REWINDING:

Receiving procedures and Visual Inspection

Learning Objectives

You will be able to :

Complete a motor check-in procedure, using the appropriate forms and tags.

Perform a visual inspection of a motor.

Record inspection results.

Background

Performing a careful visual inspection when a motor comes into your shop will give you an estimate of
how long the job will take and whether assistance from another shop will be needed. This will not only
help you as the shop technician or shop supervisor, but will give the customer the feeling that his piece
of gear is in

Fill out a tag on each incoming motor, Include the following:

Customer name

Motor type

Motor H

Motor Sl. No.

Date

Other information, as required

Give applicable sections of the tag to the person who delivered the motor competent hands.

Obtain background information

Does the motor have a history of frequent failures? If so, are the failures normally mechanical or
electrical? Has maintenance been recently performed on the motor or the driven unit prior to the
malfunction? What action, if any, was taken by customer when the malfunction was first discovered?

ROTATIONAL SHAFT MOVEMENT. ROTATE THE MOTOR SHAFT CLOCKWISE AND COUNTERCLOCKWISE
TO DETERMINE BINDING.

VERTICAL SHAFT MOVEMENT. MOVE THE MOTOR SHAFT ‘UP AND DOWN’ IN THE VERTICAL LANE TO
DETERMINE BEARINGWEAR.
HORIZONTAL SHAFT MOVEMENT. MOVE THE MOTOR SHAFT’BACK AND FORTH’IN THE HORIZONTAL
LANE TO DETERMINE END-LAY.

ENDPLATE GAP- A MOTOR SHOWING ENDP LATES NOT PROPERLY MOUNTED. THIS PREVENTS THE
ROTOR FROM TURNING.

Quality Assurance package

Complete applicable portions of the Quality Assurance package. The Quality Assurance package provides
space for most of the information on the shipping tag plus any documents that were delivered with the
motor.

Visual Inspection

NOTE: A representative of the customer must witness the inspection and, if applicable, sign the
completed inspection sheet.

Visually insect the outside of the motor for the following and other defects.

Loose or broken arts. A loose bolt may be stripped.

Distortion of end bells indicated by a gap at the mating surface

Cracked, bent, or welded bearing caps

Loose or missing bolts or bolts of the wrong size or material

NOTE: Distorted or misaligned end bells can cause rotors to bind

Rotate the shaft by hand (see figure) to check for freedom of movement. Note any binding or rubbing.

NOTE: Use the motor overhaul sheet or comparable form every time a unit comes into the shop. Do NOT
hesitate to record the conditions as they are.

While making the visual inspection, note conditions in the appropriate section of the Quality Assurance
Logbook.

If the rotor bums or binds when it is rotated, omit the runout measurement

Take a shaft runout reading if the bearings are good; record the results.

Review Questions

If you can correctly answer the questions below, you have learned the key points in this lesson.

1. What is the purpose of a receipt inspection?

Estimate time needed for repairs

 Determine material condition of motor
Assemble appropriate maintenance forms
All of the above
2. What motor background information would be important to the shop?
Motor manufacturer
Operating status of the motor
Recent maintenance performed
person discovering failure
3. What condition is indicated by excessive vertical (lateral) shaft movement?
Misaligned end bells
Bent shaft
Bearing wear
Missing thrust washer
INTRODUCTION TO AC MOTOR REWIND
Learning Objectives
You will be able to:
Identify and use three-phase ac motor rewind terminology and related formulas.
Identify sources of rewind information.
Understand basic types of winding connections.
Understand winding diagram development by use of formulas, technical documentation, and/or
actual stator windings.
Develop winding diagrams for series star, parallel star, series delta, parallel delta, and consequent
pole connected motor windings.
Background
The first step in rearing a stator for rewinding is to determine the type of winding it has, or should have,
and develop the appropriate winding diagram. In order to do this, you must understand:
Basic rewind terminology and formulas
Types of three-phase winding connections
Sources of connection and rewind data
Availability of documentation
How to obtain necessary data
Once all the necessary information has been assembled, development of the winding diagram can begin.
Note For purposes of this course, motors are considered to be four-ole, three-phase, 50 H
Alternate Pole Polarities for One phase of a Four-pole, Three-phase AC Motor
Basic rewind terminology, formulas, and definitions
SYNCHRONOUS SEED
This term refers to the seed of the rotating field in the stator. The motor rotor will never turn at
synchronous seed due to various mechanical friction losses, windage, and builtin slip. The difference
between synchronous seed and actual rotor seed is called slip and is expressed in a percent of
synchronous seed.
The usual amount of slip in a 50-Hertz, three-phase motor is two or three percent. Synchronous seed
must be known to determine the number of poles and pole-phase groups (Gs) in the stator winding and
can be easily determined by use of the following formula:
Note: The number 120 is a constant (K) and the frequency used for examples in this lessons will always
be 50 Hertz.
N (seed) = 120 x F (frequency)÷ (poles) or N=KF+
Example: Synchronous seed of a four-pole motor
N=120 x 50 ÷ 4
N=6000 ÷ 4
N=1500 r/m
HASES:
As the name implies, three-phase motor stator winding will consist of three separate groups of coils
called phases. Phases must be displaced from each other by 120 electrical degrees. Phases must be
electrically balanced (contain the same number of coils) and connected for the same number of poles.
Phases will always be designated as A, B, and C.
POLES:
Poles refer to a coil or group of coils wound and connected to produce a unit of magnetic polarity. Poles
are referred to as either north or south. The number of poles a stator is wound for will always be an
even number and refers to the total number of north and south poles. For example, a four-pole motor
will have two north and two south poles alternately spaced around the stator. (see figure at right). The
number of poles in the stator must be known to determine the number of Gs in the motor and can be
easily determined by the formula below.
= 120 F ÷ N
Example: = 120 x 50 ÷ 1500
= 6000 ÷ 1500
=4
ACTIVE COILS PER PHASE
An active coil is a coil that is electrically connected in the stator circuit. (It is sometimes necessary to
install, but not connect, certain coils in the stator winding. Coils that are not connected are called
dummy coils and will be discussed next in this lesson). Each phase must contain an equal number of
active coils to ensure electrical balance (phase current). In almost all cases, the total number of coils in
the stator will be equal to the number of slots. Active coils per phase can always be determined by
dividing the total number of coils by three (number of phases).
Active coils per phase = total coils ÷ phases
Example :
36 (total coils) ÷ 3 phases = 12 active coils per phase
In this example the answer is a whole number, meaning all coils in the winding will be active. In this case
the winding is known as an integral slot winding. If the answer is a mixed number, the winding is called a
fractional slot winding.
Example :
62 (total coils) ÷ 3 phases = 20 2/3 coils per phase
In this example, the winding will require the use of two dummy coils to compensate for the fractional
number
DUMMY COILS :
As discussed previously, dummy coils are used to fill slots but are not electrically connected in the stator
circuit. If only one dummy coil is required, it can be installed in any slot. If two dummy coils are required,
they can be installed in any slots 180 mechanical degrees apart. Dummy coils will always be left open
circuited.
POLE-PHASE GROUS (PPGs)
This term refers to the number of coils connected in series to form the magnetic pole of a phase. Each
phase must contain an equal number of PPGs. Total PPGs can be determined by multiplying the number
of motor poles by three (number of phases).
Example: 4 poles x 3 phases = 12 PPG
COILS PER POLE-PHASE GROUP (C/PPG): As the name implies, this term refers to the number of coils
that comprise an individual PPG. The number of coils in the PPGs may or maynot be equal. C/PPG can be
determined by dividing the total active coils by the number of pole-phase groups, or.
C/PPG = total active coils ÷ pole-phase groups
C/PPG= TAC ÷ PPG
Example: How many C/PPGs will a four-pole, three-phase motor with 36 active coils have?
Example: How many C/PPG will a six-pole, three-phase motor with 48 active coils have?

