energy being furnished by i

battery.
Those propelled by internal combustion engines.
(2)
Those propelled by steam.
(3)
Those having gas-electric or steam-electric propulsion in wnich th'
(4)
energy of the prime mover is electrically transmitted to the axle or wheel
21. Economic field of application. Each type of commercial trucl-
has its distinct field of economic application, that of the electric vehici
being found in city delivery embracing the interchange of merchandis
between railway terminals and docks, stores and factories, and retail deli\
eries. The electric vehicle possesses superior advantages over other niear
of merchandise transportation due to its inherent characteristics of rapi'
acceleration and retardation permitting it to maintain a high average spee
and due further to its freedom from intricate mechanism for transmittin
the motor energy to the wheels and the absence of numeroiis reciprocatic
parts.
22. Economic field of gasoline vehicle. The gasoUne motor vehic
finds its best field of application in uninterrupted long-haul deliveries whe:
the mileage exceeds that safely and conveniently obtained from the electr,
truck, its economic value being governed entirely by the individual chars'
teristics of the particular business to which it is applied.
23. Economic field of electric vehicle. Electric trucks are more ec,
nomical and satisfactory than gasoline trucks for approximately 85 per cet
of all city haulage. The salient characteristics whicn contribute to the hi)
efficiency and low operating costs of electric trucks are:
(o) The low cost of electrical energy.
(6) Operation at a safe economical speed.
(c) Ease of maintenance of battery service.
id) Reliability and uniform driving power of the electric motor, whi
delivers maximum power to the rear wheels.
(e) Substantial construction and elimination of reciprocating membe
which almost wholly ehminate road troubles, reduce maintenance expei;
to a minimum and obviate the necessity for high-salaried mechanics. '

(/) Minimum vibration and prevention of careless speeding prolonR

life of the electric truck, and make it more than double that of a g.i-
truck.
(ff) The motor draws no energy from the battery when the brake* i;
;,

applied or when the truck is coasting.

(A) Low cost of insurance.
1496
 ELECTRIC VEHICLES Sec. 17-24

S4. The chassis of the various makes differ only in some special features
design.
)f The main frame members are comprised of rolled or pressed
channels, -with cross members secured to the side sills with either proper
[iteel
fmgle iron and gusset plates or integral gusset plates.
! 25. Bepresentative types of chassis are illustrated in Fig. 2 and 3,
i
bowing respectively the side elevation and plan of a Ward one-ton chassis
(,nd a Walker 3>^-ton chassis. Both of these types employ a single motor,
fhe former with a worm-drive axle and the latter with a special balanced
fxive as described more fully in Par. 32.

ackle Tie Rod Brake Cam Shaft

Fig. 2. —Elevation and plan view of 1-ton Ward electric chassis.

The battery compartment is usually carried amidship by structural

6.
8 members hung from the main chassis frame and having truss rods from
.!

t lower corners of the compartment to the side sills of the frame. In

8 le cases the battery is mounted on top of the side frames and partly under
t driver's seat. The underslung type of battery compartment has the
f owing advantages: (a) Low center of gravity, resulting in less tendency
«;n turning corners for the weight to be thrown from the inside to the out-
H wheels and therefore less tendency to skid; (6) the overall length of the
trk is reduced, which enables the truck to be more easily operated in con-
ned traffic zones and narrow places and requires less garage space; (c)
Pnits the use of removable battery cradles and facilitates the interchange
ol atteries.
f. Springs. The front and rear springs are usually of the semi-elUptio
'J , ofhigh-grade alloy steel, heat treated.
.
Axles. The front axles are usually of I-beam section, drop forged
'.

'
high-grade steel, with drop-forged steering knuckles and steering
I

i'
arms. The rear axles embodying the transmission of the motor
:kle
iE
?y to the wheels differ in design on all the different makes of trucks.
1497
 Sec. 17-29 ELECTRIC VEHICLES

29. Transmission systems embody various combinations of chain, spui

gear, bevel gear and worm drives. Considerable difference of opinion existi
as to what constitutes the most desirable method of motor application am
the best transmission design. The essential elements of a transmissioi
comprise means of reducing the high speed of the motor to the comparativelj

^Jbnke Support

Fig. 3. —Elevation and plan view of 3 J-ton Walker electric chassis.

Fia. 4. —Rear axle assembly. Motor cover removed.

