Maintenance and Rewinding of

Electrical Induction Motor for Short-

term Training
Based on July 2023 curriculum version 1

Module Title : Maintaining and Rewinding Electrical Induction Motors

Module Code : EIS IEC M04 07 23
Nominal Duration :140hrs
Prepared By : Ministry of Labour and Skill

August, 2023
Addis Ababa, Ethiopia
Table of Contents :
Acknowledgment ........................................................................................................................... 3
Introduction to the Module .......................................................................................................... 4
Unit One: Maintenance and Repair Electrical System ......................................................... 5
1.1 Introduction of Maintenance........................................................................................ 6
1.2 Types of Maintenance .................................................................................................. 6
Unit Two: Diagnosis and Rectify Faults in Electrical Induction Motor ............................ 11
2.1 Troubleshooting Faults in Electrical induction motor ............................................. 11
Unit Three: Maintain and repair electrical Induction motors ........................................... 19
3.1 Electric Motor Parts.................................................................................................... 19
3.2 Dis-assemble procedure of the motors ...................................................................... 21
3.2 1 Data collection from customers……………………………………………..........21
3.2.2 Dis- assemble Procedures of motors……………………………………………..21
3.3 Assemble the motors ................................................................................................... 22
3.3.1 Planning and prepare rewinding procedure ……………………………………22
3.3.2 Test and verify functionality ……………………………………………………62
3.3.3 Completion of workplace report…………………………………………………62

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 2 of 73 Author/Copyright Induction Motor August, 2023
Acknowledgment
The Ministry of Labor and Skills (MoLS) is grateful for the invaluable technical assistance provided by the
Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH in developing this short term
training Module. This endeavor was made possible through the Ethio-German Sustainable Training and
Education Programme (STEP), a joint initiative with the ministry, commissioned by the German Federal
Ministry for Economic Cooperation and Development (BMZ) and co-financed by the European Union.

We would also like to thank INTEGRATION GmbH for their financial support, technical guidance, and
facilitation of the workshop to develop this document. We are also grateful to the MoLS experts, TVET
trainers, and esteemed industry practitioners for their time and expertise in Development of this Training
Module.

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 3 of 73 Author/Copyright Induction Motor August, 2023
Introduction to the Module

Electric motors serve as integral components in diverse industries and applications, spanning from
manufacturing and transportation to household appliances. They play a pivotal role in powering
complex machinery and equipment, thereby necessitating meticulous maintenance to ensure their
efficient and dependable operation. While electric motors are designed to operate incessantly for
extended durations, akin to any other mechanical device, they require regular upkeep to optimize their
performance and extend their lifespan.

This module covers:

 Plan and prepare for maintenance and repair work

 Diagnosis and rectify faults in Electrical motor
 Maintain and repair electrical motors

Learning Objective of the Module

 Plan and prepare for maintenance and repair work

 Diagnosis and rectify faults in Electrical motor
 Maintain and repair electrical motors

Module Instruction

For effective use of this module, trainees are expected to follow the following module instruction:

1. Read the information written in each unit.

2. Accomplish the Self-checks at the end of each unit.
3. Perform Operation Sheets at the end of units.
4. Do the “LAP test” giver at the end of each unit and
5. Read the identified reference book for Examples and exercise.

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 4 of 73 Author/Copyright Induction Motor August, 2023
Unit One: Maintenance and Repair Electrical System

This unit is developed to provide you the necessary information regarding the following content
coverage and topics:
 Introduction of Maintenance
 Types of maintenance
 Run to Failure Maintenance (RTF)
 Preventive Maintenance (PM)
 Corrective Maintenance (CM)
 Improvement Maintenance (IM)
 Predictive Maintenance (PDM)
This unit will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:
 Perform Motors Maintenance
 Perform Preventive maintenance
 Perform Predictive maintenance
 Apply Corrective maintenance
 Repairing/Rewinding
 Plan and prepare rewinding procedure
 Rewind stator coils of single-phase and three phase AC motor

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 5 of 73 Author/Copyright Induction Motor August, 2023
1.1 Introduction of Maintenance
“Maintenance” as the name suggests it is the action necessary for retaining or restoring a piece of
equipment or machine to the specified operable condition to achieve its maximum useful life.
Objectives of Maintenance:
 Reducing breakdowns and emergency shutdowns.
 Optimizing resources utilization.
 Reducing downtime.
 Improving spares stock control.
 Improving equipment efficiency and reducing scrap rate.
 Minimizing energy usage.
 Optimizing the useful life of equipment.
 Providing reliable cost and budgetary control.
 Identifying and implementing cost reductions.
1.2 Types of Maintenance
1.2.1. Run to Failure Maintenance (RTF)
Disadvantages of Run to Failure
 Its activities are expensive in terms of both direct and indirect cost.
 Its activities are very difficult to plan and schedule in advance.
1.2.2. Preventive Maintenance (PM)
It is a daily maintenance procedure (cleaning, inspection, oiling and re-tightening), designed to retain
the healthy condition of equipment and prevent failure through the prevention of deterioration,
periodic inspection or equipment condition diagnosis by measuring deterioration. Just like human life
is extended by preventive medicine, the equipment service life can be prolonged by doing preventive
maintenance.
It is further divided into Periodic maintenance and Predictive maintenance( condition based).

A. Periodic maintenance ( Time based maintenance - TBM) : Time based maintenance consists of
periodically (at pre-determined intervals) inspecting, servicing and cleaning equipment and
replacing parts to prevent sudden failure and process problems.

Some of the most important elements included in preventive maintenance are.

 Motor ventilation
Ministry of Labor and Skills Maintain and Rewinding Version -1
Page 6 of 73 Author/Copyright Induction Motor August, 2023
  Humidity and condensation
 Loose connections
 Voltage and current imbalance
 Under voltage and overvoltage
 Bearings, Bearing life, Bearing lubrication
 Lubrication type, Lubrication Intervals

B. Predictive Maintenance(PM)
The objective of predictive maintenance of electric motor maintenance is to reduce maintenance costs
by detecting problems at an early stage and deal with them.
Observations of motor temperature, vibrations, etc. are only a few examples of data that can help
predict when the motor needs to be repaired or replaced. Following are some of the tests that provide
the necessary data about the state of the motor.

 Bearing considerations
 Insulation considerations
 Ground insulation test
 Cleaning and drying stator windings
 Surge test
 High potential testing – HIPOT
 AC high potential phase to ground test and phase-to-phase test
 Motor temperature
 Thermo graphic inspection
It is classified into two kinds according to the methods of detecting the signs of failure:
A. Condition-based predictive maintenance
B. Statistical-based predictive maintenance
A. Condition-based predictive maintenance depends on continuous or periodic condition
monitoring equipment to detect the signs of failure.

B. Statistical-based predictive maintenance depends on statistical data from the meticulous

recording of the stoppages of the in-plant items and components in order to develop models for
predicting failures.

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 7 of 73 Author/Copyright Induction Motor August, 2023
 1.2.3 Corrective Maintenance (CM)
Corrective maintenance is planned when a run-to-failure maintenance strategy is used. In this type,
actions such as repair, replacement, or restore will be carried out after the occurrence of a failure in
order to eliminate the source of this failure or reduce the frequency of its occurrence.
This type of maintenance is subdivided into three types:
A. Remedial maintenance which is a set of activities that are performed to eliminate the
source of failure without interrupting the continuity of the production process.
B. Deferred maintenance which is a set of corrective maintenance activities that are not
immediately initiated after the occurrence of a failure but are delayed in such a way that
will not affect the production process.
C. Shutdown corrective maintenance which is a set of corrective maintenance activities
that are performed when the production line is in total stoppage situation.
The main objectives of corrective maintenance are:-
 To maximization of the productions.
 To elimination of breakdowns
 To elimination of unnecessary repair, and the reduction of the deviations from
optimum operating conditions.
The difference between corrective maintenance and preventive maintenance is that for the corrective
maintenance, the failure should occur before any corrective action is taken.
Corrective maintenance is different from run to failure maintenance in that its activities are planned
and regularly taken out to keep plant’s machines and equipment in optimum operating condition.
 The way to perform corrective maintenance activities is by conducting four important steps:
1. Fault detection.
2. Fault isolation.
3. Fault elimination.
4. Verification of fault elimination.