PPGs = 4x3 =12

C/PPG=36÷12 =3
In this example, the result is a whole number meaning that each PPG will contain the same number of
coils, in this case, 3.
When the result is a mixed number, the C/PPG will not be equal and the exact combinations of C/PPG
must be determined.
PPG = 6 X 3 = 18
C/PPG = 48 ÷ 18 = 2 - 12/18 The mixed number 2-12/18 indicates that some
Poles 1 2 3 4 5 6 Total
Phase A 2 3 3 2 3 3 =16
Phase B 3 2 3 3 2 3 =16
Phase C 3 3 2 3 3 2 =16
Totals 8 8 8 8 8 8 =48

Poles 1 2 3 4 5 6
Phase A 2 2
Phase B 2 2
Phase C 2 2
 Groups will have two C/PPG and some will have three C/PPG. In this example, the numerator of the
fraction indicates the number of PPGs that will contain the larger number of C/PPG. In other words, 12
of the 18 PPGs will contain 3 coils each and the remaining 6 groups will contain 2 coils each.
We can check this configuration by multiplying as follows:
12 PPG x 3 coils = 36 coils
6 PPG x 2 coils = 12 coils
36 + 12 = 48 coils
For electrical balance, coil grouping must phase will contain the same number of active d the stator.
In our example, we had 12 groups of 3 coils each and 6 groups of 2coils each. By dividing the groups by 3
(the number of phases), it can be seen that each phase will contain 4 groups of 3 coils and 2 groups of 2
coils or 16 coils per phase.
The most common method of determining how the grouping will be laid out is to draw a matrix and
enter the smaller number of coils first, as shown below
Than, enter the larger number of coils in the blank spaces and check both the number of active coils per
phase as well as the total number of active coils, as in the example below.
COIL SPAN OR PITCH
Coil span or pitch is defined as the number of slots separating the sides of a coil including the slots in
which the coil sides lie. The coil span or pitch is normally referred to by the individual numbers of the
sides in which the coil sides are laid during rewind, i.e., 1 and 6, 2 and 7, 3 and 8, etc
TYPES OF WINDINGS
BASKET WINDING:
Defined as a single layer winding, the basket winding is also called the half-coil winding. This winding
will have one coil side per slot, with the total number of active coils equal to one-half of the total
number of slots.
DISTRIBUTED WINDING:
This winding is defined as a double layer winding and is the most common type of winding. It will have
two coil sides per slot, with the total number of active coils equal to the total number of slots
Types of winding connections
WYN (STAR) CONNECTION : The wye or star connection is defined as where the finishes of each phase
are connected together, and the starts are connected to the line leads. The diagram for this winding
resembles an inverted letter Y. The wye can be connected in series or parallel configuration
DELTA CONNECTION:
In the delta connection, the finish of each phase is connected to the start of the next phase. The diagram
tor this winding resembles the Greek letter delta. The winding can be connected in series or parallel
configurations.
Methods of connecting PPGs
SHORT JUMPER:
This method is defined as when PPGs are connected finish-to-finish and start-to-start. It is the most
common connection method and is used extensively in single-speed motors and in all instances of
unequal coil grouping. Connections of each phase are identical. This method interconnects adjacent
groups of alternate polarity within each phase. Each jumper spans 180 electrical degrees.
Refer to the figure during the following discussion.
Typical short jumper connections for a four-pole motor winding would be as follows:
Begin at the start of A1 (As), go finish-to-finish, start-to-start, finish-to-finish, start-to-start. Etc., to A10
(Af). C phase and B phase follow the same way. The connection sequence will be the same, regardless of
the number of poles.
LONG JUMPER:
This method is used when connections are made finish-to-start and start-to-finish. It is used mainly for
connecting consequent pole, single-winding, dual -speed motors. In some cases, it is also used for
connecting one or both of the individual windings in two-speed, two-winding motors. Connections for
each phase will be identical. This method interconnects alternate PPGs of the same polarity within each
phase. Each jumper spans 360 electrical degrees. Alternate polarities are achieved by using a single
short jumper as the center connection of each phase.

Refer to the figure during the following discussion.

Typical long jumper connections for a four-pole motor winding would be as follows:

Begin at A1 start (As), finish-to-start, finish-to-finish (short jumper), start-to-finish, to A10 (Af).
Connection sequence will be the same regardless of number of poles.

SKIP GROUP;

This term refers to the method of starting connections for individual phase. It can be used with either
long or short jumper methods. It provides physical displacement between starts of phases to help
eliminate potential short circuits.

Refer to the figure showing typical short jumper and skip group connection during the following
discussion.

Connections will always be as follows, regardless of the number of poles in the motor:

A phase is started with G1. C phase is started with G3. B phase is started with PPG5.

The skip group method may be referred to as the “1-3-5 method” for obvious reasons.

Terminal markings:

Terminal markings are used to identity the end leads of various PPGs in a three-phase winding. Terminal
marking numbers are standard and are derived by dividing the number of PPGs in each phase and
assigning numbers to them.

The standardized marking system allows us to connect the PPGs in series of parallel as necessary. The
standard marking system is as follows:

A T1 T T an T1

Phase ‘ 4, 7, d 0
 B T2 T T an T1

Phase , 5, 8, d 1

C T3 T T an T1

Phase , 6, 9, d 2

In most cases, the majority of terminal connections are made internally as part of the stator winding and
only terminals T1, T2, and T3 are brought out to the motor connection box.

However, dual voltage and dual seed motors will have more terminal leads brought out and will be
discussed later in the lesson.

Sources of winding information

There are several sources of particular winding and connection information. Of course, the actual stator
winding of the motor to be rewound is one source of information available. This will be discussed in
another lesson.

The actual stator winding information should always be verified, if possible. In other words, do not
assume that a failed motor was wound correctly. This is especially true in a motor that failed shortly
after rewinding or a motor that has a history of frequent failures.

The manufacture’s technical manual will normally contain all necessary rewind information. Included
will be connection diagrams, wire size, coil pitch, and number of wires in hand, as well as other motor
repair and arts replacement information.

The manufacturer can supply all necessary information from the company ,s files. Calling or writing the
manufacturer also has the advantage of obtaining information on any engineering changes that have
been recommended by the firm. Also, the manufacturer ’s representative may possibly point out errors
or omissions in the technical manual.

The motor nameplate can be used to obtain information such as motor operating revolutions per
minute(r/m), amperes (ams), and temperature rise.

Winding diagram development

As we discussed previously, the vast majority of motor windings are connected by short jumper. In
addition, skip group (the “1-3-5”method) connections will always be used.

The first step in developing any winding diagram is to correctly draw, label, and connect the PPGs. The
winding diagrams to be developed will be for 2 four-pole, three-phase motor.

Each segment shown in the figure opposite represents one PPG. Starting at the left, number the PPGs
from 1 through 12.
Label PPG1 with the letter A, PPG2 with the letter B, PPG3 with the letter C to denote the three phases.
Working left to right, label the remaining PPGs A, B, C, A, B, C, etc.

Draw an arrow under PPG1 so that the arrow head is pointing towards the right side of the page. Draw
an arrow under the remaining PPGs while alternating the direction of the arrow heads.

Label each PPG with the letter s (start) on the left edge and the letter f (finish) on the right edge.

Beginning with the start of PPG1 (A phase), connect all A phase PPGs so that a dc current flowing
through them would flow in the same direction as the arrows.

Label the start of PPG1 as As (A phase start) and the start of PPG10 as Af (A phase finish).

Beginning with the start of PPG5, connect all B phase PPGs and label phase starts and finishes as
appropriate.

NOTE: If connected correctly, the start of PPG2 will be finish of B phase.

Beginning with the start of PPG3 connect and label all C phase PPGs in the same manner.

NOTE: If connected correctly, the start of PPG12 will be the finish of C phase.

To connect this diagram for a series wye (star) winding, connect the phase finishes together and label
the starts T1, T2, and T3 (phase A,B,C).

Compare your drawing to the figure illustrating the typical short jumper connection. Now you can see
how winding diagrams are developed. This system can be used for almost any type of winding regardless
of the number of poles.

The only difference would be how the individual PPGs and phase starts and finishes would be
connected. This depends on the type of winding (wye or delta) and whether it is to be connected in
series or parallel.

An easier method than the one we just discussed would be to develop the diagram in the shape of the
type of winding, that is, wye or delta.

In fact, this is way that diagrams are normally shown in the manufacturer ‘s technical manual or other
technical documentation. Technical documentation will sometimes also show a circular connection
diagram in addition to the shape diagram. Circular diagrams will be discussed later in this lesson.

Now redraw the diagram you just completed in the wye (star) shape.

Series Wye (star) connection

Starting at the top of the inverted Y, label the end of the topmost line As (A phase start). Proceed in a
clockwise direction and label the other legs Bs and Cs respectively.
Starting at the outside (As end) and, working towards the center of the diagram, number the A phase
PPGs with their proper numbers.

Number B and C phase Gs in the same manner.

Starting with phase A, write the letter f (finish) between PPGs 1 and 4. This designates that the finish of
PPG1 connects to the finish of PPG4. Refer to the straight line diagram and write in s and f where
appropriate to complete A phase. Label phases B and C PPGs in the same manner.

NOTE: If labeled correctly, the diagram should show alternate starts and finishes.

Connect the phase finishes at the center of the diagram. This is the star point.

The phase starts would be labeled T1, T2, and T3 and connected to the line leads as previously
discussed.

This completes the series wye connection diagram. This connection is used for high voltage, low current
windings. The figure at right shows a circular diagram for this same winding.

Now other types of winding connections will be discussed and developed.

Parallel wye connection

This type of connection is used for low-voltage, high-current windings. Each phase is split in half and
reconnected from series to parallel as follows.

NOTE: Do NOT confuse terminal markings with PPG numbers.

Starts of PPGs 1 and 7 (T1 and T7) are connected to form T1.

Starts of PPGs 4 and 10 (T4 and T10) are connected to form T4 which would be connected to the star
point.

NOTE: On a large motor, it is usually easier to form two star points of three starts each rather than one
star point of six starts. In this case, we would connect the starts of PPGs 4, 8, and 12 and the starts of
PPGs 2, 6, and 10.