Company.)
(Walker Vclii^

low speed of the driving wheels and a differential gear which permif
wheel to turn faster than the other when the vehicle is propelled i:
curved path. •

SO. The single-motor double-reduction chain drive is not cxtensiv.

It may still be fou
used by present-day manufacturers of electric trucks.

1408
 ELECTRIC VEHICLES Sec. 17-31

^n operation on old vehicles in service in this country and on several makes

jof electric trucks manufactured in this country and in England.
31. The worin drive is usually of the semi-floating or full-floating type
having the worm, worm wheel and differential and their bearings assembled
as a unit with the cover. The housing is usually of cast steel reinforced
by tubes. The road wheel is driven through a squared shaft and driving
flange bolted to the hub, or through a splined shaft in the hubs of the differ-
ential gear and driving flange bolted to the wheel hub.
32. Balanced drive. In the Walker balanced drive, the motor, differ-
ential and transmission members are all embodied as parts of the rear axle
and wheel assembly (.Fig. 4). The power is transmitted through drive
shafts to floating pinions within each wheel, then through intermediate
spur gears housed within the disc wheels, to the internal gear which is
pressed into and keyed to the wheel bands or rims. The drive pinions
and shafts have no bearing, the pinions floating in a balanced manner
between the idler gears with which they are constantly in mesh. The
rc:ir wheels are dirt- and water-proof and are partly filled with lubricant
which is distributed continuously over all working parts. The rear wheels
an- mounted on roller or ball bearings supported by drop-forged steel stub
axles secured in the ends of the hollow rear axle. The mechanical efficiency
of this drive is very high, and stand tests indicate that efficiencies as high
as 98 per cent, are obtainable.
33. The wheel-drive systems embodying constructions in which a
motor drives each wheel separately and forms a more or less self-contained
jiiit therewith are described in Par. 34 and 35.

34. The couple gear drive, shown in Fig. 5, employs a motor mounted
na fixed horizontal position within the wheel itself, the axle stubs on which

Fig. 5. — Wheel assembly, couple gear.

le wheel turns being integral with the motor castings. The armature
aft makes a slight angle with the plane of the wheel, permitting the bevel
nions mounted on each end of the armature shaft to mesh with their
^pective halves of a double cog rack near the periphery of the disc wheel,
irust stresses arising from one bevel set are balanced by the other. This
rangement lends itself to four-wheel drive and steering.
36. Other wheel-drive systems which obviate the use of bevel gears
d embody the double spur-gear reduction are shown in Figs. 6 and 7.
lese drives are used by the Commercial Truck Company. In the concen-
|<l gear drive illustrated in Fig. 6, the gear cases are mounted between two
members, the extension of the case forming the axle spindle. The
)r is bolted to the inner side of the gear case in a fixed position and in
iwith the axle. The armature pinion engages three spur gears, which
carried by studs mounted integral with the driving shaft. The pinions
1499
 Sec. 17-35 ELECTRIC VEHICLES

which are integral with the intermediate gears, as shown in Fig. 6, engage
a single gear which is pressed into and keyed to the gear case. The driving
shaft passes through the axle spindle and connects with the outer end of the
wheel hub through the hub cap. The driving shaft has no bearing in the
axle spindle, the driving gears and driving shaft being supported and held
in proper position in the following manner: The double intermediate gear
has a cylindrical extension formed on its inner end having a diameter equal
to the pitch diameter of the small gear. A cylindrical track is formed in

Fig. 6. — Concentric gear drive. (Commercial Truck Company.)

Fio. 7. —Double spur-gear reduction drive. (Commercial Truck Company}

the motor head, the diameter of which is equal to the pitch diameter of th,
internal gear. It will thus be seen that the three bearings form a rollir
support for the inner end of the driving system, the outer end of the dnvir
shaft being supported and held centrally by the hub shaft. The gear ca;.
in a bath of oil. In!
is oil and dust tight, the gears running continuously
drive is used on trucks of H-ton, 1-ton and 2-ton capacity.
spur gear drive illustrated in Fig. 7 the moto;
In the double-reduction
which is a standard truck type, .scries wound, with a cyhndrical stce framn
is carried in a steel casting accurately bored to a
size that will allow ti

