
HVAC Training
Page: 11 of 13
Title: Chiller High Voltage Motor Terminations Lesson Plan #: NMH30L050303
g) With the terminal stud in the ceramic insulator, slide ceramic insulator over the motor lead
and thread insulator into motor housing, Torque insulator to 25 Ft lbs.
h) Lubricate terminal stud o-ring and slide over the threaded portion of the copper stud, then
install copper sleeve.
Important: The copper sleeve, which contacts the o-ring packaged with the ceramic terminal, has
been machined to fit that terminal assembly inside diameter. Do not mix terminals insulators and
sleeves, use only the sleeves, use only the sleeve provided with each individual terminal.
i) Slide the copper washer over the stud and next to the copper sleeve. If replacing the old
plastic terminal and not the terminal stud, two or more washers will be necessary because
of the difference in length between the old insulator and the new ceramic insulator.
j) Install the brass jam nut and tighten against the washers to maximum of 3 Ft lbs while
holding copper stud. This will seat the copper washer against the insulator and draw the
internal shoulder onto the stud against the internal edge of the insulator.
Note: The copper sleeve will not crush the o-ring.
If leakage occurs after the terminal is assembled, then the parts are defective and should be
replaced. Do not over tighten to eliminate leaks.
1.1.2.4 Demonstration
Prior to performing the demonstration have the trainees perform the hazard assessment and determine what PPE is
required for the task. Using the Lab Practical Evaluation and the work instructions, show the trainee how to perform the
installation.
An optional exercise is to have one of trainee's perform the installation as you explain the process. Based on the
experience of the trainee, have one trainee read the instruction and the other perform the task. Self check/Peer check.
1.1.2.5 Practice
Have trainee assemble the terminal
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