Series delta connection

This connection is used for high-voltage, low-current motors.

To form a series delta connection from a series wye, reconnect as follows.

A phase start to C phase finish to form T1

B phase start to A phase finish to form T2

C phase start to B phase finish to form T3

If connected correctly, the starts of PPGs 1 and 12, the starts, of PPGs 5 and 10, and the starts of PPGs 2
and 3 will be connected.

This winding can be recognized by the fact that it will have two phase leads connected to each line lead
with no star point present.

Parallel delta connection

This connection is used for high-current, low-voltage windings.

To form a parallel delta from a series-delta, reconnect as follows:

Divide the PPGs of each phase in half as previously described.

Connect the starts of A phase PPGs 1 and 7 and C phase PPGs 6 and 12 to form T1

Connect the starts of B phase PPGs 5 and 11 and A phase PPGs 4 and 10 to form T2

Connect the starts of C phase PPGs 3 and 9 and the starts of B phase PPGs 2 and 8 to form T3

Nine-lead dual-voltage connections

Both wye- and delta-connected stators can be used for dual-voltage motors. The PPGs must be divided
in half and connected in series for high voltage and connected in parallel for low voltage.

Nine terminal leads (T1 through T9) will always be brought out of the stator winding. Then, various
connection configurations can be made, as necessary, at the connection box.

Dual-voltage series wye connection (high voltage)

Connect A phase terminals T4 and T7.

Connect B phase terminals T5 and T8. Connect C phase terminals 6 and 9.

NOTE: Terminals T10, T11, and T12 will be permanently connected in the stator winding (star point) of
wye-connected motors.

Connect terminals T1,T2, and T3 to line leads L1,L2, and L3, respectively.

NOTE: Standard wye-connected, dual-voltage motor connections are shown at the bottom of the figure.
These same connections are normally shown on the outside of the motor housing or inside the
connection box cover of dual voltage motors.

Dual-voltage, parallel wye connection (low voltage)

Connect A phase terminals 1 and 7.

Connect B phase terminals 2 and 8.

Connect C phase terminals 3 and 9.

Connect terminals 4 (A phase), 5 (B phase), and 6 (C phase).

Connect T1-T7, T2-T8, and T4-T9 to line leads L1, L2, and L3, respectively

Dual- voltage, series delta connection (high voltage)

NOTE: Standard delta-connected, dual-voltage motor connections (low voltage) are shown at the top of
the figure. These same connections are normally shown on the outside of the motor housing or inside
the connection box cover.

Connect A phase terminals T4 and T7.

Connect B phase terminals T5 and T8.

Connect C phase leads T6 and T9

Connect T1, T2, and T3 to line leads L1, L2, and L3 respectively.

Dual-voltage, parallel delta connection

(low voltage)

Connect T1, T6, and T7 with L1.

Connect T2, T4 and T8 with L2.

Connect T3, T5, and T9 with L3

Consequent pole connections

Connecting motor winding consequent poles is a way to get two speeds from a single winding. In
addition to having two speeds, the windings can be connected to produce constant horsepower (CH)
and constant torque (CT) as well as variable torque and/or horsepower (VT/VH).

There are three types of consequent pole motors:

Constant horsepower (CH)

Constant torque (CT)

Variable torque/variable horsepower (VT/VH)

The high speed of this type of motor will always be twice the low speed. The ability to obtain two speeds
from one winding can best be explained by the formula below:

N = 120 F ÷ P
Where N= speed

120 = constant (K)

F = frequency

P= Poles

You can see from this formula that motor speed is inversely proportional to the number of poles the
motor is connected for. That is, a four-pole motor will run at twice the speed of an eight-pole motor.

Each type of consequent pole motor winding will have two separate connections. One is for the high-
speed number of poles (4,6, etc) and one is for the low-speed number of poles (8,12, etc). A specially
designed motor controller is used to supply power to the connections (speed) desired. The poles in the
high-speed connection will be connected for alternate polarities. Poles in the low-speed connection will
be connected for the same polarity, and an equal number of poles of opposite polarity will result as a
consequence. That is, the opposing same poles flux create a virtual opposite pole between them. The
name consequent pole comes from this consequence. The core and frame must be made from a special
high permeability steel to provide the flux path for these virtual poles.

Other winding characteristics are that, the windings are connected in the long jumper method (with the
exception of a mid-connection point for each phase) and they have six leads brought out to the
connection box.

Connections for the three of consequent pole motors

Discussion of VT/VH connection diagram and consequent pole motor theory of operation

As discussed earlier, terminal leads T1, T2, and T3 will always be the low-speed leads in a two-speed
motor.

NOTE: Unlike two-winding, two-speed motors that useT11, T12, and T13 to denote high-speed leads,
consequent pole motors use leads numbers T4, T5, and T6 to denote high-speed leads.

For low-speed, the winding will be connected series wye with the phase center taps T4, T5, and T6 open.

NOTE: It is important to remember that the isolating of T4, T5, and T6 on low speed and the shorting of
T1, T2, and T3 on high speed will be accomplished by the controller.

For low-speed operation, power will be supplied to T1, T2, and T3. The current will flow through all PPGs
start to finish, in the direction of the arrows, and create four poles of the same polarity.

A pole of opposite polarity is induced between each of the connected poles. This, in effect, gives us an
eight-pole winding. This motor will operate at a speed (N) of 750 r/m.

Example: N = 120 F ÷ P
N = 120 X 50 ÷ 8

N = 6000 ÷ 8

N = 750 r/m

For high-speed operation, the winding will be connected parallel wye. Power will be supplied to
terminals T4, T5, and T6 and T1, T2, and T3 will be shorted together by the controller to form an external
star point.

By tracing through the phases, it can be seen how this connection will give us a four-pole connection
and double our speed. Begin with terminal T4 and trace through a phase. You can see that current flow
through PPGs 1 and 7 is now reversed, while current flow through PPGs 10 and 14 remains the same.

Now, trace through B phase beginning with T5. Note that PPGs 11 and 5 are now reversed, while PPGs 2
and 8 remain the same. Trace through C phase beginning with T6. PPGs 9 and 3 are now reversed, while
12 and 6 remain the same.

You can see that this is the standard four-pole, parallel wye connection that was discussed earlier in this
lesson.

The figure at right shows a circular connection diagram for a consequent pole VT/VH motor. Notice that
the external connection arrangements are listed for both seeds.

Straight line connection diagrams for CH and CT connected consequent pole motors would be
developed in the same manner as the VT/VH connection just discussed.

Now, review figures showing circular connection diagrams for constant consequent pole CH and CT
motors.

Constant horsepower (CH) (same horsepower, both speeds):

Low speed: Parallel wye

High speed : series delta

Constant torque (CT) (same torque both speeds):

Low speed : series delta

High speed : Parallel wye

Variable torque/variable horsepower (VT/VH) (torque and horsepower increase with speed):

Low speed : series wye

High speed: Parallel wye

Next, develop a connection diagram for a VT/VH consequent pole motor.

Then connection diagrams for the other types of consequent pole motors will be provided.

V T/VH consequent ole winding development

Draw 12 segments to represent the 12 PPGs of a four-pole motor. Working from left to right, label PPGs
1 through 12 A, B, C, A, B, C, etc. Draw an arrow under each PPG with all arrow heads pointing towards
the right edge of the paper. Label the left edge of each PPG with an s (start) and the right edge with an f
(finish).

Draw a line straight up from PPG1 start and label it As (T1). This denotes A phase start, terminal 1.
Connect PPG 1 finish to PPG7 start. Connect PPG7 finish to PPG10 start.

This is the midpoint of A phase and will be a short jumper.

Draw another line straight down from PPG7 finish and label it T4. Connect PPG10 finish to PPG4 start.

Draw a line straight down from PPG4 finish and label it with an asterisk. The asterisk will denote that this
lead connects to the winding internal star point.

Draw a line straight up from PPG5 start and label it Bs (T2). Connect PPG5 finish to PPG11 start. Connect
PPG11 finish to PPG2 start. This is the midpoint of B phase connection and will be a short jumper.

Draw another line straight down PPG11 finish and label it T5. Connect PPG2 finish to PPG8 start. Draw a
line straight down from PPG8 finish and label it with an asterisk.

Draw a line straight up from PPG3 start and label it Cs (T3). Connect PPG3 finish to PPG9 start. Connect
PPG9 finish to PPG12 start. This is midpoint of C phase connection and will be a short jumper. Draw
another line straight down from PPG9 finish and label it T6.

Connect PPG12 finish to PPG6 start. Draw a line straight down from PPG6 finish and label it with an
asterisk.