1500
 ELECTRIC VEHICLES See. 17-36

motor to be slipped freely in place up to a definite shoulder. The case is

I
split partly around and horizontally, so that by tightening bolts through
; the lugs cast on this part of the case, the case can be securely clamped
f around the outside of the motor. The gearing between the motor and the
:
wheel consists of straight spur gears. The first pinion is mounted directly
;
on the tapered armature shaft with a key. The double intermediate gear
\ is carried by a roller bearing on an intermediate stud, which is supported
I in the same casting that carries the motor. The intermediate pinion engages
an internal gear mounted directly on the wheel hub, the outside surface of
the internal gear forming the brake drum. The axle spindle is constructed
go as to form an extension of the gear and motor case, the spindle being
approximately in line with the center of the motor. A concentric flange,
j
wluch is bored to a diameter slightly larger than the outside of the internal
gear and provided with grooves, forms a dust and grease type joint. Trun-
nions integral with the gear and motor case located at the top and bottom,
as shown in Fig. 7, are arranged to engage the axle ends and form a knuckle
construction for steering the motor wheel as a unit. The gearing is entirely
enclosed and the gear case is partly filled with a heavy grease. The axles
,
are steel forgings and are made in two parts separated by a spacer forming
I
the equivalent of a deep I-beam section. The axle forgings are enlarged
;
at the ends and bored out and bushed to receive the trunnions before de-
scribed, which are part of the motor ca.sing. _
The axle with the motor casing
thus forms a knuckle construction for steering, a thrust ball-bearing being
jmoufited in the front top axle at the trunnions. The assembly of the front
land rear constructions is the same, with the exception of the ball bearings.
(The motor wheels of the front construction are connected by the usual cross
rod with the steering rod or drive link connecting one of the motor wheels
to the steering gear. The motor wheels of the rear construction are secured
n a fixed relation to the axle, the wheels being rigidly mounted. This drive
j

3 used on trucks of 3M- and 5-ton capacity.

36. The methods of providing for torsion and propulsion stresses
n electric trucks follow the same general practice which prevails in the
jiesign of gasoline trucks. The discussion of these methods cannot be
(indertaken within the .space available, and therefore the reader is referred
o any standard treatise on the design of gasoline motor trucks.
i

17. The brakes in general conform in design to the accepted practices

\

ijif gasoline motor truck brakes. Two independent brake systems are usually
urnished, one being an external contracting-type brake on the rear wheel
unctioning as a service brake and the other being an internal expanding
^>rake on the rear wheel functioning as an emergency brake. In some cases
ioth brakes are of the internal expanding type on the rear wheel and in other
^ases an external contracting-type brake on the propeller shaft is furnished
1 addition to an internal expanding-type brake on the rear wheels. The
rakes are generally operated by foot pedals.
S8. Battery requirements. A storage battery to fulfill the require-
i'.ients of truck propulsion should have the following characteristics:
-jiy The ability to propel a loaded truck up the gradients encountered in

(6) it should be efficient; (c) it should be rugged and substantial in

>iistruction and capable of withstanding the severe shocks of service; (d) it
Isrvice;
tould have the ability to give a long period of useful service; (e) it should
ive ample capacity for the application involved.
The recommendation of the Society of Automotive Engineers regarding
imber of battery cells is as follows: The number of cells in lead-acid bat-
ries shall be 42, and the number of cells in the nickel-iron alkaline type 60.
,1 many cases 44-cell batteries cannot be properly charged on account of the

w voltage of the current supply. The 42-cell battery can be divided to

ake a more convenient arrangement of trays. See Par. 128 et seq.
39. Motors. One motor of the four-pole series-wound type is usually
iployed to propel a truck, although in some applications two or four
otors are used. Motors are discussed more fully under Par. 87 to 107.
40. Controllers are discussed more fully under the caption "Controllers,"
if^l28 to 132.
|il. Tires. The function of the tires is to provide traction, prevent slip-
^_, protect the mechanism of the vehicle from shock and vibration and
snion the load. In general all electric trucks are equipped with solid

1501
 ;

Sec. 17-42 ELECTRIC VEHICLES

tires. The carrying capacity of solid tires as specified in the standards Ol

the Society of Automotive Engineers is given in Par. 42.
42. Sizes and Carrying^ Capacity of Solid Tires
(S. A. E. Standard)

Nominal tire size Min. total

sectional area Carrying
of rubber (.1) capacity (lb.)
In.
(sq. in.)