1.2.4 Improvement Maintenance (IM)

It is one type of maintenance the aims at reducing or eliminating entirely the need for maintenance.

This type of maintenance is subdivided into three types as follows:

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 8 of 73 Author/Copyright Induction Motor August, 2023
 1. Design-out maintenance which is a set of activities that are used to eliminate the cause of
maintenance, simplify maintenance tasks, or raise machine performance from the maintenance
point of view by redesigning those machines and facilities which are vulnerable to frequent
occurrence of failure and their long-term repair or replacement cost is very expensive.

2. Engineering services which include construction and construction modification, removal and
installation, and rearrangement of facilities.

3. Shutdown improvement maintenance which is a set of improvement maintenance activities

that are performed while the production line is in a complete stoppage situation.

Self-Check 1

Part-I: Choose the correct answer

1. One of the following is Objectives of Maintenance?
a. Optimizing resources utilization.
b. Reducing downtime.
c. Improving spares stock control
d. all
2. What are objective of predictive maintenance in electric motor?
a. To maximization of the productions.
b. To elimination of breakdowns
c. to reduce maintenance cost
d. The identities of for external deliveries
3. What are Disadvantages of Run to Failure
a. Its activities are expensive in terms of both direct and indirect cost.
b. Humidity and condensation
c. Loose connections
d. Voltage and current imbalance
Part-II: True/False
1. Preventive Maintenance is It is a daily maintenance procedure?
2. The objective of predictive maintenance of electric motor maintenance is to reduce maintenance
costs by detecting problems at an early stage and deal with them?
3. Preventive Maintenance It is a yearly maintenance procedure?

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 9 of 73 Author/Copyright Induction Motor August, 2023
Part-III: Short Answer
1. What are ways to perform corrective maintenance activities is by conducting four important steps:

________________________________________
________________________________________
________________________________________
_______________________________________

2. Write at list four main Objectives of Maintenance?

________________________________________
________________________________________
________________________________________
________________________________________

3. Write tow most important elements included in preventive maintenance are.

________________________________________
________________________________________

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 10 of 73 Author/Copyright Induction Motor August, 2023
Unit Two: Diagnosis and Rectify Faults in Electrical Induction Motor

This unit is developed to provide you the necessary information regarding the following content
coverage and topics:
 Troubleshooting Faults in Electrical induction motor
 Identify Faults
 Causes of Faults
 Corrective actions/remedies
This unit will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:
 Identify cause of troubles
 Explain the cause for Motor fail to start
 Discuss why motor starts and then stop
 Explain the cause for bearings over heated
 Discuss why Motor giving noise

2.1 Troubleshooting Faults in Electrical induction motor

Troubleshooting is a systematic approach to problem-solving that is often used to find and correct
issues with complex machines, electronics, and motor systems. The first step in most
troubleshooting methods is gathering information on the issue, such as an undesired behavior or a
lack of expected functionality.
Ministry of Labor and Skills Maintain and Rewinding Version -1
Page 11 of 73 Author/Copyright Induction Motor August, 2023
 Faults in A.C single phase motors

Main faults Causes/faults Corrective actions /Remedies

1. Motor fail to start Supply may be cut off  Check the main supply with test lamp
at the motor’s terminals, at starters,
terminals or in the main switch of the
motor.
Over load or low  Rotate the rotor by hand, if it is free to
starting torque move then reduce the load
Open circuit in relay  Check with test lamp in series of the
circuit or centrifugal supply and correct
switch
Capacitor may be  Check the capacitor with series test
defective in capacitor lamp and replace
type motor
Rotor shaft may be  Rotate the rotor shaft to see its free
jammed in the bearing motion and check the bearings end
or bushes. play.
Stator windings may be  Check the winding and polarity of
open circuited or coils with test lamp and if any end is
reversed coil connection found broken, join it is or solder it and
if the polarity is wrong, correct them
by doing the connection of ends of
each coil properly.

2. Fuses blown off as Protective gear may be  Check and see it is in correct order
soon as the motor is started defective
Motor may be over loaded.  Check and reduce the load
Stator winding may be short  Check the winding with series test
circuited or earthed lamp or megger and correct it
Connection of stator  Check the connections physically and
windings may be wrong also with series test lamp and correct

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 12 of 73 Author/Copyright Induction Motor August, 2023
 them.
3. motor starts and then Supply voltage may be too  Check the supply voltage with
stop low voltmeter and switch off the motor till
the voltage is increased
Motor may be over loaded  Check the load physically and reduce
it
Connection of the stator  Check with series test lamp and
winding may be wrong. correct them
4. bearings over heated Bearing may be squeezed.  Check and grease them
Belt may be too tight  Check and loses the belt
Motor may over loaded  Check and reduce the load
Bent shaft or rotor  Check and straight it.
Rotor may be rubbing the  Check and set the rotor shaft.
stator cores
5. motor frame may be Misalignment of drive  Check and correct it
over heated
Adjustment of pulley may  Set it correctly.
not be properly
Ventilating may not be Maintain the proper ventilation
proper.
Drive troubles Check and correct it.
6. Motor giving noise Motor loosely fitted on the Check and tighten the nuts.
foundation
Any part of the motor may Check and tighten it properly.
be loosely fitted
Rotor may be rubbing the Check and set rotor shaft properly.
stator core.
Bearing may be squeezed Check and grease the bearings.

7. speed of the motor is Supply voltage may be Check with the voltmeter and stop the motor
reduced suddenly reduced till the voltage is increased.

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 13 of 73 Author/Copyright Induction Motor August, 2023
 Open circuit in stator wedge. Check with series test lamp and join
connection.
Motor may be mechanically Check and reduce the load
or electrically loaded
suddenly.
8. speed of the motor is Supply voltage may be Check with the voltmeter and stop the motor
increased suddenly increased till the voltage is normal.
Load on the motor is reduced Check and increase the load on the motor up
too much to normal.
9. heavy sparking at Brushes rocker may not be in Set the rocker in the neutral position
brushes in case of magnetic neutral axis
repulsion or universal Pitted commutator Get the commutator be turned on the lathe.
motors Open ,short fault may be in Check the armature for these faults and
armature replace it
Motor may be over loaded Check and reduce the load
10. hunting of repulsion Pitted commutator Get it turned on the lathe.
or repulsion stat induction Shorting in gear or brushes Check and overhaul the gear and brushes.
motor

Faults in A.C Induction Motors

Main faults Causes Corrective actions /remedies

1.motor fail to start Supply may be cut off Check the main supply with test lamp.
Main switch may be in off Check the main switch and switch on.
position.
Fuses may be blown off. Check them physically and replace them.
Overload control may be tripped. Let the overloaded control be cooled and start
again.