NOTE: If drawn correctly, your drawing should show 6T leads, with T1, T2, and T3 connected to PPG1, 5,
and 3 starts respectively. T4, T5 and T6 should be connected to PPG7, 11, and 9 finishes respectively.
The internal star point should be formed by PPG4, 6, and 8 finishes (see the figure)

Review questions

1. The difference between synchronous speed and actual rotor speed is called……..
Hertz
Magnetic speed
Slip
Consequent speed
2. A coil that fills a stator slot but is not connected is called a/an………
Dummy coil
 Extra coil
Inverted coil
Pole phase coil

3. How many C/PPGs will a four-pole, three-phase, 36-coil motor have?

36

18

12

4.A single layer, or half-coil, winding would be a…………..

Distributed winding

Basket winding

Consequent winding

Circular winding

5.The most common winding connection is the …………..

Long jumper

High jumper

Short jumper

Mixed jumper

MOTOR DISASSEMBLY

Learning Objectives

You will be able to:

Use the proper procedures to disassemble a motor.

Conduct and record all necessary electrical and mechanical tests.

Background
The additional damage frequently caused by improper disassembly of a motor adds to the required
repair time. Improper disassembly of a motor damages bearings, windings, and bells and frames. The
procedures taught here are intended to protect the equipment, thus shortening repair time.

Preparation for disassembly

Place the motor to be repaired on a working surface that will be at a comfortable height for the
technician. Ensure the motor is in a solid, flat position on the workbench.

Inspect the motor.

Remove shaft keys and couplings, if necessary.

Tag and place any pieces that are removed in a parts an.

Examine the end bells for cracks or other damages that could cause problems.

Use a prick punch to mark the end bells, field frame, and outer bearing caps. Use existing
matchmarks if possible.

Examine the end bells to determine the type of bearing housing.

End bell removal

Never be hasty or careless in disassembling a generator or a motor. Handle the components with
care to avoid damaging them, or causing a need for additional adjustment.

NOTE: Never use vise-grips, pipe wrenches, back crescent wrenches, or pliers.

If there are bolts through the end bell to the grease retainers, use the correct size wrench to remove
these bolts at both ends.

Remove end bell bolts.

Note any incorrect bolts or missing bolts, lock washers, etc

CAUTION: Use a mallet or wood block and hammer when separating the end bells from the frame. Do
NOT use a chisel.

NOTE: Support the rotor with a pipe and jack during end bell removal.

Remove the end bell.

Using the proper tools, loosen the end bell, and slide it over the pipe to clear the motor frame.

WARNING: Be extremely careful when inserting NOMEX paper. Do NOT place your fingers between

the rotor and stator.

 Insert a piece of NOMEX paper between the rotor and stator to prevent contact.

Remove the jack and pipe. The rotor can be lowered onto the NOMEX paper you installed
between the rotor and the stator.

Remove, tag, and piece the end bell in the parts pan. Use zip close bags for small parts.

Remove all bolts from the rear end bell and note any incorrect bolts.

CAUTION: Do NOT drop the rotor on the winding.

Remove the rear end bell in the same manner as the forward end bell. Tag and place in parts pan.

CAUTION: After removal, install the rotor in V-blocks or secure the rotor by other means to keep it from
rolling.

Remove the rotor from the motor by carefully sliding it across the previously inserted NOMEX
paper. Tag the rotor.

Conduct electrical and mechanical tests.

Use a megohm bridge to measure insulation resistance; record the results on the motor data sheet
(electrical).

Use a low-range bridge to measure phase resistance of windings. Record results on the motor data
sheet (electrical).

Surge test the winding and record results on the motor data sheet (electrical).

Perform a dc high-potential test. If the ground reading is low or the dc high-potential test is
unsatisfactory, clean the winding.

If the surge test of phase balance test is unsatisfactory, rewind the motor.

Conduct a shaft radial runout test if it has not been previously done. Record the results on the
motor data sheet (mechanical)

Remove bearings from the rotor

Conduct snap gage readings on the shaft bearing journals and bore gage readings on the end bell
bearing housings. Record the results.

Route the rotor and end bells to the machine shop if repairs are necessary due to results of bearing
journal, bearing housing, or shaft radial runout tests.

Review questions

1.When matchmarking an end bell, use a ……………………….

 Marking pen

Chisel.

Screwdriver

Prick punch

2. Which of the following tools is acceptable for use in end bell removal?

Prybar

Mallet

Screwdriver

Pipe wrench

3.What should be used to keep the motor rotor from resting on the stator?

NOMEX paper

Wood wedges

Rubber sheet

Card board

4.What should be used to keep small parts together?

Tape

Ziplock bags

Lockwire

Metal cans

5.Which of the following tests is NOT performed on a disassembled motor?

Phase resistance balance

Bearing bore measurement

Bearing face runouts

DC hi-pot

BEARING REMOVAL
Learning Objectives

You will be able to:

Remove a shaft bearing with bearing pullers without damaging the shaft.

Remove a seized shaft bearing using a high-seed grinder without damaging the shaft.

Background

One of the most common jobs an electrician perform is changing bearings. When bearings are removed
properly. It is a relatively simple, quick job. When done improperly, damage can result, causing many
man-hours to be lost. The two proper methods of removing bearings are the use of the bearing puller or
use of a high-seed grinder.

Bearing puller method

Remove the locknut and spider washer (if installed). Select the correct bearing puller size. Assemble
the bearing puller set.

CAUTION: Always remove bearings by applying pressure to the inner ring

Position the wrench on the inner nut of the bearing puller set. Position the soft center between the
pulling attachment jackscrew and shaft end.

WARNING: When the bearing comes off, ensure that the bearing puller set does not fall and injure
personnel.

Use the correct size wrench to hold the jacking screw while turning the jacking nut (the inside nut).
Note bearing movement. Continue turning the inside nut. The bearing should come off the bearing
journal.

Seized bearing removal

CAUTION: Never use a torch to loosen a bearing. A torch may cause shaft distortion.

If the bearing does not move after using a bearing puller set with moderate pressure, the bearing is
seized on the shaft. Use a high-seed grinder to remove the bearing.

WARNING: Wear safety eyeglasses or goggles when grinding.

NOTE: While using the high-seed grinder, use rags to protect the rest of the motor from metal articles.

Use a high-speed grinder with a NEW cutoff blade to cut the outer race completely through in two
places 180 degrees opposite each other and parallel to the shaft.

Cut the bell cage in two places at diametric opposites. Remove the cage and balls.
Cut the inner race at two diametrically opposite points parallel to the shaft. Do NOT cut into the shaft or
the journal shoulder.

Holding the grinder at a 45-degree angle, make two cuts at right angles to the first two cuts.

Start the cuts 1/8 to ½ inch from the land (journal shoulder). This cut reduces the thickness of the metal
at the land and provides a relief.

CAUTION: Use the chisel to slit the bearing race. Do NOT try to cut the race with the chisel.

Use a cold chisel and a ball peen hammer to slit the inner race off the shaft. Place the point of the
chisel directly into the groove cut by the grinder.

After bearing removal

Regardless of which bearing removal method was used, visually insect and clean the shaft-bearing
journal.

NOTE; Always suspect shaft damage when a bearing is seized on a shaft.

Take a reading with a snap gage and record the reading on the motor data sheet (mechanical)

Route to the machine shop if journal repairs are required.

Review questions

1. On what part must the bearing puller apply pressure?

Inner bearing ring
Motor shaft
Ball cage
Outer bearing ring
2. What does the puller jackscrew rest on?
Depression in shaft end
Bearing locknut
Brass soft center
Steel spacer

3. When grinding off a bearing race, how many cuts should be made, and how far apart?

3 cuts, 120 degrees apart

2 cuts, 180 degrees apart
2 cuts, 90 degrees apart
2 cuts, 2 inches apart

MOTOR INSULATION AND INSULATION PREPARATION

Learning Objectives
You will be able to:

Name the types of insulation used in an electric motor and describe their functions.

Fabricate slot cell insulation, coil separators, slot wedges, protective paper liners, and phase
material for installation in a stator reared for rewinding.

Background

Rewind electricians must be familiar with the types of insulating materials utilized in motor rewind. In
addition, they must know how to properly fabricate and install the insulating components where
required.

Types of insulation

The type of insulation used is related to its function.

MAGNET WIRE FILM protects individual coil turns from voltage stress and environmental factors.

SLOT CELL INSULATION provide protection between the magnet wire and the stator core.

COIL SEARATORS provide separation between coil sides in the same slot.

SLOT WEDGES provide tight packing of magnet wire in slots and keeps slots cell insulation in place.

HASE MATERIAL provides separation of magnet wire end turns into phase groups of approximately the
same potential.

SLEEVING provides insulation over soldered connections, to separate connections from end turns.

VARNISH bonds magnet wires to prevent mot on (vibration between the wires) and also provides
environmental protection.

Preparation of slot cell insulation

Measure length and depth of stator slots. Record measurements.

Procure a sufficient amount of 0.007-inch thick NOMEX paper to fabricate slot cell insulation for the
total number of stator slots.

NOTE: Since the tear strength of NOMEX is greater in one direction than the other, cut the pieces so that
the higher tear strength is at right angles to the slot length to prevent tears in the edges of the material.
This is usually indicated by marks or a line printed on the paper.

