Document kind Document identity Revision

Information 3AAM100872 A
Owner organization Document type Date of revision (yyyy-mm-dd) Status Page(s)

BU Motors and Generators Machine Description Document 2014-05-08 Valid 1(3)

Division/Department Prepared by Approved by Security level

FIDRI/PEE Jaakko Virtanen Liisi Schulman External

Surge test for stator coils during production

Motor type Inspected by Date Motor type Inspected by Date

X AMA Eerik Kinnunen 2014-05-07 AML
AMC AMS
AMD X AMZ John Shibutani 2014-05-07
X AMG John Shibutani 2014-05-07 DMI
AMGe M3
X AMI Eerik Kinnunen 2014-05-06 X HXR Eerik Kinnunen 2014-05-07
AMK X NXR Eerik Kinnunen 2014-05-07
Note! This document covers product families that are marked with X. Restrictions to the scope of the document have been described in the body text.

Table of Contents
1 Purpose ..................................................................................................................................................... 1
2 Test specifications ..................................................................................................................................... 1
3 Performing the test ..................................................................................................................................... 2
3.1 Test voltage ........................................................................................................................................ 2
3.2 Acceptance criteria ............................................................................................................................. 2

1 Purpose

This Machine Description Document describes a test procedure which can be performed to stator coils during
winding work if the test is ordered by the customer. The purpose of the test is to ensure the good quality of coil
turn insulation and to ensure that stator coils are similar. Test method is valid for IEC, IEEE and NEMA
machines, both motors and generators. This document is intended mainly for the use of ABB employees who
need to explain to a third party the technical details of an offer. However, this document is external in nature and
can also be given to the customer.

2 Test specifications

Test method for coil testing, test voltages, and interpretation of the results are based on the following standards:
- IEC 60034-15 (2009): Impulse voltage withstand levels of form wound stator coils for rotating a.c.
machines
- IEEE Std. 522 (2004): Guide for testing turn insulation of form wound stator coils for alternating-current
electric machines

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
Copyright 2014 ABB.
Information Valid 3AAM100872 A
Surge test for stator coils during production 2014-05-08 2(3)

3 Performing the test

Test is performed during winding work. Before the test, all coils are first installed into stator, slot wedges are
then assembled and winding support structures are built. Test is then performed to each coil individually before
any electrical connections between coils are made. Surge voltage is fed into the coil to be tested while the stator
core is grounded.

3.1 Test voltage

Test voltage is chosen according to IEC 60034-15 or according to IEEE Std. 522, whichever is higher.
Test voltage according to IEC 60034-15:
U p = 0.5 0.65 (4 U N + 5 kV )
Test voltage according to IEEE Std. 522:

2
U p = 0.7 3.5 U N
3
Impulse front rise time shall be between 0.2 s and 0.5 s.

3.2 Acceptance criteria

Both IEC 60034-15 and IEEE Std. 522 give some guidance how to look at the surge curves. The actual pass/fail
criteria is however based on comparison; therefore this test is often called surge comparison test. Comparison
is accepted interpretation method by IEC 60034-15 and IEEE Std. 522.

The decaying of the pulses depends on resistance and inductance of the coil. In practice this means the length
of the coil copper and number of rounds the copper creates. A short circuit between copper turns effectively
shortens copper distance and cuts off copper rounds. If an interturn short circuit merges, both resistance and
inductance of the coil shall decrease. In that case voltage pulses fed into coil will decay faster compared to coils
with higher resistance and inductance.

Since all of the coils in stator need to be similar to one another, the comparison between the coils will reveal
damaged coil. A short circuit between coil rounds will give a voltage curve which decays faster than the other
voltage curves. Thus the acceptance criteria in surge comparison test is that all of the coils must give a similar
voltage curves when the same surge comparison tester is used with the same voltage setting.

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
Copyright 2014 ABB
Information Valid 3AAM100872 A
Surge test for stator coils during production 2014-05-08 3(3)

Revision history
Rev. Date Prepared by Division/ Description
(yyyy-mm-dd) Department

A 2014-05-08 J. Virtanen FIDRI/PEE Creation version

B

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
Copyright 2014 ABB