1

Testing of Rotating AC
machines - Part II

Compilation By: Prof. S. N. Jani

 2

Induction Motor Testing

• All induction motors are tested before
shipment from the factory.
• This testing can be subdivided in two
groups:
1. Routine tests
2. Complete or prototype tests
• IEEE Std 112–1996 applies to induction
motor testing.
 3

1. Routine tests
• The primary purpose of the routine test is to
insure freedom from electrical and
mechanical defects, and to demonstrate by
means of key tests the similarity of the motor
to a “standard” motor of the same design.
• The “standard” motor is an imaginary motor
whose performance characteristics would
agree exactly with the expected performance
predictions.
 4

• Depending on the size of the motor, some or all

of the following tests could constitute routine
tests:
1. Winding resistance 8. Insulation resistance
measurement measurement
2. No-load running 9. Bearing temperature
current and power rise
3. High-potential test 10. Magnetic center at
4. Locked-rotor test no-load
5. Air-gap measurement 11. Shaft voltages
6. Direction of rotation 12. Noise
and phase sequence 13. Vibration
7. Current balance
 5

2. Prototype tests
• The purpose of a prototype test is to
evaluate all the performance
characteristics of the motor.
• This test consists of the following tests in
addition to the routine tests:

1. No-load saturation characteristic

2. Locked rotor saturation characteristic
3. Locked rotor torque and current
4. Loss measurement including stray load loss
5. Determination or measurement of
efficiency
6. Temperature rise determination
7. Surge withstand test
 6

Insulation Resistance test

• During general maintenance work and before
the machine is started up for the first time or
after a long period of standstill, the insulation
resistance of stator and rotor windings must
be measured.
• The insulation resistance measurement
provides information about the humidity and
dirtiness of the insulation.
• Based upon this information, correct cleaning
and drying actions can be determined.
• For new machines with dry windings, the
insulation resistance is very high.
 7

• The resistance can, however, be extremely

low if the machine has been subjected to
incorrect transportation, storage
conditions and humidity, or if the
machine is operated incorrectly.

• NOTE: Windings should be earthed briefly

immediately after measurement in order
to avoid risk of electric shock.
 8

The Basics of Insulation Resistance Testing

• How significant is insulation resistance testing?
• Since 80% of electrical maintenance and testing involves
evaluating insulation integrity, the answer is "very
important."
• Electrical insulation starts to age as soon as it's made.
• And, aging deteriorates its performance.
• Harsh installation environments, especially those with
temperature extremes and/or chemical contamination,
cause further deterioration.
• As a result, personnel safety and power reliability can suffer.
• Obviously, it's important to identify this deterioration as
quickly as possible so you can take the necessary corrective
measures.
 9

• Correlation between the insulation

resistance and the temperature:
• R = Insulation resistance value at a
specific temperature
• R40 = Equivalent insulation resistance at
40°C
• R40 = k x R
• Example:
• R = 30 M Ω measured at 20°C
• k = 0.25
• R40 = 0.25 x 30 MΩ = 7.5 M Ω
 10

Minimum values for insulation resistance

• Criteria for windings in a normal condition:
• Generally, the insulation resistance values for dry
windings should exceed the minimum values
significantly.
• Definite values are impossible to give, because
resistance varies depending on the machine type
and local conditions.
• In addition, the insulation resistance is affected
by the age and usage of the machine.
• Therefore, the following values can only be
considered as guidelines.
 11

• The insulation resistance limits, which are given

below, are valid at 40 °C, and when the test
voltage has been applied for 1 minute or
longer.
Rotor
• For induction machines with wound rotors:
R (1-10 min at 40 °C) > 5 MΩ
• NOTE: Carbon dust on slip rings and uncovered
copper surfaces lower the insulation resistance
values of the rotor.
Stator
• For new stators:
• R(1-10 min at 40 °C) > 1000 M Ω. If the
measuring conditions are extremely warm and
humid, R(1-10 min at 40 °C) values above 100
M Ω can be accepted
• For used stators:
• R(1-10 min at 40 °C) > 100 M Ω
 12