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 14 of 73 Author/Copyright Induction Motor August, 2023
 Earth fault may be in the winding. Check the fault with series test lamp and
insulated the winding with cotton tape.
2. Motor gives One of the three Check for open phase with the
noise Phase may be cut off and the Test lamp and if fuse is found blown replace
motor is running on the single it.
phase.
Misalignment of motor Check and correct the alignment
Belt may be tight Loose the belt
3. Motor is over Motor may be loaded Check and reduce the load.
heating Control, may be defective. Check the starter fuse. main switch etc and
correct them.
Ventilating may be defective poor Maintain the proper ventilating.
Drive troubles Check and correct it.
Stator winding may be short Check for short circuit. Earth fault with series
circuited or earthed. test lamp or megger and removed the defects.
4. Bearing Bearings may be squeezed. Check and regressed the bearing with proper
overheated grading lubricant.
Belt may be too tight. Check and reduce the tension of the belt.
Excessive gear end thrust. Reduce the gear pressure.
Rotor shaft may be bent Check and straighten it.
Using wrong grade of lubricant Use the lubricant of proper grade.
5. Motor starts and Starting gear may be defective Check the contact and correct them.
stops Connections of stator winding may Check and tighten them.
be loose.
Loose connection at the motor’s Check and tight them.
terminals.
6. Motor works Supply voltage may be reduced. Check the voltage voltmeter and stop the
with reduced speed. motor till the voltage is increased up to
normal.
Motor may be overloaded. Check and reduce the load.
Stator winding may be open Check with series test lamp and join

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 15 of 73 Author/Copyright Induction Motor August, 2023
 circuited. disconnected ends.
7. Motor works Starting gear may be defective Check and correct it.
with high speed. Supply voltage increased Check the voltage with voltmeter and stop the
suddenly. motor till it falls to normal.
8. Motor runs at Rotor may be open circuited Check the open circuit with series test lamp
slow speed with and correct it.
external resistance Brushes are not making contact. set the brushes to make the contact.
cut off in case of Open circuit in the stator or rotor Check the winding for open circuit with test
slip ring induction winding. lamp and connect the disconnect ends.
motor.
9. Motor run at low External resistance cut out Set the rheostat.
speed. Open circuit in rotor circuit Test for open circuit and remove the open
circuit.
Dust between brushes and rings. Clean them by dusting.
Brushes are not free in holders. Set the tension of spring.
Excessive vibration Check the alignment and any part may be lose
check and tighten them.

Operation Sheet 2.1. Diagnosis and rectify faulty Induction motor

Operation title: Diagnosis and rectify faulty Induction motor
Purpose: Repair defective motor.
Instruction: following each step below and given equipment repair and make operational the faulty
motor. You have given 1hr for the task and you are expected to complete all needed for the diagnosis
and repair.
Tools, Equipment, and Materials
Table. material and equipment list
Item Quantity
1 Multi meter 1
2 Electrician hand tools 1 set

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 16 of 73 Author/Copyright Induction Motor August, 2023
 3 Tachometer 1
4 Wrenches 1sets

Procedure
Step1. Preparation (collect information, familiarize the device)
Step 2 – Observe(visual inspection)
Step 3 – Define Problem Area
Step 4 – Identify Possible Causes
Step 5 – Determine Most Probable Cause
Step 6 – Test and Repair

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 17 of 73 Author/Copyright Induction Motor August, 2023
LAP Test 2.1. Diagnosis and rectify fault of a motor

Task 1: Check and test fault area(internal or external of the motor).

Task2. Rectify the fault if it is external of the motor
Task 3: Disassemble the motor by following the correct procedures if the fault is internal.
Task4: Diagnosis and troubleshoot the fault
Task 5: Test and verify motor functionality

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 18 of 73 Author/Copyright Induction Motor August, 2023
Unit Three: Maintain and repair electrical Induction motors

This unit is developed to provide you the necessary information regarding the following content
coverage and topics:
 Electric motor parts
 Dis-assemble procedure of the motors
 Data collection from customers
 Steps of motor dis- assemble
 Assemble the motors
 Planning and prepare rewinding procedure
- Motor data collection
- Material Preparation for rewinding
- Develop rewinding diagram

 Rewind stator coils of single-phase and three phase AC motor

 Test and verify functionality
 Complete workplace report
This unit will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:
 Identify Electrical measuring instruments.
 Identify parts of Electric motor
 Discuss the Electrical parts of the motor.
 Discuss Mechanical parts of motors.
 Perform Assemble electric motors.
 Perform Dis -assemble electric motors.
 Test and verify functionality
 Test and verify repaired motors’ functionality

3.1 Electric Motor Parts

A. Stator
The stator is made up of several thin laminations of aluminum or cast iron. They are punched and
clamped together to form a hollow cylinder (stator core) with slots as shown in Figure 1. Coils of

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 19 of 73 Author/Copyright Induction Motor August, 2023
 insulated wires are inserted into these slots. Each grouping of coils, together with the core it
surrounds, forms an electromagnet (a pair of poles) on the application of AC supply. The number
of poles of an AC induction motor depends on the internal connection of the stator windings.

Figure 3.1 :Stator Part of motors

B. Rotor
The rotor is made up of several thin steel laminations with evenly spaced bars, which are made up
of aluminum or copper, along the periphery. In the most popular type of rotor (squirrel cage rotor),
these bars are connected at ends mechanically and electrically by the use of rings. Almost 90% of
induction motors have squirrel cage rotors. This is because the squirrel cage rotor has a simple and
rugged construction. The rotor consists of a cylindrical laminated core with axially placed parallel
slots for carrying the conductors. Each slot carries a copper, aluminum, or alloy bar. These rotor
bars are permanently short-circuited at both ends by means of the end rings, as shown in Figure
below.

Figure 3.2 :Rotor Part of motors

C. Commutator
The commutator is mounted on the rotor of a dc machine and it performs with help of brushes a
mechanical rectification of power from
- ac to dc in case of generators and
-dc to ac in case of motors.

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 20 of 73 Author/Copyright Induction Motor August, 2023
The ends of armature coils are connected to the commutator, which together with the brushes rectifies
the alternating emf induced in the armature coils and helps in the collection of current.
It is cylindrically shaped and is placed at one end of the armature.
The construction of the commutator is quite complicated because it involves the combination of
copper, iron and insulating materials.
The connection of armature conductors to the commutator is made with the help of risers.
3.2 Dis-assemble procedure of the motors

3.2 1 Data collection from customers

Before dis-assemble the motors we have to ask the customers why they can’t work properly what is
the symptoms. And then we have to test the motors using different testing methods on each parts.
Verify defects of motor

It is important to re- check and test the expected defected motor before disassembling it.

Visual Tests

• Check that motor frame is mechanically sound.

• Remove terminal cover plate and check for ingress of foreign material, moisture etc.

• Check for signs of overheating, arcing or burning.

• Check ventilation is clear.

Electrical Tests

• Identify windings using a continuity tester.

• Measure the resistance of the windings (3 identical readings).

• Measuretheinsulationresistancebetweeneachwindingandbetweenwindingsand frame.

Mechanical Tests

• Check that the rotor is free to rotate and does so smoothly/quietly.

• Check that motor interior is free of dirt, dust, water and oil.

• Check for play in bearings.

3.2.2 Dis- assemble Procedures of motors

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 21 of 73 Author/Copyright Induction Motor August, 2023
1. Remove the pulley of motor on the shaft, also remove the fan cover and then open the fan, which is
screwed on the shaft of motor for cooling purpose.
2. The shaft or pulley of the motor is always in front of your eyes and then you mark a line on the did
covers and on the yoke. The advantage of this line is that, when you closing the motor you easily meet
these mark points and close the motor cover.
3. Open the nut-bolts or screws of the end-covers of the motor by using spanner or screw driver.
4. Two screw drivers are inserted in motor cover and apply a little pressure internally as a result, the
cover of the motor is easily opened.
5. After that, the rotor of the motor is easily come out.
6. The back side and cover of the motor are removed, by using the method, which are mentioned in
point (4).
7. The bearings of the motor are dip into kerosene oil and then apply the grease into the bearings.
8. Clean the stator of the motor carefully.

