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INDUCTION MOTORS

Compilation By: Prof. S. N. Jani

Induction Motor Testing

All induction motors are tested before shipment from
the factory.
This testing can be subdivided in two groups:
1. Routine tests
2. Complete or prototype tests
IEEE Std 1121996 applies to induction motor
testing.

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

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

following tests could constitute routine tests:
1. Winding
resistance
measurement
2. No-load
running
current and power
3. High-potential test
4. Locked-rotor test
5. Air-gap measurement
6. Direction of rotation
and phase sequence
7. Current balance

8. Insulation resistance
measurement
9. Bearing temperature
rise
10. Magnetic center at noload
11. Shaft voltages
12. Noise
13. Vibration

2. Prototype tests
The purpose of a prototype test is to evaluate all the
performance characteristics of the motor.
This test consists of the following tests in addition to
the routine tests:
1. No-load saturation characteristic
2. Locked rotor saturation characteristic
3. Locked rotor torque and current
4. Loss measurement including stray load loss
5. Determination or measurement of efficiency
6. Temperature rise determination
7. Surge withstand test

No-load running current and power

This is obtained by measuring volts, current and input
power at rated voltage with motor unloaded.
The no-load saturation curve is obtained by repeating
this test at various voltages between 20% and 125%
of rated voltage.

Current balance
With the motor running on no-load at rated voltage,
the current in all three phases are measured and
comparison can then be made between the highest
and the lowest values for acceptability.

Winding resistance
This is measured usually using a digital bridge, or a
calibrated ohmmeter if the resistance is greater than
one ohm.
The value is then corrected to 25C for comparison
with the expected value.

Insulation resistance measurement

Insulation resistance is useful as a long-term
maintenance tool.
Measured during the life of the motor, it provides an
indication of the quality and relative cleanliness of
the stator winding insulation. The test made in the
factory before the motor is shipped is a good
benchmark for this purpose.
For this test, all accessories with leads located at the
machine terminals are disconnected from the motor,
and their leads are connected together and to the
frame of the machine.

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High potential test.

This test entails applying a test voltage between the
windings and ground for one minute, the test voltage
being equal to twice the line voltage plus 1000 volts.
The voltage is applied successively between each
phase and the frame, with the windings not under test
and the other metal parts connected to the frame.
All motor accessories that have leads located in the
main terminal box are disconnected during this test,
with the leads connected together to the frame or
core.

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Vibration test.
The normal test entails reading vibration at the
bearing housing with the motor running uncoupled
and on no-load at rated voltage and frequency.
The limits are established in NEMA MG1.
See the following table.
The unit of measure is peak velocity in in/sec, and
the permissible magnitude is a function of speed.

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Bearing temperature rise.

This test is made by operating the motor unloaded for
at least two hours while monitoring the bearing
temperature.
The test is continued until the bearing temperature
stabilizes.
A good indication of this is when there is less than
1C rise between two consecutive readings taken half
an hour apart.

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Shaft voltage check.

Any unbalances in the magnetic circuits can create
flux linkages with the rotating systems which can
produce a potential difference between the shaft ends.
This is capable of driving circulating currents through
the bearings resulting in premature bearing damage.
See IEEE Std 1121996 for details of this test.

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Stray load loss

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

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The method thus entails subtracting two relatively

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

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The fundamental frequency losses can be measured

by the rotor removed test, in which consists of
measuring the power input with the rotor removed
from the motor.
The high frequency component is measured by the
reverse rotation test, which entails measuring the
power input to the motor, with the rotor being driven
in the reverse direction to the stator revolving field,
and at synchronous speed.
For details of this test, see IEEE 1121996.

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

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The losses in the induction motor consist of the

following:
1. Stator I2R loss
2. Rotor I2R loss
3. Core loss
4. Friction and windage loss
5. Stray load loss

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IEEE Std 112 gives 10 different methods for the

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

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Method A Input-Output method.

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

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Method Binput-output with loss

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

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Once the value of the stray load loss is determined,

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

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1. Stator I2R loss is calculated from a knowledge of

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

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5. The motor is run with no load at rated voltage

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

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Method F (and variations)equivalentcircuit method.

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

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It also yields the most accurate determination of the

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

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The low frequency locked-rotor test measures the

stator and rotor leakage reactance and rotor
resistance at close to the running frequency.
The stator and rotor leakage reactances for
equivalent circuit are separated using the ratio of
these parameters provided by design.
Also calculated value of full-load slip, and either
tested value of stray load loss, or loss assumed
according to Table 4.6 are used.
The machine performance is then calculated using
the parameters established from the test.
Losses as determined from no-load tests are
introduced at appropriate places in the calculation to
obtain overall performance.

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Temperature test
The reason for doing temperature tests is to
determine and verify the temperature rise of various
parts and windings of the motor when operated at its
design load, voltage and frequency, and to insure
that unacceptably high temperatures do not exist in
any part of the motor.
Proper instrumentation of the motor by the
installation of thermocouples, resistance
temperature
detectors,
thermometers,
together with prompt measurement of the winding
temperature at shutdown is critical for this test.

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Also important is the need to ensure that the motor is

shielded from conditions such as rapid change in
ambient temperature and presence of air currents,
since these will reduce the accuracy of the test.
The motor can be loaded by coupling it to a
dynamometer, or by the so called dual frequency
equivalent loading method.
The test is continued until the motor is thermally
stable.
In the dual frequency test method, the test
machine is operated at no-load at rated voltage and
frequency, and a low frequency power at a different
frequency is superposed on the winding.

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For this test, the frequency of this auxiliary power is

set at 10 Hz below the primary frequency, and the
voltage is adjusted so that the stator winding current
equals the rated load current.
Since the motor is supplied with power at two
different frequencies, it is subjected to oscillatory
torques that will cause the motor vibration during the
test to be higher than normal.
The temperature rise determined by the dual
frequency method is usually within a couple of
degrees of that obtained by the direct loading
method.

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It is important that the hot resistance of the

winding after shutdown be measured promptly
to preserve accuracy in the calculation of losses
and in the determination of temperature rise by
the resistance method.
IEEE 112 requires that this reading be taken
within the time after shutdown shown in Table
4.7.

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Slot Discharge Test

This test is performed to evaluate the coil surface
grounding in the slot portion.
The stator coil outer surfaces are painted with
conducting varnish in order to make good
electrical contact with the machine frame to
prevent voids.
However, at higher voltages, ionization can take
place in the voids, resulting in insulation
damage.
The slot discharge test consists of applying
approximately 7 kV AC and observing the
wave form on an oscilloscope.

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This wave form is compared to a wave form of

one coil side arcing to the slot at a single point.
The slot discharge phenomena usually consist of
high frequencies, such as 2500 Hz/s.
The line disturbances are usually filtered out in
order to obtain an accurate slot discharge
phenomena.

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Insulation Resistance test

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

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The resistance can, however, be extremely low if

the machine has been subjected to incorrect
transportation and storage conditions and
humidity, or if the machine is operated
incorrectly.
NOTE: Windings should be earthed briefly
immediately after measurement in order to
avoid risk of electric shock.

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Correlation between the insulation

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

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Minimum values for insulation resistance

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

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The insulation resistance limits, which are given

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

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Stator winding insulation resistance

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

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3. Verify that the frame of the machine and the

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

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Figure 1: Connections of the stator windings for insulation

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

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Rotor winding insulation resistance

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

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4. The shaft is earthed

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

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The insulation resistance meter is connected

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

Figure 2: Insulation resistance measurement of the rotor

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