Stator winding insulation resistance

measurement
• The insulation resistance is measured using an
insulation resistance meter.
• The test voltage is 1000 V DC (Usually).
• The test time is 1 minute, after which the
insulation resistance value is recorded.
• Before the insulation resistance test is
conducted, the following actions must be
taken:
1. Check that the secondary connections of the
current transformers (CT's), including spare
cores are not open.
2. Verify that all power supply cables are
disconnected.
 13

3. Verify that the frame of the machine and

the stator windings not being tested are
earthed.
4. The winding temperature is measured.
5. All resistance temperature detectors are
earthed, Possible earthing of voltage
transformers (not common) must be
removed.
 14

Figure 1: Connections of the stator windings for

insulation resistance measurements
a) Insulation resistance measurement for star
connected winding
b) Insulation resistance measurement for delta
connected winding
c) Insulation resistance measurement for one
phase of the winding. The 'MΩ' represents the
insulation resistance meter.
 15

Rotor winding insulation resistance

measurement
• The insulation resistance of the rotor winding
is measured with an insulation resistance
meter.
• The test voltage of the rotor windings should
be 1000 V DC.
• Required notes and measures:
1. Verify that all power supply cables are
disconnected from the main supply.
2. Verify the slip ring unit connection cables are
disconnected from their supply.
3. Verify that the frame of the machine and the
stator windings are earthed.
 16

4. The shaft is earthed

5. The rotor winding phases not been tested
are earthed. The rotor winding can be
internally connected in a delta or star
connection. If this is the case, it is not
possible to measure the phases individually.
6. The carbon brush connections are checked
to be in good order.
7. The measurement device is checked.
8. The stator winding temperatures are
measured, and considered as a reference
value for the rotor winding temperature.
 17

• The insulation resistance meter is connected

between the whole rotor winding and the shaft
of the machine, see Figure 2 Insulation
resistance measurement of the rotor winding.
• After performed rotor winding measurements,
the rotor winding phases must be briefly
earthed in order to discharge the windings.

Figure 2: Insulation resistance measurement of the rotor

winding
In the figure above the rotor is star-connected.
 18

Stray load loss

• The stray load loss is that part of the total loss
that does not lend itself to easy calculation. It
consists of two parts, viz., losses occurring at
fundamental frequency, and losses
occurring at high frequency.
• The stray load loss can be determined by the
indirect method or by the direct method.
• By the indirect method, the stray load loss is
obtained by measuring the total losses using
the input-output method and subtracting from
them the sum of stator and rotor I2R losses,
the core lose and the friction and windage loss.
 19

• The method thus entails subtracting two

relatively large quantities from each other
and is, therefore, not very accurate.
• For greater accuracy, and for the
determination of efficiency by the loss
segregation method, the direct
measurement techniques must be used.
• In this, the fundamental frequency and
high frequency components are measured
separately and require two tests:
• The rotor removed test
• The reverse rotation test
 20

• The fundamental frequency losses can be

measured by the rotor removed test, in
which consists of measuring the power input
with the rotor removed from the motor.
• The high frequency component is
measured by the reverse rotation test,
which entails (requires) measuring the power
input to the motor, with the rotor being
driven in the reverse direction to the stator
revolving field, and at synchronous speed.
• For details of this test, see IEEE 112–1996.
 21