Figure 3.3 : Disassembled motor parts

3.3 Assemble the motors

3.3.1 Planning and prepare rewinding procedure

Understand Rewinding terminologies
 Conductor:
 The active length of a wire or strip in the slot.
 Turn:

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 22 of 73 Author/Copyright Induction Motor August, 2023
  A turn consists of two conductors separated from each
 other by a pole pitch or nearly so, and connected in series as shown
 in fig.(a)
The conductors forming a turn are kept a pole pitch apart in order that the emf in two are additive to
produce maximum resultant emf.

Figure:3.4: illustration of Winding diagrams terminologies

 Coil: A coil may consist of a single turn or may consist of many turns, placed in almost similar
magnetic position, connected in series.
 Coil-Side: A coil consists of two coil sides, which are placed in two different slots, which are
almost a pole pitch apart.
Number Of Phases And Phases Spread
 An ac winding, meant to be user for a 'm' phase system, should produce emfs of equal magnitude
in all the phase.
 These emfs should have identical waveforms and equal frequency.
 Their displacement in time should be y =2/m electrical radians.

 This is obtained by having similar pole phase groups (a pole phase group is defined as a group of
coils of a phase under one pole) and arranging the groups to have an effective displacement of y
=2/m electrical radians in space.
A. Motor data collection
We can Take data from name plate and internal data
From Name Plate we get:
Ministry of Labor and Skills Maintain and Rewinding Version -1
Page 23 of 73 Author/Copyright Induction Motor August, 2023
-Type of Phase -Speed of motor (RPM)
-Horse Power - Number of Voltage
-Number of Current -Temperature
- Serial Number of motor -Connection types
-Frequency Value
From Internal part of Motors
-Number of Slots -Number of coils
-Pole pitch -coil pitch
-Types of winding -Types of connections
-Number of coils per groups in starting and running winding
-Coil size - Types of wire
-Number of turns in running and starting winding coils in different pitch
B. Rewinding Instruments
a. Winder Machine
A motor rewind means that a coil is rewound and reinstalled for the necessary armatures or other
components. The goal is to get the motor back to functioning at its optimal level. Motor rewinding
can help with motors that are either performing inefficiently or have stopped working altogether
Coil Winder Machine.

Figure3.5: Motor winder machine

b. Copper coil
Magnet wire or Enameled wire is a copper wire coated with a very thin layer of insulation. We have
different range of Enameled Copper Winding Wires coated with a layer of insulation and comes with
good mechanical properties such as tensile strength, elongation etc. The material is electrolytically
refined copper and fully annealed to take maximum benefits of the customization in hermetic
applications in Electrical Motors, Transformers, Switchgear, Consumer & Industrial Electronics, Auto
Electrical, Refrigerators, Air Conditioners, Domestic Appliances, Pumps & Fans and more.

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 24 of 73 Author/Copyright Induction Motor August, 2023
 Figure3.6 : Enameled Copper Wires
c. Insulation Paper
Insulation paper for motor winding is a general term for electrical insulating paper, which is used
as an insulating material for electrical equipment such as cables and coils. In addition to their good
insulation and mechanical strength, they also have their own characteristics. Today we'll see if
insulation paper for motor winding can withstand voltage.

Figure 3.7 : Insulating Paper

d. Slot Wedge
Slot Wedges are made of either magnetic or nonmagnetic Material, being used as Slot Closures to hold
the stator windings in the slots formed between the stator teeth. Slot wedges made of magnetic
material are a significant means to improve the efficiency of a motor or generator. Magnetic slot
wedges reduce slot ripple in the air gap flux caused by the changing reluctance due to the slots, and
also reduce the associated eddy current losses due to the interaction of the harmonics in the air gap
flux with the conducting surface of the rotor.

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 25 of 73 Author/Copyright Induction Motor August, 2023
 Figure3.8: Slot Wedge
e. Varnish
The varnishing method used in the repair process is important for efficiency and for the application of
the electric motor or generator. Varnishing the windings of an electric motor or generator functions to
insulate the windings from contaminants, to make the windings rigid and tight, and to dissipate heat.

Figure 3.9: Varnish

f. Electric motor bandage
An electric motor coil bandage has at least two or more independent coil legs of a rotor or a
stator each having a face connection which includes a coil rod connected to the individual coil
leg. A bandage extends around a plurality of sets of the coil rods of identical coils and a rubber
elastic compressible cushion is disposed between adjacent rods and is adapted to glide
relatively to the insulation surface of these rods.

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 26 of 73 Author/Copyright Induction Motor August, 2023
 Figure 3.10: Bandage
g. Oil Can
The oil pump is a part of an engine lubrication system that pumps oil under pressure. It pumps oil from
the sump through the galleries to the rotating bearing, the sliding pistons and the camshaft of the
engine. The primary purpose for the system is to pressurized oil lubricating oil to circulate within the
engine moving parts. The pumped oil also maintained the temperature of the engine. There are
different types of oil can, based on their shape and purpose. In this training it used for pumping the
varnish to the rewinding motor coil.

Figure 3.11: oil can

h. Mallet hammer
A mallet is a hammer used to strike an object without damaging it. They are typically lightweight
and made from solid wood, rubber, or leather.

Figure3.12: mallet hammer

i. Bearing Puller
A bearing puller is a tool which is used to remove components such as bearings, gears and pulleys
from a shaft or a recess. The puller securely grips the component with specially designed jaws
before driving it off the shaft. Pullers are used in every industry for safely and effectively
dismounting bearings. Whether you’re working in the automotive industry or the food and
beverage industry, a bearing pulley could facilitate easy dismounting of your bearings and other

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 27 of 73 Author/Copyright Induction Motor August, 2023
 components. Every bearing puller falls into the broad categories of either an external bearing puller
or an internal bearing puller.

Figure3.13: Bearing puller

C. Rewinding procedures

1. Taking Data – is recording the specific and original data of the motor. The information is
gathered before and during stripping the damaged windings.

Collect with great care all necessary name plate data and inside data such as coil pitch, pole
pitch, number of turns per coil, numbers of coils, number of slots, length of coil(s),cross-
sectional area of coil wire.

2. Stripping the Winding

a) Burn the old winding by using oven or torch to remove the varnish.

b) Take care not to damage the slot lamination.

c) Cut the coils by using cold chisel or hacksaw.

d) Remove the wedges before pulling out the wires.

Figure3.14: Coil removing

Ministry of Labor and Skills Maintain and Rewinding Version -1
Page 28 of 73 Author/Copyright Induction Motor August, 2023
3. Insulating the Slots

a) Clean first the slots.

b) Copy the size and format of the removed slot insulation.

c) Make the required length of wedge (bamboo) for slot lock.

d) Insert the insulation inside the slot. Ensure that it is fitted correctly.

Figure 3.15: Inserting wedge

4. Develop winding diagram (as single layer or double layer)

5. Prepare coils using manual or automatic winding machine

Figure 3.16: coil preparation

6. Inserting the Coils into the Slots

Ministry of Labor and Skills Maintain and Rewinding Version -1
Page 29 of 73 Author/Copyright Induction Motor August, 2023
a) By using the form winding method, the coils must be inserted part by part.

b) Avoid forcing the coils to be fed in the slots simultaneously.

c) Sometimes, it is advisable to use a funnel to ease the task.

d) Avoid overlapping or crossing the coils to maximize the space of the slots.

e) Remove the kinks in the wire before inserting it into the slots.

f) After all coils were inserted, put the wedge or slot lock. Be sure that no coil was wrongly placed
outside the slot insulation.

Figure 3.16: Coil Insertion

7. Connecting the Windings

a) After all coils are inserted; the next step is to connect them.

b) The coils must be connected in the set of Begin(b) to Begin and End(e) to End terminals in order to
form an alternate polarity in the pole or the first pole is wound clockwise, the second pole is
counter clockwise and the third is clockwise again and so on…

c) Care should be taken to alternate the direction of the winding for each pole.