32 X 3 75/660 5.00 1,000

36 X 3 75/762 5.00 1,000
32 X 3i 90/660 6.75 1,300
34 X 3J 90/711 6.75 1,300

36 X 90/762 6.75 1,300

32 X 100/660 7.75 1,700
34 X 100/711 7.75 1,700
36 X (2) 100/762 7.75 1,700

34 X 125/711 10.75 2,500

36 X 125/762 10.75 2,.500

\ 40
34
X
X
125/864
150/711
10.75
13.75
3,000
3,500

36 X 6 150/762 13.75 3,500

40 X 6 (.3) 150/864 13.75 4,000
34 X 7 175/711 16.75 4,500
36 X 7 175/762 16.75 4,500

40 X 7 (3) 175/864 16.75 5,000

36 X 8 (4) 200/762 19 75
. 5,500
36 X 10 (4) 250/762 25.75 7,500
40 X 10 (4) 250/864 25.75 8,000

40 X 12 (4) 300/864 31.75 10,000

40 X 14 (.4) 350/864 37.75 12,000

(1) Includes both hard and soft rubber.

(2) Single tires for single and dual wheels.
(3) Dual tires for dual wheels.
(4) Single tires for dual wheels.
43. Instruments. The type of instrument now in general use on deo
trie trucks is the ampere-hour meter. This instrument gives a visual ilidl
cation of the condition of charge of the battery, both while operating 'tb
vehicle and while charging, and also facilitates automatic charging.
44. The rating of electric trucks, according to the recommendation
of the Society of Automotive Engineers, is as follows:
Speed rating. The electric-vehicle speed rating shall be based on cor
tinuous operation with one-half load over hard, smooth and level roads C
pavements at the average battery voltage.
Mileage rating. The electric-vehicle mileage rating shall be based oi
a continuous run at the S. A. E. rated speed with one-half load over hut
smooth and level roads or pavements.
45. Commercial tractors are identical in design with the commercii
truck, except as regards the mounting of the battery, shorter wheel base an
lower operating speeds. Tractors may be generally subdivided into thrti
classes:
(1) Trailer type.
(2) Semi-trailer type.
(3) Crane type. _ . ,

46. The trailer type of tractor comprises those equipped with spm!
draw bars or pintle hooks, designed to haul a trailer or a train of trailer;
In this type the battery is generally mounted in a steel compartment ( j
top of the frame side sills. This type is usually capable of haulmg a traihi 1
load of ten to twenty tons gross weight.
'

1502
 ELECTRIC VEHICLES Sec. 17-47

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Sec. 17-47 ELECTRIC VEHICLES

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 .

ELECTRIC VEHICLES Sec. 17-48

48. The semi-trailer type of tractor comprises those eqiiipped with

fifth wheels, trailer attachments, or swivel connections, designed to haul a
semi-trailer. The battery is generally underslung amidship, with some-
times a portion of it mounted directly behind the cab on top of the frame
side sills. This type is usually designed to haul a semi-trailer of ten tons
gross weight, one-third of the total trailer weight being carried by the rear
end of the tractor.
49. The crane type of tractor is eqmpped with an electrically-operated
hoist, with either fixed or swinging boom, designed to carry one ton on the
hoist hook, or to hoist two tons with tractor stationary and sprags set. In
addition, this type is usually equipped with spring drawbar or pintle hook
for hauling trailers.
50. Commercial specifications of trucks and tractors. The principal
characteristics of various types of commercial trucks and tractors are given
in detail in Par. 47.
INDUSTRIAL TRUCKS AND TRACTORS
1
61. Systems of trucking. Three standard systems of storage-battery
industrial trucking are in use. The choice of industrial trucks or tractors
to meet the particular requirements of any industry should be based on a
"arpful analysis for the purpose of determining which system will best meet
fhr existing or contemplated arrangement of buildings and departments and
Teiiornl transportation facilities. The three systems are:
1 Platform hauling, in which the truck is required to wait while being
loaded and unloaded by hand, gravity or crane.
2. Electric self-loading and self-unloading, or semi-self-loading and un-
loading.
Electric lifting platform and tiering trucks, which eliminate load-
(a)
ing and unloading by means of false platforms or skids.
(6) Semi-self-loading or unloading trucks such as crane and hopper
trucks.
3. Tractor-trailer systems in which the power unit is coupled to and draws
one or more unit loads on wheels, either singly or in trains.
62. Platform trucks are in more general use because of the fact that for
nost installations the commodities are mixed in character. These trucks
re manufactured in numerous models or designs, from which the most
uitable type may be selected for a particular application. Among the
mportant factors in making a selection are the height, width and length
f the truck desired. The proper height of the platform is dependent, in
eneral, uoon the character of the material to be loaded. Standard heights
f truck-loading platforms are 12, 17, 18, 20, 24 and 33 in. The character
f the runways or roads over which the truck will travel may affect the size
f the wheels and consequently tne height. The higher platforms are to
icilitate the loading of baggage, mail, express, or the like, from car floors
nd the loading of castings and other heavy materials by means of cranes.
63. The battery mounting in low-platform types is over the driving
xle at one end, enabling the use of wheels of small diameter at the other end
eneath the low loading platfornf.
64. The battery mounting in high-platform type is beneath the load-
ig platform. The wheels are of the same size, thus providing ample clear-
;ace under the truck. This design provides maximum loading space.
58. Width. The question of width is determined by the aisle, doorway
nd equipment clearances. With trucks which employ four-wheel steering,
le question of clearance is of lesser importance because of the greater flexi-
ility in handling. The standard widths of trucks are 30, 37, 40 and 45 in.
he wheel treads should be such as to provide ample stability under all
mditions of operation.
66. Length. The length of the standard trucks is dependent upon the
laracter of merchandise to be transported, but the wheel base should not
! so long as to impair adaptability. In some cases the ability to control
i,truck from either end will provide the greatest flexibility in operation.
Folding platforms for the operators to stand upon and adjustable
.j;ates facilitate the operation of trucks in congested zones, on elevators
in freight cars.