𝑷𝑺𝑳 = 𝑷𝑺𝑳𝒔 + 𝑷𝑺𝑳𝒓

Stray load Loss at Fundamental Frequency

𝑷𝑺𝑳𝒔 = 𝑷𝒔 − 𝑺𝒕𝒂𝒕𝒐𝒓 𝑰𝟐 𝑹 𝒍𝒐𝒔𝒔; with rotor being
removed

Stray Load Loss at High Frequency

𝑷𝑺𝑳𝒓 = 𝑷𝒓 − 𝑷𝒎 − (𝑷𝒓𝒓 − 𝑷𝑺𝑳𝒔 + 𝑺𝒕𝒂𝒕𝒐𝒓 𝑰𝟐 𝑹 𝒍𝒐𝒔𝒔) ;
with rotor being rotated at synchronous speed
in the reverse direction of stator field.
 22

𝑷𝒓 = 𝑴𝒆𝒄𝒉𝒂𝒏𝒊𝒄𝒂𝒍 𝑷𝒐𝒘𝒆𝒓 𝒓𝒆𝒒𝒖𝒊𝒓𝒆𝒅 𝒕𝒐 𝒅𝒓𝒊𝒗𝒆 𝒓𝒐𝒕𝒐𝒓

𝒘𝒊𝒕𝒉 𝒗𝒐𝒍𝒕𝒂𝒈𝒆 𝒃𝒆𝒊𝒏𝒈 𝒂𝒑𝒑𝒍𝒊𝒆𝒅 𝒊𝒏 𝒕𝒉𝒆 𝒔𝒕𝒂𝒕𝒐𝒓

𝑷𝒎 = 𝑴𝒆𝒄𝒉𝒂𝒏𝒊𝒄𝒂𝒍 𝑷𝒐𝒘𝒆𝒓 𝒓𝒆𝒒𝒖𝒊𝒓𝒆𝒅 𝒕𝒐 𝒅𝒓𝒊𝒗𝒆 𝒓𝒐𝒕𝒐𝒓

𝒘𝒊𝒕𝒉𝒐𝒖𝒕 𝒗𝒐𝒍𝒕𝒂𝒈𝒆 𝒃𝒆𝒊𝒏𝒈 𝒂𝒑𝒑𝒍𝒊𝒆𝒅 𝒊𝒏 𝒕𝒉𝒆 𝒔𝒕𝒂𝒕𝒐𝒓

𝑷𝒓𝒓 = 𝑬𝒍𝒆𝒄𝒕𝒓𝒊𝒄𝒂𝒍 𝑰𝒏𝒑𝒖𝒕 𝑷𝒐𝒘𝒆𝒓 𝒕𝒐 𝒔𝒕𝒂𝒕𝒐𝒓 𝒅𝒖𝒓𝒊𝒏𝒈

𝒓𝒆𝒗𝒆𝒓𝒔𝒆 𝒓𝒐𝒕𝒂𝒕𝒊𝒐𝒏 𝒕𝒆𝒔𝒕

𝑷𝒔 = 𝑬𝒍𝒆𝒄𝒕𝒓𝒊𝒄𝒂𝒍 𝑰𝒏𝒑𝒖𝒕 𝑷𝒐𝒘𝒆𝒓 𝒕𝒐 𝒔𝒕𝒂𝒕𝒐𝒓 𝒘𝒊𝒕𝒉 𝒓𝒐𝒕𝒐𝒓

𝒓𝒆𝒎𝒐𝒗𝒆𝒅
 23

Machine Rating in kW Stray Load Loss percent of

rated load

1 – 90 1.8 %

91 – 375 1.5 %

376 – 1850 1.2 %

1851 and greater 0.9 %

 24

Efficiency tests
• Efficiency is the ratio of the motor output
power and the motor input power.
Output
• Efficiency =
Input
Output
• =
Output  Losses
•
Input  Losses
• =
Input
• It can thus be calculated by a knowledge of
power input and power output, or of power
output and losses, or power input and losses.
 25

• The losses in the induction motor consist of

the following:

• Stator I2R loss

• Rotor I2R loss
• Core loss
• Friction and windage loss
• Stray load loss
 26

• IEEE Std 112 gives 10 different methods for

the measurement of efficiency.
• Only three of these methods will be
described here, one each for fractional-
horsepower, medium and larger
induction motors.
• For a more complete description, see IEEE
Std 112–1996.
 27

Method A— Input-Output method.