Use scissors or a paper cutter to cut piece of NOMEX paper 1⅟ 2 inches longer than the length of the
stator iron and 1⅟2 inches wider than double the depth of the slots. The extra length provides for the
3/8-inch folded cuff on each end of the paper. The extra width allows for the width of the slot and
provides enough paper above the slot to guide the wire and close the slot.
 Use the cuffing machine to make a 3/8-inch cuff on each end of this piece is also referred to as the
inside piece.

Cut another piece of NOMEX paper 3∕4 inch longer than the length of the stator iron, and 1⅟ 2 inches
wider than double the length of the slots. This piece is also called the outside piece.

NOTE: Rolls of precuffed paper in various common stator core lengths may be purchased. Once the
proper size roll is selected, only the slot depth cut needs to be made.

Join the two pieces of NOMEX paper by fitting the smaller (outside) piece inside the cuff of the
larger (inside) piece.

Roll the two pieces around your index finger with the edge of the cuff away from your finger.

Insert the slot cell insulation into a stator slot to ensure it fits properly.

Fabricate additional required cell insulation the same way, then lay the slot cell insulation aside
until actual coil insertion takes place.

Preparation of coil separators and slot wedges

Measure the width of the stator slots.

NOTE: Select this material in widths that will fit snugly against the sides of the slot.

Procure enough of the silicone glass coil separator and NOMEX slot wedge material to fabricate the
number required.

Cut the silicone glass coil separators ⅟2 inch longer than the slot cell insulation after cuffing. This is equal
to core length plus 2 inches. It is the longest piece. In motors with less than 2 inches of end room, you
may have to adjust this slightly smaller to allow enough space for the second coil half.

Cut the NOMEX slot wedges the same length as the slot cell insulation after cuffing.

Preparation of phase material and protective paper liner.

Procure a sufficient amount of 0.007-inch NOMEX paper to fabricate phase material and protective
paper liner.

Cut phase material pieces in the form of a triangle. Cut triangles larger than necessary to butt against
the slot cell insulation to completely separate the coils of adjacent groups against the slot cell. Excess
insulation will be trimmed.

NOTE: The protective paper liner will lay in the stator bore and protect the uninstalled coil sides from
rubbing and chafing on the stator iron.

Cut a protective paper liner 3∕4 inch wider than the stator iron and approximately a the length of the
stator inner bore circumference.
Review questions

1. How wide is the cuff on the each end of the slot insulation?
¾ inch
3/8 inch
½ inch
1/8 inch
2. The coil separator will be……………………….
2 inches longer than the core
The same length as the cuffed edge
Two times the depth of the slot.
The same length as the slot wedge.
3. The total thickness of the slot insulation will be…………………
0.007 inch
0.010 inch
0.014 inch

0.020 inch

4. Use………….to insulate coil sides in the same slot each other.

A slot wedge

Phase paper

Sleeving

A separator

TESTING AND VARNISHING REWOUND MOTORS

Learning Objectives

You will be able to:

Conduct required postwinding test procedures to a rewound stator.

Correct any deficiencies found in the stator, or take action to have them corrected.

Test insulating varnish to ensure proper viscosity.

Varnish and bake a rewound stator in accordance with procedures.

Insect the stator after varnishing and baking to ensure the correctness of the procedures.

Background
During this lesson, we will be discussing and accomplishing the electrical tests that are required before
varnishing (dipping) a rewound stator. We will then discuss and accomplish the required varnishing an d
baking procedures.

Post-winding electrical tests

NOTE: Record all test results in section 5 of the Typical Motor Data Sheet (Electrical).

Conduct insulation resistance to ground test with a megohmmeter or equivalent instrument. Record
results.

Conduct phase resistance balance test with a Kelvin bridge or low-reading ohmmeter. Record results.

Conduct a surge comparison test with a surge comparison tester. Record results.

Take action as necessary if the winding fails any test. Complete the motor winding checklists (sheet 1
and sheet 2) before varnishing.

Prepare to varnish the winding when all tests are satisfactory.

Varnishing preparation

Insert bolts in stator bolt holes to keep the varnish from entering and lugging the holes.

CAUTION: The first dip will be accomplished with the connection side of the stator winding in the up
position.

Attach a dipping harness or wire roe slings to the stator so that the stator bore will be in the vertical
position during and after dipping.

Place the stator in the bake oven which has been reheated to 302 0F (1500C)

WARNING: Always wear thermo-insulated gloves when handling heated components.

At the end of the allotted baking time, remove the stator from the oven and allow it to cool to
approximately 1040F (400C).

Varnishes

Solvent varnish

The viscosity of the varnish should be between 150 and 220 centipoise. Varnish with a viscosity over 250
centipoise will be thinned with xylene in accordance.

Solventless varnish

When environmental regulations prohibit use of solvent varnish, a solventless dip varnish must be used.

Lift the stator with the varnish tank chainfall and position the stator over the center of the varnish tank.
CAUTION: Do NOT thin solventless varnish.

First varnish dip and bake

Lower the stator and immerse it in the varnish until bubbling stops.

Raise the stator clear of the varnish and allow it to drain over the tank for about 5 minutes.

CAUTION: Close the cover on the varnish tank as soon as the stator is moved.

Position the stator over a shallow pan lined with paper and allow the stator to drain and air dry for 1
hour.

Immediately begin wiping the varnish from the end bell mating surfaces, the tops of the laminations
inside the stator bore, and , if applicable, the bottom of the mounting feet with a lint-free cloth (dipped
in xylene for solvent varnish only).

Rotate the stator periodically during the air drying process to prevent pocketing of the varnish.

CAUTION: Ensure that the stator is always positioned so that the bore is in the vertical position.

Place the stator in a bake oven that has been reheated to 302 0F (1500C)+or -10 percent and cure for 6
to 8 hours.

WARNING: Always wear thermo-insulated gloves when handling heated components.

Remove the stator from the bake oven and allow it to cool to approximately 104 0F (400C).

Second dip and bake

The sling should still be in lace from the first dip and bake. If not, attach a dipping harness or slings to
the stator so that the stator bore will be in the vertical position with the winding connection side down.

Lift, position and immerse the stator in the varnish as previously described.

Raise the stator from the varnish after about 1 minute.

CAUTION: Close the cover on the varnish tank as soon as the stator is moved.

Repeat the air drying, draining, wiping and baking procedures previously discussed.

Place the stator in a bake oven that has been reheated to 302 0F (1500C)+ or- 10 percent and bake for 6
to 8 hours.

Remove the stator from the oven and allow the stator to cool to approximately 104 0F (400C).

Third dip and bake

The sling should still be in lace from the second dip and bake. If not, attach a dipping harness or slings to
the stator so that the stator bore will be in the vertical position with the winding connection side up.

CAUTION: Close the cover on the varnish tank as soon as the stator is moved.

Repeat all other procedures discussed for the second dip and bake.

Winding inspection

Inspect the windings. Ensure that the following conditions are met.

Note Solventless varnish will not be very glossy.

Windings are clean, smooth, and glossy, with good binding and filling.

Varnish is uniform over the entire winding surface.

Wedges are properly in place and bonded.

Varnish surface is not cracked.

Varnish is not soft and tacky (improperly cured).

Windings are not damaged.

End bell mating surfaces, tops of laminations in the stator bore, and the bottom of mounting feet, as
applicable, are free of varnish.

Take corrective action as necessary for any unsatisfactory conditions noted.

Review questions

1. What is the temperature of the bake oven to cure the varnish?

700 degrees F

400 degrees F

302 degrees F

104 degrees F

2. What temperature should the winding be when dipping it into the varnish?

700 degrees F

400 degrees F

302 degrees F
 104 degrees F

3.How long should a dipped stator air-dry before it is put into the bake oven?

5 minutes

30 minutes

1 hour

4 hours

4.What position must the stator be in for dipping?

Vertical

Horizontal

Either

Both

MOTOR ASSEMBLY AND FINAL TESTING

Learning Objectives

You will be able to:

Assemble a rewound motor following all safety precautions.

Perform and record all final electrical tests.

Background

After a motor has been carefully machined, fitted with new bearings and rewound, the electrician must
assemble and test it. If the assembly is not performed carefully, the winding or motor may be damaged
and repair time will be lost. Repair personnel assembling a rewound motor frequently may be under
pressure to rush the job, but still must ensure that assembly and testing procedures are performed
properly.

Preparation before reassembly

Ensure that the following conditions are in effect.

All arts are in the work area.

All new hardware has been received.

Bearings on the shaft are properly fitted and greased.

 Bearing housing machine work is complete.

All defects noted in the receiving and disassembly inspection have been corrected.

Varnish has been removed from mating surfaces, the laminations, and feet.

All chainfalls and slings are rigged for handling heavy components

Pre-assembly tests

The following pre-assembly tests must be performed on the windings and entered in section 5 of the
motor data sheet (electrical):

Insulation-to-ground test

Resistance balance test with double bridge

Surge comparison test.