1505
 Sec. 17-58 ELECTRIC VEHICLES

68. Steering and wheel drive. Trucks are designed for two-wheel
drive, with two-wheel steering; four-wheel drive, with four-wheel steering;
or two-wheel drive with four-wheel steering.
59. The self-loading and self-unloading types of industrial truck
equipment comprise the elevating platform, tiering, crane and hopper trucks,
the most popular type being perhaps the electric lifting or elevating plat-
form type.
60. The elevating-platform type of truck is fitted with a lifting plat-
form having a carrying capacity of 4,000 lb. The platform proper is raised
and lowered by an electric motor and is designed to run under low portable
platforms which are electrically lifted by the platform of the truck and set
down without necessity of rehandling. The height of the lift is generally
3 to 5 in. with 4,000-lb. load. The lifting mechanism is operated by an
independent motor supplied from the storage battery which propels the
truck.
61. Worm lift. In this type the lift is effected by means of a steel worm.
The load when raised is sustained on a horizontal plane which takes the
entire strain off the lifting mechanism.
62. Screw lift with rocking platform. In this type a motor is direct
connected to a worm and gear for driving the elevating mechanism. The
spider on which this gear is mounted forms a special clutch adjusted to slip
at a fixed overload, in such manner that if the load should catch under an

^ obstruction
lessly.
when lifting, the motor with gear and worm will rotate harm-
This clutch is threaded at the center and, when revolving, propels
a square multi-thread screw in or out, depending on the direction of motor
rotation. The entire mechanism is enclosed in an oil-tight malleable case.
The extension of the screw shaft is attached flexibly to the platform on which
the load is lifted. The platform is mounted on two heavy links at the rear
and one at the front end, providing a three-point support. The action
of the screw draws or thrusts the platform backward and upward until the
links become practically vertical and raise the load 4j in. Guides attached
beneath the platform steady the load when raised.
A travel limit rod is connected with the motor reversing switch and opens
the circuit when the platform reaches either the upper or lower limits of
travel. Whenever the motor switch is opened, a special brake on the end
of the armature shaft quickly stops the mechanism. The principal advan-,
tage of this type is the fact that the operator is able to perform all the labor^
of loading, transfer and unloading without difficulty. 1