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 30 of 73 Author/Copyright Induction Motor August, 2023
 Figure 3.17: Connect terminals

8. Lacing the Coils

a) After the coils were correctly soldered and connected. Motor thread or yarn is used to lace the
winding to keep the coils in good shape and fit inside the casing. It also protect the coils not to
be detached during the motor’s running operation.

b) The thread used is a special type which is intended only for motor and transformer rewinding.

c) The thread must be correctly tied in order to avoid loss of time and rewinding effort.

Figure 3.18: Lacing the Coils

9. Testing the New Winding

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 31 of 73 Author/Copyright Induction Motor August, 2023
a) After the rewinding and connections of coils are completed, it is essential to test and check the
motor.

b) Using Ohmmeter; check the motor for Short circuits, Open circuits, Ground circuits and Incorrect
connections and polarity.

c) Incorrect connections could be discovered by using compass method and nail method (for small
motors).

d) Using compass method, the winding of the motor must be connected to the low voltage direct
current or low voltage alternating current.

10. Varnishing and baking

a) After the winding is thoroughly tested, the stator is let to dry to remove any kind of moisture. Then
the stator winding is sprayed by dropping the varnish.

Figure 3.19: Varnishing

b) Varnish may also be applied by spraying or brushing. After that, let it drip the remaining varnish
and put it inside the baking oven.
c) The oven temperature must be in between 110°C to 140°C and the stator motor must be in hot
oven, and cook it for about 4 hours.

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 32 of 73 Author/Copyright Induction Motor August, 2023
 Figure 3.20: Stator motor in the oven

d) Varnishing and baking bonds the entire winding and it helps to increase the mechanical and
dielectric strength of the wires.
11. Assemble the motor
12. perform no load test
13. Connect it with its load and perform load test

Figure 3.21: Figurative steps of rewinding

3.3.2 Develop rewinding diagram of three phase and single-phase AC motor

A. Winding Diagrams of Three Phase AC Motor

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 33 of 73 Author/Copyright Induction Motor August, 2023
They are two basic physical types for the windings. They deal differently with the mechanical problem
for arranging coils in sequence around the armature.
The two types are:
1. Single layer winding and
2. Double layer winding
1. Single layer winding
In this type of winding arrangement, one coil side of a coil occupies the whole of the slot.
Single layer windings are not used for machine having commutator. In single layer, the number
of coils is half of the No. of slot. C= 1/2S, but No. of Slot= No of Coil Side.
The most common types of single layer windings are
A. Concentric winding
B. mush winding
C. Chain winding
2. Double layer Winding
It has two coil sides per slot, and has identical coils with one coil sides of each coil lying in the top
half of the slot and the other coil side in bottom half of another slot. In double layer windings No. of
Slot= No. of coils. But number of slots is half of the number of coil sides. This type of winding is
suitable for large AC machines.
 The three most common types of single layer windings are
1. Concentric windings (Unequal coil span)
2. Mush windings (equal coil span)
3. Chain windings (equal coil span)
1. Concentric Winding
Three-phase concentric winding consists of coil groups laid in the slots so that all the coils of each
group are concentric.
That is, the coil with the smallest slot pitch is surrounded by the coil with the next larger slot pitch and
so on to make up a coil group.

Each coil consists of several turns and the cross-over from one coil to the next is indicated by a short-
slanted line (jumper).
In order to construct the diagram for a winding, the following data must be known:

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 34 of 73 Author/Copyright Induction Motor August, 2023
 S - The number of slots in the stator
P – The number of poles
m – The number of phases
YS – The pitch of the winding
a – The number of parallel circuits in the windings
 The pith of the winding is determined by the formula:

S
YS 
P

 The pitch is the distance between two sides of a coil expressed as the difference between the
numbers of the slots in which the sides lie.

 Another important value of the winding of ac machines is the number of slot per phase per pole
denoted by the letter q. It can be determined by the formula

S
q
Pm

 Sometimes q is called a pole-phase group is defined as a group of coils of a phase under one
pole.

 The number of slots per pole per phase in concentric winding can be seen directly from the
diagram. It is equal to the number of coils in a coil group

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 35 of 73 Author/Copyright Induction Motor August, 2023
 Figure 3.22: Coil Groups and pole pitch

 As soon as all the coils have been laid in the slots, the coil groups are connected in to phases.

 Each group is provided with two leads for the start and finish of the group.

 The total number of leads is therefore twice the number of coil groups.

 A stator winding must have six leads brought out to the terminal panel these leads being the
beginnings and ends of the three phases.

 All the remaining leads must be interconnected in the respective phases with in the winding.

 It is now necessary to decide in order to determine the beginnings and ends of each phase.

 The coil groups in each phase should be interconnected by joining there unlike leads, i.e. start to
finish, or finish to start

In General, Two Mains Rules are Followed

 The distance between the beginning of the phase and the distance between the ends of the phase
must be equal to 120 electrical degrees.

 Any slot can be chosen as the beginning of the first phase.

Example 1: Developing a 3-phase motor winding diagrams

Based on the collected data and calculated data, develop winding diagram for the motor given as

Given data
S=24; p=4;m=3; a=1; type=Concentric
• Solution

a) The number of coil groups, K

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 36 of 73 Author/Copyright Induction Motor August, 2023
 P 4
K  3  3  6
2 2
b) The number of slots per pole per phase, q

S 24
q  2
m  p 3 4

c) Coil pitch

S 24
YS   6
p 4
The shorter coil pitch = YS-1=6-1=5
The larger coil pitch = YS+1=6+1=7

d) The electrical angle, 

  180  P  180  4  720

720 
   30
e) The angle between adjacent slots,  S 24

120
120
   4 slots
f) The distance between the beginning of each phase,   30

g). the beginning of Phase A is slot 1, then the beginning of phase B is slot 1+=5 and the
beginning of phase C is slot 1+2=1+8=9
Phase sequence

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 37 of 73 Author/Copyright Induction Motor August, 2023
 A
C’
B’ 600

C B

A’

Figure 3.23 (a): Three-Phase sequence spreads in 24 slots,4-poles of AC machine stator

Procedure For Constructing Of Concentric Windings

Data: S= 24, P = 4, a = 1, q = 2, K = 6
1.Draw 24 vertical lines and number them

1 3 5 7 9 11 13 15 17 19 21 23

2 4 6 8 10 12 14 16 18 20 22 24

Figure 3. 23 (b): coil sides arrangements in 24 slots 4-pole machine

Coil Groups of Phase A
2. The first and second slots will be occupied by left-hand sides of the first coil group of phase A.

3. Leave four, or 2q slots free for other two phases occupy slots 7 & 8 with the right hand side of the
first coil group.

4. Next to it lie a second coil group of the same size which occupies slots 13,14,19,20.

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 38 of 73 Author/Copyright Induction Motor August, 2023
1 3 5 7 9 11 13 15 17 19 21 23

2 4 6 8 10 12 14 16 18 20 22 24

Figure 3. 23 (c): Concentric winding of coil group of Phase A

Coil Groups of Phase B
5.The 5th and 6th slots will be occupied by left-hand sides of the first coil group of phase b.
6.Leave four, or 2q slots free for other two phases occupy slots 11 &12 with the right hand side of the
first coil group.
7.Next to it lie a second coil group of the same size which occupies slots 17,18,23,24.

1 3 5 7 9 11 13 15 17 19 21 23

2 4 6 8 10 12 14 16 18 20 22 24

Figure 3. 23 (d): Concentric winding of coil group of Phase

Coil Groups of Phase C
8. The 8th and 9th slots will be occupied by left-hand sides of the first coil group of phase c.
9. Leave 2q slots free for other two phases occupy slots 15 &16 with the right hand side of the first
coil group.
10. Next to it lie a second coil group of the same size which occupies slots 21,22,3,4.