AC high-potential test

Insulation resistance-to-ground test

Phase balance test.

The winding must ass all tests or the motor cannot be assembled for delivery.

Motor assembly

Wrap the bearings in lint-free material to prevent contamination.

Prepare a stator protector; obtain a sheet of NOMEX, rag paper, or gasket material long enough to
extend from one end of the motor winding to the other, and wide enough to cover about one-fourth of
the inner circumference of the core. This is to protect the stator from the rubbing of the rotor as it slides
into the stator bore.

Place the stator protector inside the stator on the bottom of the stator.

CAUTION: Keep the rotor off the windings while inserting it in the stator.

Insert the rotor into the stator. Ensure that the stator protector remains in lace. The rotor will slide
easily on the stator protector.

NOTE : Ends of the all-thread rods should point towards the end or the rotor.

With the rotor resting in the stator, attach all-thread rods of sufficient length to the baring retainer
bolt holes on the front of the rotor. Place the front end bell adjacent to the front end of the shaft.
Position the all-thread rods through the end bell grease retainer bolt holes.
CAUTION: Check the punch matchmarks on the end bell and the stator frame to ensure alignment and
proper assembly.

Slide the front end bell on the shaft over the bearing. Guide the all-thread through the retainer holes.
Align the matchmarks.

Catch the end bell to frame bolts, but do NOT tighten yet.

Use the all-thread rods to pull the retainer in line. Catch the retainer bolts in the two empty holes,
but do NOT tighten.

After the bolts are caught, remove the all-thread rods and install remaining retainer bolts.

NOTE: If there is a separate grease cu on the motor, fill it one-third full with grease before catching the
bolts. Ensure the grease tube access to the retainer is aligned.

Attach all-thread rods of sufficient length to the back bearing inner retainer. Place the back end bell on
the back end of the motor shaft and slide it towards the motor frame.

Fit the pipe over the drive shaft, if necessary. Support the shaft on the machinist ’s jack and /or place
wood blocks under the pipe or shaft.

Move the back end bell onto the pipe, if used. Remove the stator protector. Move the back end bell
towards motor stator and position the all-thread rods, through the retainer bolt holes. Slide the back
and bell over the back bearing as close to the frame as possible. Make sure matchmarks are aligned.
Catch end bell frame bolts, but do NOT tighten them.

Remove the jack, blocks and pipe.

Pull the ends of the all-thread rods to position the end bell retainer.

NOTE: If there is an outside grease cup, it should be one-third full of grease and in position at this time.

Catch the retainer bolts through the holes without all-thread rods in them. Remove the all-thread
rods. Catch remaining retainer bolts.

Pull all end bell bolts up evenly (back and front). Alternate from end to end. Tighten on diametric
opposites (this is called diagonal sequencing).

Rotate the shaft continuously and slowly while tightening the bolts to detect cocking.

Torque in accordance with specifications.

Pull up the retainer bolts following the above procedures.

When all bolts are torque, the rotor must rotate freely. Listen for rubbing as rotor moves.

Post assembly testing

Perform insulation resistance-to-ground and phase resistance balance tests to ensure that the winding
was not damaged during assembly.

Move the assembled motor to the test area.

Ground the motor frame.

CAUTION: Rest line leads in a special box to ensure lead separation.

Connect the motor to the proper line voltage. Test run the motor for 30 minutes.

NOTE: Results of a phase current balance test must show current within five percent for phases, three
percent for submarine motors.

Conduct a phase current balance test. Maximum imbalance allowed is 5 percent for surface craft and
three percent for submarine motors.

Check bearings for unusual heating or noise.

Use s Strobotac or hand-held tachometer to check motor seed.

Monitor the motor to ensure that it is operating properly during the test run.

Stop the motor and disconnect it from the line.

If all motor tests are satisfactory, the motor is ready for delivery.

Review questions

1. How long must you test run a motor after reassembly?

10 minutes

30 minutes

45 minutes

60 minutes

2. What are threaded rods used for?

To support the motor during assembly
To support the rotor during insertion
To capture the inner bearing housing
To align the end bells during assembly
3. After reassembly, shaft runout must be no greater than----------
0.02 inch
0.002inch.
2.00inch.
 0.0200inch.

METHOD OF REWINDING AND BALANCING THE ARMATURE

METHOD OF REWINDING AND BALANCING THE ARMATURE

At the end of this lesson you shall be able to

Explain the method of rewinding a DC armature

Explain the methods of soldering/brazing/hot stacking of the winding ends to the commutator raisers

Explain the necessary of banding and the method of banding

State the necessary of balancing and the method of balancing the armature

Method of winding the armature

To start the armature winding, the armature is mounted on the winding stand as in Fig; then the shaft,
armature core and slots are insulated as per the insulation scheme taken from the data.

Winding methods

There are two methods of winding the armature

1. Hand winding

2. Formed coil winding

Hand winding

For hand winding, four numbers of slot feeders are laced in the two designated slot at a distance from
the coil pitch.

The required number of turns are wound into the slots, say slots Nos. 1 and 4 as in Fig. Enough tension is
applied on the wire to make a tight winding without breaking the wire.

A loop is made at the end of the first coil and the beginning of the second coil. The second coil is started
in the designated slot and the coil is wound with the same number of turns as in coil 1.

T he span of coil 2, has to be equal to that of coil 1. When the second coil is finished, a loop is made
again and then the third coil is started. In this manner the winding is continued, until all the coils have
been wound. The end lead of the last coil is connected to the beginning lead of the first coil.

After the entire armature is wound, there will be two coil sides in each slot, in double layer winding. It
has to be ensured that all the coils have the same pitch and turns.

The loops made at the end of the coils will look as shown in Fig, and have to be connected to the
commutator raisers.
The procedure of making loops while winding, explained here, is for simplex lap winding. This method is
usually adopted for small armatures.

For wave winding and multiplex windings, connection for raisers shall be taken from the coil ends
according to the winding pattern.

Formed coil winding

For this method, wooden formers are made to the dimensions of the armature coils, similar to those of
the field coils as explained .

The total number of coils required for the armature are wound and kept ready. The inactive side of the
coils is bound with tae and tied with cotton strings as shown in Fig.

The active side of the coil is spread as in fig and the coil sides are inserted in the respective armature
slots, conductor by conductor as shown in Fig. Similarly all the coils of the armature are placed in the
respective slots and the coil ends are looped and soldered to the respective commutator segments.

Lead swing

One of the most important operations in winding an armature is to lace the coil leads in the proper
commutator bars. Leads may be placed in the bars in any of the three different positions, depending on
the original location.

The following method is used in determining the position of the leads in the commutator.

Stretch a piece of cord or string through the centre of a slot, as shown in Fig, a, b,& c. Note whether it is
in alignment with the commutator bar or with the mica between the bars.

If the data call for a lead swing of the three bars to the right, lace the lead of the first coil three bars to
the right, counting the bar that lines u with the slot as no 1. All the other leads follow in succession.

If the centre of the slot is in line with the mica, consider the bar to the right of the mica as bar No.1.
Connection of winding ends with the commutator segments.

After winding the armature, the end leads of the armature conductors are laced in the slits of the
commutator raisers. (Raiser slits should be properly cleaned and well reared to receive the conductors.)

For secure and good electrical contact, these conductors are well cleaned to remove insulation and dirt.
Then the conductor ends are laced in the respective raiser slits and soldered brazed or hot-stacked.

Soldering

For soldering, electric irons are generally used on small armatures and gas irons on the larger ones. The
size of the iron used depends on the size of the commutator.
Leads are soldered to the commutator by means of soldering iron or torch. The procedure of soldering is
as follows.

First the soldering flux is applied over the wires to be soldered and also the identified commutator
raiser. The wires are then laced in the respective raisers. Then the tip of the soldering iron is kept on the
commutator raiser as shown in Fig, for sometime until the heat from the iron is transferred to the area
of the commutator raiser.

This heat transfer could be identified by the bubbling of the flux. When the commutator raiser is
sufficiently hot, the solder is placed on the commutator raiser, and the iron is kept over it and the solder
is allowed to flow entirely around the leads.

To prevent the solder from flowing down the back of the commutator and thereby causing short circuits,
raise one end of the armature.

To prevent the solder from flowing from one bar to another, the iron is held as shown in Fig. Excess flux
is wiped out after the soldering is completed.

Brazing

In the case of large armature windings, the armature winding lead ends are brazed with the respective
commutator raiser slits by means of a gas torch. Close inspection and care should be exercised in the
control of the flame.

Hot stacking

In the case of small DC armature conductors are kept in the commutator raiser slits and spot welded.
This is called hot stacking.

A specially designed hot-stacking machine is available for this purpose.

Banding the armature

A temporary banding is sometimes applied on the armature before the permanent banding is done, to
keep the coils in position and to facilitate shaping of the overhang.

Permanent bands are used on armatures to hold the armature end leads in position. A cord band is used
on small armatures to prevent the leads from flying out of the slots, while the armature is rotating.