63. Tiering type. The tiering lifting truck is similar to the elevating'
platform type (Par. 60) with the exception that the loads may be lifted any
distance from 1 in. to 6 ft. or more, thus making the truck a combination
electric-lifting platform truck and tiering machine. This type also has a*
carrying and raising capacity of 4,000 lb. It will mechanically pick up,
transport and deposit its load without the nece.ssity of rehandling, and to »
certain extent will perform the work of a portable crane.
64. Crane type. A crane truck embodying an electrically-operated
hoist and boom crane mounted on a standard electric platform truck ii.
useful for handling and moving heavy materials or machinery which are-
not within range of the usual travelling cranes. This type extends the
service of the traveling-crane or mono-rail system to the yards or to adja-.
cent buildings where the construction and head room restrict the use of an
overhead carrier. Crane trucks are built for lifting capacities of 1,000, 2,000;
and 3,000 lb. The boom may be raised or lowered to permit landing th(
load at any point on the platform of the truck. The boom is also equippec,-
with a swivel base so that it may be swung to either side. j

66. Hopper trucks for the handling of coal, ashes, sand and .similaiij
materials are in general built in two types, comprising the double side dum[!,
and the end dump. In some of the end-dump types the hopper can b<J
dumped by a separate motor energized from the truck battery.
66. The tractor-trailer system of inter-plant transportation
roved to be the more economical and adaptable type of transfer unit \^
E eavy drawbar pull is reciuired and where large tonnage is to be hiin.
daily. This system is comprised of a power unit and as many indiviiln i

trailers without motive power as may be required. Although any type '

1506
 ELECTRIC VEHICLES Sec. 17-^7

ruck may be used to haul trailers singly or in trains, the battery capacity
s usually insuflScient for the continuity of ser\-ice required.
The tractor power unit may be kept in operation almost continu-
67.
(usly and does not have to remain idle during the loading and unloading
•perations, as is the case with load-carrying trucks.
68. Use of the truck as a tractor. Any type of truck may be used to
Iraw trailers, but in general the battery capacity is insufficient for continu-
ous service and trucks as a class are not designed with the necessary drawbar
>ull for this work. The drawbar pull depends directly upon the weight on
he driving wheels and the torque capacity of the motor.
',
69. Drawbar pull. The normal drawbar pull is the maximum rating
nder which the tractors are designed to operate continuously, assuming
^verage conditions. The maximum drawbar pull is attained just before
he driving wheels begin to slip. The total load in tons which can be moved,
icluding weight of trailers, may be calculated on the basis of 50 lb. drawbar
•ull per ton, assuming trailers with good bearings traveling on level dry
trick, concrete or wood floors.

70. Steering and wheel drive. Tractors are equipped with two-wheel
rive,with single- wheel, two- wheel or three- wheel steering, depending upon
le type.
'
71. The
frame design follows generally-accepted automotive practice
^ery closely. The frames are made of I-beams, heavy channeb, or angle-
on sections, depending on the type of truck or tractor. The frame is sxip-
orted on the axles either by hea\-y coil springs or by semi-elliptic springs.
n. Wheel construction.
i
[ Wheels in general are of the solid or cast
rcvoh-ing on roller or ball bearings and equipped with either solid
[•T)e,
:ressed-on rubber or fabric tires. The carrying capacity of solid tires
Ncommended in the Standards of the Society of Automotive Engineers is
'ven in Par. 73.
73. Industrial Truck Tires
(S. A. E. Standard)

Nominal tire sizes Wheel dimensions

Nominal Width Diameter Felloe width

diameter 'in.) (in.) Un.) (in.)

3i 6 2i
5 6 41
3i 12 2i
5 12 41

3i 16 2i
5 16 4i
31 20 2f
3i 24 2i
Wheel diameters shall be 4 in. less than the nominal tire diameters.
'The height of the finished tire shall be 2 in. for all sizes.
74. Axles and housings. The axles and housings are made of steel and
aform to standard automotive design practice.
76. Transmission. The types of transmission in general use include
; worm, chain and spur-gear drives.

T*- The chain drive consists of a drivnng pinion on the motor shaft
ich engages a sprocket wheel through a silent chain. This sprocket,
'bodying a compact differential, transmits the mechanical energy through
teel countershaft to sprockets at either end, which in turn engage sprocket
eels on the respective driving wheels by means of roller chains.
n. The worm drive consists of a high-grade steel worm, phosphor bronze
"pi^'heel and differential, with all bearings assembled as a unit in a cast-
el housing, each road wheel being driven
through a shaft. All power-
nsmitting parts are in oil-tight housings and operate in a bath of oil.
(8. The spur-gear drive in general comprises a
double-reduction sptir
r, entirely enclosed and
operating in oil.

1507
Sec, 17-79 ELECTRIC VEHICLES

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