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 39 of 73 Author/Copyright Induction Motor August, 2023
 21 4
22 3

1 3 5 7 9 11 13 15 17 19 21 23

2 4 6 8 10 12 14 16 18 20 22 24

22 3

21 4

Figure 3. 23 (e): Concentric winding of coil group of Phase A

11.Current direction

N
1-6
21 4

22 3

1 3 5 7 9 11 13 15 17 19 21 23
N
S N S
2 4 6 8 10 12 14 16 18 20 22 24

22 3

21 4

Figure 3. 23 (f): Current direction through each coil under each pole
12. Coil groups interconnection
Connect group connection phase A, phase B, Phase C and then brought out terminals as shown in
figure 3.23 (g) and thereby (h):

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 40 of 73 Author/Copyright Induction Motor August, 2023
Connect group connection phase A, phase B, Phase C and then brought out terminals as shown in
figure 3.23 (g) and thereby (h):
Phase A Phase B Phase C
A B C

1 +7 8
5 12 9 16
I 2 +5 7 II III
6 11 10 15

13 +7 20
17 24 21 4
IV +5 V VI
14 19
18 23 22 3

A’ C’
B’
Figure 3. 23 (g): Connection diagram

21 4

22 3

1 3 5 7 9 11 13 15 17 19 21 23
N
S N S
2 4 6 8 10 12 14 16 18 20 22 24

22 3

21 4

A C’ B C A’ B’

Figure 3. 23(h): coil groups and pole groups connections of concentric winding.
2.Mush winding
This winding is very commonly used for small induction motors having circular conductors. This
is a single layer winding where all the coils have same span (unlike the concentric winding where
coils have different spans). Each coil is wound on a former, making one coil side shorter than the
other. The short coil sides are placed first and then the long coil sides. The long and short coil sides

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 41 of 73 Author/Copyright Induction Motor August, 2023
 occupy alternate slots. It will also observe that the ends of coil situated in adjacent slots cross each
other i.e., proceed to left and right alternatively. That is why sometimes it is known as a basket
winding.
Coil-sides of mush winding arrangement inside the slots

Figure 3.24: Coil-sides of mush winding arrangement inside the slots

Figure 3.25: Basket Winding

The following should be kept in mind while designing a mush winding, that is
➢ The coils have a constant span.

➢ There is only one coil side per slot and therefore the number of coil sides are equal to number of
slots.
➢ There is only one coil group per phase per pole pair and therefore, the maximum number of
parallel paths per phase is equal to pole pair.
➢ The coil span should be odd. Thus, for a 4 pole 36 slot machine, coil span should be 36/4=9
while for a 4 pole 24 slot machine, the coil span should not be 24/4=6; it should be either 5 or 7
slots. This because a coil consists of a long and a short coil side. The long and short coil sides are
placed in alternate slots and hence one coil will be in an even numbered slot and the other in a odd
number slot giving a coil span which is an odd integer.

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 42 of 73 Author/Copyright Induction Motor August, 2023
 Example#3: on mush winding Given data S=12; p=2; m=3; a=1; type=Mush • Solution a) The
number of coil groups, K i.e., there is one coil group per phase b) The number of slots per pole per
phase, q i.e., there are two coils in a group 1. Coil pitch Full-Pitc
Example#2: on mush winding
Given data S=12; p=2; m=3; a=1; type=Mush
Solution
a) The number of coil groups, (K)

i.e., there is one coil group per phase

b) The number of slots per pole per phase(q )

i.e., there are two coils in a group

c.) Coil pitch

Full-Pitch
This is an even number and hence winding is not possible with an even coil span. Therefore, it is
shortened by one slot and a coil span of 5 slots is used.
d)The electrical angle( )

e) The angle between adjacent slots()

f) The distance between the beginning of each phase()

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 43 of 73 Author/Copyright Induction Motor August, 2023
g)If the beginning of Phase A is slot 1, then the beginning of phase B is slot 1+=5 and the beginning
of phase C is slot 1+2=1+8=9

Phase Sequence

Figure 3.26 (a): Three-Phase sequence spreads in 24 slots,4-poles of AC machine stator

Connection Diagrams

Figure 3.26 (b): Connection diagram

Procedure For Constructing of Mush Windings

Data: S= 12, P = 2, a = 1, q = 2, K = 3
1. Draw 12 vertical lines with short and long coil-sides consequently and number them

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 44 of 73 Author/Copyright Induction Motor August, 2023
 Figure 3.26 (c): coil sides arrangements in 12 slots 2-pole machine
Coil Groups of Phase A

Figure 3.26(d): coil group of phase A

Coil Groups of Phase B

Figure 3.26(e): coil group of phase B

Coil Groups of Phase C

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 45 of 73 Author/Copyright Induction Motor August, 2023
 Figure 3.26(f): coil group of phase C
Current direction

Figure 3.26(g): current Direction

Coil group interconnection Phase A

Figure 3.26(h): Phase A: Coil group interconnection

Coil group interconnection Phase B

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 46 of 73 Author/Copyright Induction Motor August, 2023
 Figure 3.26(i): Phase B: Coil group interconnection
Coil group interconnection Phase C

Figure 3.26(j): Phase C: Coil group interconnection

Terminals

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 47 of 73 Author/Copyright Induction Motor August, 2023
 Figure 3.26(k): Terminals
3. Chain Winding
In all aspect chain winding is similar to mush winding. But the difference is all coil side is similar in
chain winding. Chain winding have Diamond shapes.
Example 3.
Chain Winding
• In all aspects, this winding is similar to that of mush winding except that both coil
sides of a coil have equal length and diamond shape.

Given data
S=12; p=2;m=3; a=1; type=chain
• Solution

All solution producers have the same with mush windings

a) The number of coil groups, K

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 48 of 73 Author/Copyright Induction Motor August, 2023
 P 2
K  3  3  3
2 2
b) The number of slots per pole per phase, q

S 12
q  2
m  p 3 2
c) Coil pitch

S 12
YS   6
p 2
This is an even number and hence winding is not possible with an even coil span .
Therefore , it is shortened by one slot and a coil span of 5 slots is used.
a) The electrical angle, 

  180  P  180  2  360

b) The angle between adjacent slots, 

 360
   30
S 12
c) The distance between the beginning of each phase, 

120
120
   4 slots
 30
d) If the beginning of Phase A is slot 1, then the beginning of phase B =1+=5 and the beginning
of phase C =1+2=1+8=9

Phase sequence

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 49 of 73 Author/Copyright Induction Motor August, 2023
 Figure 3.27 (a): Three-Phase sequence spreads in 12 slots,2-poles of AC machine stator
Connection diagram

Figure 3.27 (b): Connection diagram

Terminals
10 3

8 12 1
5

1 3 5 7 9 11

2 4 6 8 10 12

8 5
12 1
10 3

A C’ B A’ C B’

Figure 3.27(c) : Terminal of chain winding.

2. Double layer Winding

Double layer windings differ from single layer winding mainly on the following main points: Each slot
is occupied by the side of two coils and each coil is arranged to form two-layer round stator. One layer
Ministry of Labor and Skills Maintain and Rewinding Version -1
Page 50 of 73 Author/Copyright Induction Motor August, 2023
of the winding lies in the bottom half of the slots and the other in the top half of slots. Unlike the
concentric winding double layer winding consists of identical coils all of the same shape and pitch. In
a double layer winding, the coil pitch is the distance between the top and the bottom sides of the coil
expressed by the number of slots spanned or by the coil sides or by the number of slots occupied by
each coil side. In double layer windings No. of Slot= No. of coils. But number of slots is half of the
number of coil sides.
This type of winding is suitable for large AC machines.
A coil pitch may be full or fractional. Majority stator windings use a fractional pitch because:
✓ The amount of copper used in the overhang (end winding) reduced and hence a saving on copper,
and
✓ The magnitude of certain harmonics in the emf and also emf is reduced.