Large armatures have steel bands for the same purpose. For large armatures having open-type slots,
steel or tae bands are used to prevent the coil from flying out of the slots.

Cord bands

The procedure for making a cord band on an armature is shown in Fig, and the following directions
should be observed.
Use a proper size of banding cord heavy for larger armatures, light for smaller armatures. Start at the
end nearest the commutator and wind several turns in layers, allowing about 150mm long cord at the
beginning to be free. Bend the cord in the form of a loop as shown in fig.

After winding several turns over the loop, insert the last end of the cord band through the loop, and
then pull the free end of the loop. This will pull the end under the Core band and secure it there. Then
the pulled end of the cord can be cut off.

Use enough pressure in winding so that the band will be tight.

Steel bands

Steel bands are laced on the front and back ends of the coils. These bands are up on the armature in a
different manner than in the cord bands. The procedure is illustrated in Fig, and is as follows. Place the
armature in a lathe and lace mica or paper insulation in the band slot around the entire armature to
insulate the band from the coil sides. Hold the insulation in lace by tying a turn of cord around it.

Place small strips of tin or copper under the cord, equidistant around the armature, in order to secure
the band after it is wound.

Use the same gauge steel band wire as is found in the original band. Steel bands must be up on the
armature with much more pressure than is needed for cord bands. It is therefore, necessary to utilize a
device called a wire clam to provide the required pressure.

This device consists of two pieces of fibre fastened together by means of two screws and two wing nuts.
The steel band wire is fed through this clam to the armature. The clam has to be secured to a bench so
that it can be held stationary while slowly turning the armature while banding.

Take care not to up too much pressure on the wire, otherwise it will break. After the band is laced on
the coil, copper or tin strips are turned over and the entire bend is soldered. One by one each band is
completed in this manner.

Testing the new winding

After the rewinding and connections are completed, it is important that both the winding and the
connections are tested for shorts, grounds, open circuits and correctness of connections. This must be
done before varnishing the winding so that any defect that is found may be corrected more readily.
Detailed instructions for making these tests are given in the information section of Exercise3.

Baking and varnishing

After the armature has been wound, soldered and banded and tested, the next operation is varnishing.
This process makes it moisture-roof and also prevents vibration of the coils of wire in the slots. Vibration
has a tendency to impair the insulation on the wires and cause shorts. Moisture will also cause the
insulation on the wires to deteriorate. Before varnishing the armature, it must be reheated to drive cut
the moisture on it. Armatures may be varnished by either baking varnish or air-drying varnish. Air-drying
is applied to the armature when baking is undesirable or inconvenient. Baking varnish is more effective
because the moisture can be eliminated fully only by baking.

Balancing the armature

Armatures should be tested for mechanical balancing after they are varnished. This is very important;
otherwise undue vibration and unusual noises may be produced due to the imbalance of the armature.
Ultimately it may lead to repeated bearing problems, loosening of nuts etc. Hence the armatures are
balanced before assembly.

Balancing of armature is mainly done, using dynamic balancing machines. Anyhow for small armatures
static balancing can be done, when dynamic balancing machines are not available.

Static balancing

A balancer, similar to the balancing grinding wheel in machine shops, may be used. These balancers are
built in various sizes. The method of balancing an armature using this type is as follows.

Place the armature on the balancing ways, and roll the armature gently. When the armature comes to a
shop, the heavier portion of the armature will be at the bottom. Mark this point (portion) with a chalk
piece.

With such successive rolling, if the armature stops at different positions, the armature is balanced, and if
it stop in a particular position, it is necessary to counterbalance it with weights diagonally opposite to
the heavy portion.

This is accomplished by lacing a lead or a small metal piece on the banding of the armature. In small
armatures, this weight may be laced in the lace of the wedge, under the banding.

Experience will determine the amount of metal necessary to balance the armature. This method of
balancing is called’ static balancing’.

Dynamic balancing

Dynamic balancing machines are available to balance the armature or rotating the arts of electrical
machines. The armatures are fixed on those machines and rotated at the rated seed. A pointer or an
indicator shows the position on the armature and the weight to be added. The balancing machines
available are either with the mechanical balancing or with the stroboscopic balancing.

TESTING OF ARMATURE

At the end of the lesson, you shall be able to describe the methods of testing armature such as the

Winding resistance test

Insulation resistance test

 Growler test

Voltage drop test

Testing the winding

After an armature is wound and the leads are connected to the commutator, a test should be
conducted. From this test, defects may be revealed, which might have occurred during winding.

The common defects in armature windings are grounding, shorts in the coils, open in the coil and
reversal in the coil connection. These defects can be located by different test procedures.

Armature winding resistance test.

Resistance of the armature coils measured by using a low range ohmmeter and preferably with the
Kelvin bridge. Resistance between consecutive segments in the case of simplex la winding (for wave and
multiplex windings at a distance of commutator itch Yc) is measured.

Figure shows a simple arrangement to measure the resistance between the successive commutator
segments.

As shown in Fig, a cotton tape with a counterweight is passed around the commutator to hold the
connecting leads to the segments.

Measurement of resistance is done in all the coils by changing the position of the connecting leads to
successive commutator segments.

The resistance measured should be the same in all coils. Lower resistance shows short in turns, while a
higher resistance shows higher numbers of turn or open in the coil.

Insulation resistance test

With a bar copper wire short all the commutator segments.(Fig)

Test the insulation resistance between the body and the commutator or segments by a 500V Megger,
for armatures rated u to 250 volts.

The IR so measured shall be greater than 1 mega-ohm. If the value is less than 1 mega-ohm, moisture in
the winding or a weak insulation is to be suspected. This test is sometimes conducted by a series test
lam and is called the ground test. It will only indicate if any coil is grounded, and not the insulation
resistance.

Growler test

A simple and most common method to test armature winding for short and open coils is by a growler.

Growler
There are two types of growlers-

1) Internal growlers
2) External growlers.
An external growler is used for testing small armatures and an internal growler for large DC armatures
and AC motor stator windings.
External growler
An external growler shown in Fig is an electromagnetic device that is used to detect and locate
grounded, shorted and open coils in an armature. This growler consists of a coil wound around an iron
core and is connected to a 240 volt AC line. The core is generally H shaped and cut out on to so that the
armature will fit on it, as shown in fig.
When an alternating current is applied to the growler coil, the voltage will be induced in the armature
coils by transformer action.
Internal growler
An internal growler, such as the one used for stators, may be used for armatures as well. These are
made with or without built-in feelers.
The growler with a built-in feeler has a flexible blade attached to the growler so that a hacksaw blade
or similar instrument is not necessary.
This type is especially desirable in smaller stators that have no room for a separate feeler. Fig shows an
internal growler with a separate feeler, used for large armatures.
Growler test for grounded coil
The armature to be tested is placed on the growler and then the growler is switched ‘ON’. Place one
lead of an AC milli-voltmeter on the to commutator bar the other meter lead on the shaft, as shown in
fig
If a reading is noticed on the meter, turn the armature so that the armature so that the next
commutator bar is in same position as the earlier one, and test as before.
Continue in this manner until all the bars are tested. Where the meter gives no deflection, it is an
indication that the grounded coil is connected to this particular bar.
Growler test for shorted coil
The procedure to test for short circuits in an armature as follows.
The armature to be tested is placed on the growler and then the growler is switched on. A thin piece of
metal, such as a hacksaw blade, is held over to the slot of the armature as shown in Fig.
In case of short in the winding, the blade will vibrate rapidly and create a growling noise. If the blade
remains stationary, it is an induction that no short exists in the coil under test.
After several to slots have been given the hacksaw blade test, turn the armature so that the few slots
are on to. Test as before and continue this procedure for the entire armature.
An armature having cross connections or equalizers cannot be given the hacksaw blade test. This type of
armature will cause the blade to vibrate at every slot, which would seem to indicate that possibly every
coil is shorted.
Test for open coil
Growlers are also provided with meters (milli-volt or ammeter) on the panel with variable resistance. In
this case an open in the armature coil can be found out as follows.
Growler test for an open coil
To locate an open coil with a growler, set up the armature on the growler on the growler in the usual
manner. Test the top two adjacent bars with an AC milli-voltmeter as shown in fig.
Rotate the armature and continue testing the adjacent bars. When the millivoltmeter bridges the two
bars connected to the open coil, the meter pointer will not deflect. All the other bars will give a
deflection. This test for an open coil can be made without the meter by shorting the two tops bars with
a piece of wire.
Absence of a spark indicates that the coil is open. The open may be either at the commutator bar or in
the coil itself. The procedure may be used to determine the location of the loads of a shorted coil.
However, the hacksaw blade test is the most satisfactory method of determining a shorted coil.
Drop test
The most accurate method of testing the armature for correct resistance, number of turns, short and
open reversed coil connection is by the drop test. Connect a low voltage DC supply across the
commutator segments at a distance of pole pitch.
Insert a variable resistance in series with the circuit. Switch ‘ON’ the DC supply and connect a milli-
voltmeter to the adjacent segments as in fig
Adjust the readings to a specified value, by using a variable rheostat. Record the milli-voltmeter readings
on the consequent commutator segments by rotating by rotating the armature in one direction. The
position of the segments and the connection should be the same as in the first set up. The result could
be concluded as enumerated below.
If all the readings are the same, the winding is correct.
If the millimeter reads zero or low voltage, the coil connected to the segment is short.
If the milli-voltmeter reads high voltage, the coil connected to the segments is open.
If the milli-voltmeter deflects in the reverse direction as shown in fig, the coil connected with the
segments is reversed.
Generally armatures are tested as a routine for insulation resistance and for shorted coils. Only when a
fault in the armature winding is suspected, a drop test is conducted.
Maintain service and troubleshoot DC Machine
Objectives
At the end of this exercise you shall be able to
Interpret the name-late details of the DC machine and record it
Visually insect the DC machine and re-test it to locate the fault
Dismantle the DC machine, overhaul it.
Maintain and service the arts of the DC machine
Reassemble and test the DC machines
Troubleshoot the Dc machine
Requirements Materials