• This method is suitable for fractional-
Horsepower motors.
• In this method, the motor is loaded by means
of a brake or a dynamometer.
• Readings of electrical power input, voltage,
current, frequency, slip, torque, ambient
temperature and stator winding resistance are
obtained at four load points, more-or-less
equally spaced between 25% and 100% load,
and two loads above the 100% point.
• Motor efficiency is then computed using the
procedures laid out in Form A in IEEE Std 112.
 28

Method B—input-output with loss

segregation.
• This method is the only method suitable for
testing motors designated energy efficient
through 250 horsepower size range.
• The method consists of several steps which
need to be performed in a set order.
• By this method, the total loss (input minus
output) is segregated into its various
components with stray-load loss defined as
the difference between the total loss and the
sum of the conventional losses (stator and
rotor I2R losses, core loss, and friction and
windage loss).
 29

• Once the value of the stray load loss is

determined, it is plotted against torque
squared, and a linear regression is used to
reduce the effect of random errors in the test
measurements.
• The smoothed stray load loss data are used to
calculate the final value of the total loss and
the efficiency.
• The tests required to be performed to develop
the loss information are described below.
 30

1. Stator I2R loss is calculated from a knowledge

of the rated stator current and the resistance
of the stator winding corrected to the
operating temperature.
2. Rotor I2R loss is calculated from a knowledge
of the input power at rated load, the stator I2R
loss, the core loss and the per unit slip.
3. Rotor I2R loss=(measured input power—stator
I2R loss—core loss)×per unit slip.
4. The core loss and friction and windage losses
are determined from the no-load running
current and power test.
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5. The motor is run with no load at rated

voltage and frequency.
• The friction and windage loss is obtained by
plotting the input power minus the stator I2R
loss vs. voltage, and extending this curve to
zero voltage.
• The intercept with zero voltage axis is the
friction and windage loss.
6. The core loss is obtained by subtracting the
sum of stator I2R loss at no-load current and
rated voltage, and the friction and windage
loss from the no load power input at rated.
 32

Method F (and variations)—equivalent-

circuit method.
• This test is usually used for a motor whose size
is greater than 250 hp, and its size is such
that it is beyond the capabilities of the test
equipment.
• This method uses the equivalent circuit of the
induction motor to determine the performance
from circuit parameters established from test
measurements.
• The test provides acceptable accuracy for
starting and running performance.
 33

• It also yields the most accurate determination of

the losses and hence the efficiency.
• This method uses two locked rotor tests: one at
line frequency, and the other at reduced
frequency (a maximum of 25% of rated
frequency).
• These tests, in conjunction with the running
saturation test, delineate (define) the classical
equivalent circuit parameters of the motor.
• From the no load saturation test, the
magnetizing reactance, the stator leakage
reactance and the magnetizing conductance
can be determined.
• The rated-frequency locked-rotor test measures
the stator and rotor reactance and the rotor
resistance under initial starting conditions.
 34

• The low frequency locked-rotor test measures

the stator and rotor leakage reactance and
rotor resistance at close to the running
frequency.
• The stator and rotor leakage reactance for
equivalent circuit are separated using the ratio of
these parameters provided by design.
• The machine performance is then calculated
using the parameters established from the test.
• Losses as determined from no-load tests are
introduced at appropriate places in the
calculation to obtain overall performance.
 Air gap