The full pitch is determined by:

 Usually, the full pitch is shortened by one-sixth i.e., for example if the full pitch is 12 a
fractional will be 10.
 Since the coils are wound with a continuous length of wire there are no connections between
turns.
Double Layer Three phase windings
 The main value characterizing the two-layer winding is the number of slots per pole per phase.

 By looking double layer winding externally, it is not possible to determine q.

 The total number of coils in two-layer winding is equal to the number of slots since each side of
a coil occupies one half of a slot which is equivalent to occupying one full slot per coil.
 In order to avoid making solder joints between coils, several coils, depending upon slots per pole
per phase, are generally wound from a single length of wire in to full coil group.
 The number of coil groups per phase is an equal to the number of poles the whole winding. That
is:
Ministry of Labor and Skills Maintain and Rewinding Version -1
Page 51 of 73 Author/Copyright Induction Motor August, 2023
  This is twice that in a single-layer winding.
Rule for double layer windings
The coil groups should be connected to each other by joining the leads of like polarity
i.e., the finish of one group to the finish of the next group and the start of one group to
the start of the next group.

Figure 3.28 : Rule for double layer windings

Example 4: on double layer winding
Given data S=12; p=2; m=3; a=1; type=Double layer: the pitch shortened by one slot
• Solution
a) The number of coil groups, K

i.e., there is two coil groups per phase

b) The number of slots per pole per phase, q

i.e., there are two coils in a group

c) Coil pitch

i.e : Full-Pitch
d) The electrical angle, 

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 52 of 73 Author/Copyright Induction Motor August, 2023
e) The angle between adjacent slots, 

f)The distance between the beginning of each phase,    =180P =18

g) If the beginning of Phase A is slot 1, then the beginning of phase B is slot 1+=5 and the beginning
of phase B is slot 1+2=1+8=9

Phase sequence (Top layer Coil-sides)

Figure 3.28 (a): Three-Phase sequence spreads in 12 slots,2-poles of double layer motor

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 53 of 73 Author/Copyright Induction Motor August, 2023
 Figure 3.28(b): Connection Diagrams

Procedure for Constructing of Double Layer Windings

Draw 24 vertical lines to represent the two coil sides lying in each of the 12 slots. For each slot the full
line at the left-hand side will represent a top a coil side and broken line at the right-hand side a bottom
coil side.

Figure 3.28. (c): coil sides arrangements in 12 slots 2-pole machine

The top part of slot 1 will be taken as the beginning of the first phase. According to the selected
fractional pitch, the conductor from slot 1 is now connected to that in the bottom coil side in slot 1 + 5
= 6’.

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 54 of 73 Author/Copyright Induction Motor August, 2023
Since q = 2 i.e., each coil group will consist of two coils. The conductor must therefore leave the
bottom of slot 6 to enter the top of slot 2 and from there the bottom of slot 7. The lead emerging from
slot 7 will be finish of the first coil group.

Figure 3.28(d): Phase A coil groups

Figure 3.28(e): Phase B coil groups

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 55 of 73 Author/Copyright Induction Motor August, 2023
 Figure 3.28(f): Phase C coil groups

Current Direction

Figure 3.28(g): current directions

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 56 of 73 Author/Copyright Induction Motor August, 2023
 Phase A: Coil groups interconnection

Figure 3. 28(h) : Phase A: Coil groups interconnection

Phase B: Coil groups interconnection

Figure 3. 28(i) : Phase B: Coil groups interconnection

Phase C: Coil groups interconnection

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 57 of 73 Author/Copyright Induction Motor August, 2023
 Figure 3.28(j) : Phase C: Coil groups interconnection

Terminals

Figure 3. 28(k) : Coil groups interconnection

B. Winding Diagrams of Single Phase AC Motor

Example : Design Single Phase 24 Slots 4 Poles Motor Winding

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 58 of 73 Author/Copyright Induction Motor August, 2023
Starting Winding

Figure 3. 29(a) : starting winding

Starting Windings

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 59 of 73 Author/Copyright Induction Motor August, 2023
 Figure 3. 29(b) : starting winding

Starting and Running Windings

Figure 3. 29(c): Starting and Running Windings

Current Direction

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 60 of 73 Author/Copyright Induction Motor August, 2023
 Figure 3. 29(d): Current Direction

Terminals

Figure 3. 29(e): Terminals

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 61 of 73 Author/Copyright Induction Motor August, 2023
3.3.3 Test and verify functionality

The following final tests are to be performed as final checks:

 Motor testing is to be carried out on an isolated test bed. Megger test to be carried out before test
run. Insulation resistance test (Megger test) must be carried out before any test run.

 The motor is to be run at nameplate voltage, frequency and speed. Record the current drawn per
phase and document.

 The motor shall be vibration acceptance tested. and the vibration spectrum for each position
measured and recorded. The vibration test should be carried out on a specialized test bed using
calibration equipment. Record the vibration spectrum for each position measured. Accepted
result of vibration test are shown in table below.

 Bearing temperatures to be measured using a non-contact tool (ex: an infrared thermometer or an

infrared camera) and recorded once stabilized.

Table: Vibration Severity - ISO 10816-1, image from Fluke

3.3.4 Completion of workplace report

Ministry of Labor and Skills Maintain and Rewinding Version -1
Page 62 of 73 Author/Copyright Induction Motor August, 2023
What is a work report?
A work report is a formal document that discusses information about a specific topic related to an
aspect of your job. Most work reports are addressed to a particular audience, such as a manager.
Depending on the type of work report, you may be given a report brief that outlines what you should
include in your report. Most reports should be written in a structured format to clearly demonstrate
what the report is trying to convey.
Related: 5 Steps for Great Business Writing (With Tips)
How to write a work report
Writing effective work reports takes practice and requires good communication skills. The more
reports you write, the more efficient you will be in composing them. The following are steps you can
take to write a professional report in the workplace:
1. Identify your audience
Knowing who will be reading your report is an important step in determining how you will format
your report, what to include and the tone you should use when writing it. For example, if you are
writing a sales report for your manager, will anyone else be reading the report? If you're composing a
business analysis report, will your higher-ups be reading the report or only your immediate supervisor?
Establish who will be reading your report and cater the report to these specific people.
2. Decide which information you will include
After determining who your audience is, you should focus on identifying the purpose of your report to
decide what information should be included. If you know who will be reading the report, you could
ask questions regarding what they expect to see. Choose to include information that will provide the
clearest picture of what you are trying to convey.
For example, if you're writing a sales report, your report may need to include information about
whether sales goals are being met, products and services that are selling the most, challenges you or
your team are facing and your sales forecast for the next month or quarter.
Related: How To Create an Analytical Report (And Why It's Important)

3. Structure your report

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 63 of 73 Author/Copyright Induction Motor August, 2023
When writing a report, you should structure it so that it can be easily read and digested. While each
report will vary in the sections you should include, you can use the following report components as a
guide when writing your report:

 Title or title page

 Executive summary/abstract that briefly describes the content of your report

 Table of contents (if the report is more than a few pages)

 An introduction describing your purpose in writing the report

 A body paragraph where you include the information you are conveying with the report

 Conclusion or recommendation depending on the purpose of the report

Related: What Are Project Deliverables? Types and Example

4. Use concise and professional language

You should strive to use clear and concise language when writing your report. Try to get the point
across as clearly and quickly as possible and use simple yet professional language. Avoid using "fluff"
or wordy sentences when possible. For example, rather than saying, "You might find it helpful to
regularly refresh your inbox to stay up-to-date on emails," you could say, "Regularly refresh your
inbox."
Related: How To Speak More Concisely (With 6 Steps You Can Follow)
5. Proof read and edit your report
Proof reading your work report is an essential step in the report-writing process. This gives you the
opportunity to ensure your writing is as professional as possible and to catch any mistakes before you
send it out. Proofreading also allows you to cut out any unnecessary information and make sure your
report is as efficient and effective as possible.
Once you have finished writing your report, set it aside for an hour or more before you proofread it.
This will allow you to look at the report in a fresh way and catch mistakes you may not have seen
before.
Related: Guide to Memo Writing with Tips and Examples

