REWIRING & SPECIAL DUTY CAPABALITIES,

SITE TEST ON INDUCTION MOTOR

BY MAHESH.V
1JB16EE020
 REWIRING OF INDUCTION MOTOR
Rewiring is the process of providing New Electrical Wiring
by Removing the Old Wiring Installed in the Induction motor.
• The steps to Rewiring of Induction motor are :
• Scheme of Induction motor Pre-Installed (old wiring)
• Disassembling Old Induction motor
• Winding Diagram of New Wiring to be Installed
• Cut off old windings of motor , pull out windings
• Remove front Cover of Old motor , Remove Bearings
• Sandblasting
• Insert and Isolate Insulation paper in Stator of motor
• Coil Winding According to Winding Diagram of (New wiring)

• Place Coils in stator , Bind the Coils

• Varnishing the New motor

• Install & Assembly of New Bearings

• Motor fan , fans Protective Cover of new motor

• Starter Capacitor, Electrical clips , Mounting Pulley for new motor

• Slip – Test of Rewired motor

 SPECIAL DUTY CAPABILITIES
Duty cycles of Induction motor :During Motor Manufacture duties to Consider
The motor works at a constant load for enough time to
S1 Continuous duty
reach temperature equilibrium.

The motor works at a constant load, but not long enough

S2 Short-time duty to reach temperature equilibrium. The rest periods are
long enough for the motor to reach ambient temperature.

Sequential, identical run and rest cycles with constant

Intermittent
S3 load. Temperature equilibrium is never reached. Starting
periodic duty
current has little effect on temperature rise.

Intermittent Sequential, identical start, run and rest cycles with

S4 periodic duty with constant load. Temperature equilibrium is not reached, but
starting starting current affects temperature rise.

Intermittent periodic duty
S5
with electric braking
Continuous operation with
S6
intermittent load
Continuous operation with
S7
electric braking
Continuous operation with
S8 periodic changes in load and
speed
Sequential, identical cycles of
starting, running at constant
load and running with no load.
No rest periods.
Sequential, identical cycles of
running with constant load
and running with no load. No
rest periods.
Sequential identical cycles of
starting, running at constant
load and electric braking. No
rest periods.
Sequential, identical duty
cycles run at constant load and
given speed, then run at other
constant loads and speeds. No
rest periods.
 S9 : Duty with non-periodic load and speed variations

• This is a type of duty in which load and speed both vary non-periodically, unlike
the periodic duty cycles.

• load demands at varying speeds and varying over-loads, but within the
permissible temperature rise limits.

S10 : Duty with discrete constant loads

• This is a type of duty consisting of a number of varying loads, not more than four
in each cycle.

• Each load is performed for sufficient duration to allow the machine to attain its
thermal equilibrium
 Heating and cooling characteristic curves
• The heating and cooling behavior of an induction motor, up to around twice the
rated current, may be considered as exponential, as a part of the heat generated is
offset by the heat sink (heat dissipation) through the windings.

Time constants
• These are the times in which the temperature rises or falls by 0.632
times its maximum value qm and are provided by the machine
manufacturer.
 Factor of inertia (FI)
• This is the ratio of the total moment of inertia referred to the motor shaft to the
moment of inertia of the motor. If the motor moment of inertia is G*D^2*M and
the load moment of inertia at motor speed, G*D^2*L
Shock loading and use of a flywheel
• The application of a sudden load on the motor for a short duration, in the process
of performing a certain load duty, is termed ‘shock loading’.
• This must be taken into account when selecting the size of a motor. Electric
hammers, piston pumps, rolling mills, cane crushers and cane levelers, sheet
punching, notching, bending and cutting operations on a power press, a brake
press or a shearing machine are a few examples of shock loading.
 SITE TEST ON INDUCTION MOTOR
Why testing ?
• Winding defects can occur due to insulation age, contamination, power surges,
thermal overload, damaged wire/materials, vibration, and other causes.
• They begin as energy crossing an insulation fault (such as moisture or
contamination), which isolates at least one turn. This generates additional stress
and heat across the defect, which progresses until an arc is drawn and the winding
fails.

• The primary purpose of the (On - Site 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.
 On Site Routine Tests are:
• No-load running current and power
• High-Voltage test
• Magnetic center at no-load
• Blocked-rotor test
• Winding resistance measurement
• Air-gap measurement (Ag)
• Direction of rotation and phase sequence
• Current balance
• Vibration
• Insulation resistance measurement test
• Temperature rise test
• Shaft voltages
• Noise