• An important factor in electrical rotating

machines.
• Failure mechanism associated with it
and ITS EFFECTS.
• There should be an airgap between rotor
and stator of the rotating machine so that
rotor can move without any friction except
air friction.
• If this air gap is not evenly distributed
around the 360° of the motor, uneven
magnetic fields can be produced.
• Magnetic imbalances.
• Cause movement of the stator windings,
resulting in winding failure.
• Electrically induced vibration, resulting in
bearing failure.
• The air gap fault zone describes the
measurable distance between the rotor and
stator.
• Air gap eccentricity is a condition that
occurs when there is non uniformity in
the air gap.
• When there is an eccentricity in the air
gap,
1. Varying magnetic flux within the air
gap.
2. Imbalances in the current flow, which
can be identified in the current
spectrum.
 • This unevenness in the space between the
rotor and stator will affect the alignment of
the RIC test results. (The RIC* is a graphical
representation of the magnetic coupling between
the rotor and the stator.)
1. Static eccentricity occurs when the
centerline of the shaft is at a constant offset
from the centerline of the stator. For
example misaligned* end bell.
2. Dynamic eccentricity occurs when the
centerline of the shaft is at a variable offset
from the centerline of the stator, such as a
wiped bearing.
 39

What is RIC?
• The Inductance measurements taken from
each phase of the stator windings and
compares them at different rotor
positions to further define the condition of
the rotor.
• This test is known as the Rotor Influence
Check (RIC).
• Figure shows us the results of a RIC test
performed on a healthy AC induction motor.
 40

Note that each of the three inductance patterns are 120o apart and travel
through two complete cycles over 360°. This occurs as a result of the
motor under test being a 4-pole motor. Each pole consists of 90o.
• By definition, air gap eccentricity is a mechanical
fault with the motor.
• There are several possible causes for the
Failure Mechanisms
presence of variances in the distance between a
rotor and a stator.
• The five basic types of air gap eccentricities
that can occur are:
1. Rotor Outside Diameter is eccentric to the axis
of rotation,
2. Stator bore* is eccentric,
3. Rotor and stator are round, but do not have
the same axis of rotation,
4. Rotor and shaft are round, but do not have the
same axis of rotation,
5. Any combination of the above.
42
• The following are only a few of the
possible causes of an air gap eccentricity:
1. Incorrect mounting of the motor to
its bedplate can lead to an air gap
distortion.
• A loose or missing bolt allows shifting of
the motor’s mounting foot during thermal
expansion of the frame.
• This shifting over time could lead to a
distortion of the frame.
• The common term for a motor incorrectly
mounted is soft foot.
2. During construction of the motor, out-of-
roundness of either the rotor or stator will
lead to an air gap eccentricity.
• Industry standards: for total indicated
roundness should be performed at
different locations along the length of each
of these components.
• Couple measurements are at the
circumferences of each component,
depending on the speed and size of the
motor, there are recommended tolerances
from 5% to 20% variation in the air gap.
3. Eccentricity can develop due to incorrect
tensioning of drive belts coupled to a motor.
• Incorrect alignment could also lead to a
situation similar to this with both leading to a
bowing of the rotor during operation.
4. Distorted end bells, cocked bearings, or a
bent shaft will all cause an Air gap
eccentricity,
• During the manufacturing of the rotor, uneven
mechanical stresses could be introduced into
the cage and lamination stack.
• That will lead to bowing (bend) of the
completed rotor.
46
• Increased levels of vibration due to the
uneven magnetic pull it creates between the
EFFECTS
circumferenceofofAIR
the gap
rotor eccentricity
and stator bore.
• These elevated levels of vibration can result in
excessive movement of the stator winding,
which could lead to increased friction and
eventually a turn-to-turn, coil-to-coil, or
ground fault.
• Additionally, this vibration can accelerate
bearing failure, which could seize the shaft
and overheat the windings or allow
additional movement of the shaft leading to a
rotor/stator rub (stroke).
• The uneven magnetic stresses applied to
EFFECTS
the rotor ofcoupled
AIR gapwitheccentricity
the increased
vibration will also contribute to
mechanical looseness developing in the
rotor.
• Any of these occurrences could lead to a
catastrophic failure (terrible) of the
motor, which could require a complete
rewind and possible restacking of the
iron.