Work report template

The following is a template you can use when formatting a work report:
 Project name
Ministry of Labor and Skills Maintain and Rewinding Version -1
Page 64 of 73 Author/Copyright Induction Motor August, 2023
  Date
 Prepared by: your first and last name
 Company name
 Executive summary or abstract: Use this section to note your conclusions or recommendations
that will be made in the report. You should also include the most important ideas discussed in
the report. If you're writing a daily work report or progress report, you do not need to include
this section.
 Introduction: Your introduction should be two to four paragraphs summarizing what you will
cover in the report as well as your reason for writing the report. Be as specific and concise as
possible when writing your introduction so that the reader can clearly understand what they
will find in your report. For daily or progress reports, your introduction only needs to be a few
sentences detailing work you've completed and what you plan to work on next.
 Body: For the body of your report, you should focus on detailing the information you wish to
convey. You can include results, conclusions and findings that were made related to a project.
For daily or progress reports, include the accomplishments you have achieved or tasks you
have completed.
 Recommendations: In this section, you should list your recommendations based on the
conclusions or results of a project or that will solve a particular issue. For example, you may
write "spend one hour training employees.
In addition, after completion of the motor repairs, the repair facility shall submit a report that
contains the following:
 Condition of the motor up on , electrical and/or mechanical as appropriate
 A detailed description of the work performed
 Sufficient test data demonstrating that the motor was appropriately repaired
 Condition of the motor when returned, electrical and/or mechanical as appropriate
 Copies of other records (e.g., photographs, sketches or drawings) deemed necessary for clarity

Operation Sheet 3.1 Three phase ac motor winding

Operation title: Rewinding three phase AC motor

Purpose: rewind three phase motor to the standards.

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 65 of 73 Author/Copyright Induction Motor August, 2023
Instruction: following each step given below. You have given 30hr for the task and you are expected
to complete all needed for the winding.
Tools, Equipment, and Materials
Table 1. material and equipment list
Item Quantity
1 Defective three Ac motor 1
2 Electrician hand tools 1 set
3 Enameled copper wire/ magnet wire As required

4 Motor/transformer automatic rewinding machine 1

5 Coil form (Bobbin) 1
6 Bench-Vise 1
7 Manual rewinder 1
8 Motor holder 1
9 Wire holder 1
10 Coil’s removing machine 1
11 Baking oven 1
12 Coil’s counter machine 1
13 Ohmmeter 1
14 Drawing scotch As required
15 Insulation tube As required
16 Mylar/insulation paper As required
17 Bearing puller 1
18 Varnish As required
19 Wedge/bamboo As required
20 Bandage As required
20 Insulation tape As required
21 Soldering with soldering lead 1
22 Oil/grease As required

Winding Procedure

1. Take Data from name plate and internal part of the motor

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 66 of 73 Author/Copyright Induction Motor August, 2023
2. Stripping the Winding

3. Insulating the Slots

4. Develop winding diagram

5. Prepare coils using manual or automatic winding machine

6. Inserting the Coils into the Slots

7. Connecting the Windings

8. Varnishing and baking

9. Assemble the motor

10. perform no load test

11. Connect it with its load and perform load test

Operation Sheet 3.2: Three phase ac motor winding

 Operation title: Testing Three phase Ac induction Motor

 Purpose: test the rewind three phase motor to the standards.
 Instruction: following each step below and given equipment test the rewind motor. You have
given 8hr for the task and you are expected to complete all needed for the testing.

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 67 of 73 Author/Copyright Induction Motor August, 2023
Tools and test instruments
Table 2. material and equipment list
Item Quantity
1 Multimeter 1
2 Electrician hand tools 1 set
3 Tachometer 1
4 Rewind three phase Ac motor 1
5 Nut-spinner 1
6 Cable (three wire with ground) 1

Operation Sheet 3.3 Single phase ac motor winding

Operation title: Rewinding single phase AC motor

Purpose: rewind single phase motor to the standards.
Instruction: following each step given below. You have given 15hr for the task and you are expected
to complete all needed for the winding.
Tools, Equipment, and Materials
Table 1. material and equipment list

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 68 of 73 Author/Copyright Induction Motor August, 2023
 Item Quantity
1 Defective single phase Ac motor 1
2 Electrician hand tools 1 set
3 Enameled copper wire/ magnet wire As required

4 Motor/transformer automatic rewinding machine 1

5 Coil form (Bobbin) 1
6 Bench-Vise 1
7 Manual rewinder 1
8 Motor holder 1
9 Wire holder 1
10 Coil’s removing machine 1
11 Baking oven 1
12 Coil’s counter machine 1
13 Ohmmeter 1
14 Drawing scotch As required
15 Insulation tube As required
16 Mylar/insulation paper As required
17 Bearing puller 1
18 Varnish As required
19 Wedge/bamboo As required
20 Bandage As required
20 Insulation tape As required
21 Soldering with soldering lead 1
22 Oil/grease As required

Winding Procedure

1. Take Data from name plate and internal part of the motor

2. Stripping the Winding

3. Insulating the Slots

4. Develop winding diagram

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 69 of 73 Author/Copyright Induction Motor August, 2023
5. Prepare coils using manual or automatic winding machine

6. Inserting the Coils into the Slots

7. Connecting the Windings

8. Varnishing and baking

9. Assemble the motor

10. perform no load test

11. Connect it with its load and perform load test

LAP Test 3.1. Rewind of Three phase Ac induction Motor

Task 1: Rewind three phase ac motor based on the procedures.

Task 2: Perform testing method on rewind motor.

Task 3: Rewind single phase ac motor based on the procedures

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 70 of 73 Author/Copyright Induction Motor August, 2023
Reference

1. A. Bellini, F. Filippetti, C. Tassoni, G. A. Capolino, "Advances in diagnostic techniques for

induction motors", IEEE Trans. Energy Convers., vol. 55, no. 12, pp. 4109-4126, Dec. 2008.

2. M. J. Devaney, L. Eren, "Detecting motor bearing faults", IEEE Instrum. Meas. Mag., vol. 7, no. 4,
pp. 30-50, Dec. 2004.

3. J. Faiz, B. M. Ebrahimi, "Mixed fault diagnosis in three-phase squirrel-cage induction motor using
analysis of airgap magnetic field", in Proc. Prog. Electro-Magn. Res. Symp., pp. 239-355, 2006.

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 71 of 73 Author/Copyright Induction Motor August, 2023
4. M. E. H. Benbouzid, "A review of induction motors signature analysis as a medium of faults
detection", IEEE Trans. Ind. Electron., vol. 47, no. 5, pp. 984-993, Oct. 2000.

5. Eectric Machinery, 6e, Fitzgerald.

6. Principles of electrical machines(mehta)

Ministry of Labor and Skills Maintain and Rewinding Version -1

Page 72 of 73 Author/Copyright Induction Motor August, 2023
 Participants of this Module (training material) preparation

No Name Qualification Field of Study Organization/ Institution Mobile E-mail

(Level) number
1 Desta Merga Tolera A(MSc) Electrical Automation General Wingate PTC 0913572306 [email protected]
and Control technology
2 Bereket Tesfaye A(Msc) Industrial Automation Yared Industrial 0913273546 [email protected]
G/Michael and Control Technology Technology and
Business college
3 Serkabeba Abera Robi A(Msc) Industrial Automation Hawassa Polytechnic 0926391738 [email protected]
and Control Technology college
4 Electrical Automation
Wondmagegn Derbe Bsc Akaki PTC 0913149466 [email protected]
and Control Technology