Tools/Instruments VC insulated copper wire .2.5 sq mm, 250V grade

Electrician Tool kit Cleaning brush 3 cm dia
Bearing puller Carbon tetra chloride(CTC)
DE spanner set 2 mm to 20 mm Grease type and quantity
MC ammeter 0-500 mA or Kerosene oil
MC voltmeter 0-500 mV Lubrication oil type and quantity
MC voltmeter 0-250 V Cotton cloth
Growler external with ammeter Sandpaper/sand cloth-grade and quantity

Megger 0-50 meg ohms, 500 V

 Equipment/Machines
Multimeter DC machine
Wooden mallet 8 cm dia Arbor press
Electric blower 240 V,50 Hz

TABLE 1 Visual inspection

Sl.No. Description Noticed as/ at (strike out items not applicable)

1 rotation of the shaft Free/slightly tight not rotating

2 Symptom of burn Armature/field/commutator/brush/terminal block/

no place

3 Burning smell Armature/field/commutator/brush/terminal block/

No place

4 Damaged parts

5 Loose connection

PROCEDURE

TASK 1 Ascertain the condition of the DC machine.

1 Interpret the name-late details of the given DC motor and record in Table 1. (same Table as in Ex 601)

2 Visually insect the machine and enter your findings in Table 1

3 Conduct the continuity test, resistance measurement and insulation test and enter the results in
Table2

4 Obtain the above test values at the time of installation from the section in-charge and enter the values
in Table 2

5 Dismantle the DC machine

6 Clean each part with the help of a brush and a blower. A careful study of the test results and the result
values compared between earlier and resent conditions will indicate clearly how the results with your
co-trainees and with the instructor.

TABLE 2

Test Results
Sl.no. Description of the test Test result at the time Test result before Test result after

Of installation Date servicing servicing

1 Continuity between

Series field terminals -------------------- --------------------- --------------------------

Shunt field terminals --------------------- --------------------- ------------------------

Armature terminals --------------------- ----------------------- -----------------------

2 Resistance value between

Series field terminals -------------------- ---------------------- ----------------------

Shunt field terminals -------------------- ---------------------- ---------------------

Armature terminals -------------------- ---------------------- ---------------------

3 Insulation resistance value

Between
Series field and the frame ------------------ ------------------------ ------------------
Shunt field and the frame ----------------- ----------------------- --------------------
Armature and the frame ----------------- ------------------------ ---------------------
Series field and shunt field ---------------- ------------------------- ---------------------
Series field and armature ------------------- ----------------------- --------------------------
shunt field and armature ------------------- ------------------------- -------------------------

TASK 2 Maintain, service the parts of the DC machine as stated below

1 Measure the resistance of each field coil as shown in Fig and compare the value with the figure given
by the manufacturer. If it is low or high replace the coil with a similar coil.

2 Measure the insulation resistance between each coil and the frame with a Megger. Lift is low replace
the coil with a similar coil. Enter the defect and action taken to rectify the defect in Table 3 in the
appropriate lace.

3 Test the armature for short or open circuits by connecting the ohmmeter test leads to two adjacent
commutator bars as shown in Fig.

4 Set the meter rangeto get a reading as near mid-scale as possible as shown in Fig.

5 Check that the meter reading is the same for all adjacent commutator segments. If not

(a) A high resistance indicates an open circuit.

(b) A low resistance indicates a short circuit.
6 Test the armature/commutator for earth fault by connecting one lead of the Megger to the shaft and
the other lead of the Megger to the commutator bar as shown in Fig. Enter the defect and the action
taken to rectify in Table 3 in the appropriate lace.

As the commutator is also a part of the armature winding a short or open shown by the above tests
involves commutator . Hence check the commutator as explained here before suspecting a cell defect.

Alternatively the armature can be tested for short, open or grounded coils by a growler.

In case a single open or short or ground coil is detected in the above tests, the coil could be replaced
with a similar coil; on the other hand if a number of coils are found to be defective, the armature needs
to be rewound.

7 Check the commutator for raised mica insulation. If found, undercut the mica. Fig

A tool made from a piece of hacksaw blade with the sides of the tooth ground down parallel to the
thickness of the mica and held in a suitable holder as shown in Fig could be used for undercutting the
mica.

8 Check the commutator for pitting, ridges and high bars. (Fig). If found, they could be removed by
skimming the commutator. (Turning in a lathe)

The commutator can only be skimmed (turned) to a minimum diameter specified by the manufacturer.

9 Before skimming (turning) check with a dial test indicator that the shaft center is the true commutator
center as shown in Fig

10 Get the help of a good tumer and do mount the armature in a lathe. Use a driving dog to turn the
shaft and remove minimum copper from the surface of the commutator till the pitting, ridges and high
bars are rectified. (Fig)

11 Use the sand paper/sand cloth to give fine finish to the commutator surface. Refer to Fig. Enter the
defect and the action taken to rectify the defect, in Table 3 in the appropriate place.

After finishing, check again for raised mica if necessary undercut the mica.

Badly damaged commutator needs to be replaced by a new one having the same specification.

12 Check the commutator connections in the raisers. If necessary, resolder the suspected soldering sots.
(Fig)

13 Clean away the dust, dirt and carbon deposits from the brush holder and assembly using Carbon
Tetra Chloride.(CTC)

14 Check the length of the brushes.

15 Check new brush whether it slides freely in the holder without undue side play. If necessary fit with a
smooth file. Keeping the brush sides parallel. (Fig)

16 Insert the new brush and shape the end of the curve of the commutator, using glass paper wrapped
around the commutator and light pressure in the brush (Fig)

17 While assembling the brush in the brush holder check that the brush holders are not more than
1.5mm (1/16in.) away from the commutator surface. If necessary adjust, keeping them square to the
commutator. (Fig)

18 Check the spring tension, lift is adjustable, set it to the minimum pressure that will prevent sparking
or follow the directions given by the manufacturer. (Fig)

19 Check the bearing for play, wear and damage.

20 If found OK, clean the bearing using kerosene oil and then with lubricating oil.

21 Pack the recess with a grease recommended by the manufacturer up to 80% of the space.

22 If the bearing is found defective, remove the defective one with the help of a bearing puller.

23 Replace it with a bearing having the same specification.

24 Refit the inner bearing late and then press the bearing on to the shaft in an arbor press, using a tube
and a late to apply Pressure to the inner ring of the bearing (Fig)

TABLE 3

Fault and rectification record

Sl. No. Area of defect Action taken for rectification

1 Faults in field coil

a. Individual coil resistance measurement is the same as the

others/ not the same

b. Individual coil insulation resistance is the same as the others

/not the same

2 Faults in the armature

Shorted coil

Open coil
Grounded coil
3 Faults in commutator
 Raised mica
Pittings in commutator
Burn at commutator segments
Ridges on commutator
High bars on commutator
Defective solder on raisers
Short between segments
4 Defects in brush
Worn out
Loose fitting
Bad bedding
Defective spring tension
5 Defects in bearing
Worn out
Damaged
Dry

TASK 3 Reassemble and test the Dc machine.

1 Reassemble the DC machine.

2 Check the shaft for free rotation.

If the shaft is not rotating freely, loosen the end plate studs and retighten them in proper

Sequence till the shaft is free to rotate.

3 Test the winding for continuity and insulation resistance and enter the values in Table 3.
4 Measure the resistance of the winding and record it in Table 3.
5 Load the DC machine and check its performance on load.
6 Record the observations as detailed below.

TASK 4 : Troubleshoot the DC machine

1 If any defect is notices in the machine rectify the defect following the troubleshooting chart given
in trade theory.

TABLE 4

Performance results

Sl. No. Description Performance

1 Sparking in commutator High/ Low

2 Speed of the motor-Wormai High/ Low

3 Temperature of the motor High/ Low

4 Vibrations of the motor High/ Low

5 Ability to take up the load Lower than capacity/OK

6 Noise while running High/ Low

7 Condition of the bearing High/OK