TRAINING REPORT

INDUCTION MOTORS
AND THEIR USES

MADE BY : RISHAV JAIN

 CONTENTS

S.No. Topic
PAGE NO.

1 ACKNOWLEDGEMENT 2
2 COMPANY OVERVIEW 3
3 BASICS OF INDUCTION MOTORS 5
4 CONSTRUCTION OF THREE PHASE MOTORS 11
5 CHOSING THE CORRECT TYPE OF MOTOR
12
6 WINDING 18
7 USES OF MOTORS 20
8 TESTING 25
9 CONCLUSION 31

2
 ACKNOWLEDGEMENT
On completing my training at ABB Motors,
Faridabad, I would like to thank Mr. Khusro Khan
for providing help in all situations required and for
working hard to give me the best opportunities to
learn all that I could in this short period of time. I also
feel obliged to express my gratitude to Mr. Anjan
Chatterjee, HR Co-ordinator, for granting me the
position as a trainee in this company.

Mr. Khan and other members of the production

department were very helpful in explaining, in detail,
every important aspect of the manufacturing
process. They also provided me with helpful tips for
concluding the training with this report.

Mr. Khusro Khan JITENDER

3
 COMPANY OVERVIEW
ABB motors (India) is one of the six manufacturing units of
ABB India. The factory is located at Faridabad about 40km
from Delhi in the state of Haryana in north central part of
India. The technical backup is received from ABB Motors in
European countries.

• ABB is pioneer to introduce high efficiency (eff 2) motors

in India in the year 1991
• ABB was again pioneer to introduce EFF1 motors for frame
315 & 355 in the year 1998
• It is the only motor factory in India to be accredited for
IMS (Integrated Management System) combination of ISO
9001 – 2000, ISO 14001 – 1996 & OHSAS 180001 – 1999.
• We are the only company in India to offer complete range
of EFF1 (High Efficiency motors) in frame 100 to 355.

Product Range

• Standard three-phase TEFC (HX & HX+)motors, IS:325

• Standard three-phase SPDP motors, IS:325
• High Efficiency EFF1 Motors ( Frame 100 to 280)
• M2000 motors, (Eff1 Frame 315 to 400)
• Ring frame motors, IS:2972 Part III
• Auxiliary motors for a.c. electric locomotives
• Auxiliary motors for three-phase electric locomotives
• Non-sparking motors type ‘n’, IS:9628
• Increased safety motors type ‘e’, IS:6381
• Roller table motors
• Flame Proof Motors (Frame 112 / 132 are in production,
Frame 100 under development, Frame 160 under
Certification)
• Crane duty Motors
• Brake Motors (externally mounted)

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• Induction Generators
• Windmill Generators
• Motors for frequency converter drive
• Custom built motors

Manufacturing Range

• Type Three-phase squirrel-cage induction motors

• Output 0.18 ... 500 kW; 0.25 ... 675 hp
• Voltage 415 V; 220 ... 660 V
• Frequency 50 Hz; 25 ... 60 Hz
• Duty S1 ... S8 acc. to IS:12824
• Ambient 45oC; 20 ... 70oC
• Altitude up to 1 000 m
• Insulation Class ‘F’/Class ‘H’ (VPI on request)
• Frame HX71- HX280 & M2BA315 - 400

Special Features

• High Efficiency – ABB motors are engineered for high

efficiency for minimum life cycle costs.
• Low noise level – The motors are designed to ensure low
noise level.
• Accessories – Space Heaters, thermistors, RTD and BTD’s
on request.
• Terminal Box – Terminal Box suitable for both copper and
aluminum cables. Terminal box size sufficient for easy
termination and maintenance of cable.
• All motors are provided with deep groove ball bearings
with C3 clearance for high load capacity.
• Special care taken at the time of order for considering
right bearing at the time
of order (e.g. Roller Bearings for belt Application or
Insulated bearing for VFD Application).
• Dual mounting holes – Motors are provided with 6 nos.
mounting holes instead of 4 nos. as standard practice in
the industry. This facilitates easy replacement and easy
inventory management.

5
BASICS OF INDUCTION MOTORS
AC (Alternating current) and DC (Direct current)
motors

While there are only three general types of DC motors, there

are many different AC motor types. This is because each
type is confined to a narrow band of operating
characteristics. These characteristics include torque, speed,
and electrical service (single-phase or polyphase). These
operating characteristics are used to determine a given
motor’s suitability for a given application.

What makes an AC motor different from a DC motor?

In a DC motor, electrical power is conducted directly to the

armature through brushes and a commutator. An AC motor
does not need a commutator to reverse the polarity of the
current , as AC changes polarity “naturally.”

Also, where the DC motor works by changing the polarity of

the current running through the armature (the rotating part
of the motor), the AC motor works by changing the polarity
of the current running through the stator (the stationary part
of the motor).

6
The many types of AC motor may be split into two main
groups: single-phase and poly-phase.

Single Phase:
A single-phase power system has one coil in the generator.
Therefore, one alternating voltage is generated. The voltage
curve of a single-phase AC generator is shown in Figure

Single-phase motors are generally motors with KW ratings of

one or below. (These are generally called fractional KW
motors.) They are generally used to operate mechanical
devices and machines requiring a relatively small amount of
power.

Types of single-phase motors include: shaded-pole,

capacitor, split-phase, repulsion, series (AC or universal) and
synchronous. However, the single-phase motor is generally
not used because it is inefficient, expensive to operate, and
is not self-starting.

Three-Phase
Three-phase or poly-phase motors run on three-phase
power. A three-phase power system has three coils in the
generator. Therefore, three separate and distinct voltages
will be generated. The voltage curve is shown in Figure

7
Types of three-phase motors include: induction (squirrel-
cage or wound), rotor types, commutator, and synchronous.

The Squirrel Cage Induction motor

Induction refers to electrically charging a conductor by

putting it near a charged body.

Induction Principle

The principle of the induction motor was first discovered by

Arago in 1824. He observed that if a non-magnetic metal
disk and a compass are pivoted with their axes parallel, so
that one (or both) of the compass poles are located near the
edge of the disk, spinning the disk will cause the compass
needle to rotate. The direction of the induced rotation in the
compass is always the same as that imparted to the disk.

Applying the Induction Principle to AC Motor

AC motor works by changing the polarity of the current

running through the stator (the stationary part of the motor).
The stator plays the role of the metallic disk described
above. A rotating magnetic field is established in the stator.
The conductor, called the Rotor, “follows” the rotating
magnetic field by beginning to rotate, just like the compass
needle described above.

The induction motor uses a rotor of a special design. It

resembles a cage used for exercising squirrels. This is why it
is called a squirrel cage rotor.

The rotor consists of circular end rings joined together with

metal bars. Note that the metal bars are placed directly
opposite each other and provide a complete circuit within
the rotor, regardless of the rotor's position. Rotors normally
have several bars, but only a few are shown here for clarity.

8
FIGURE: THE ROTOR OF A SQUIRREL CAGE INDUCTION
MOTOR

Squirrel cage motors are usually chosen over other types of

motors because of their simplicity, ruggedness and
reliability. Because of these features, squirrel-cage motors
have practically become the accepted standard for AC, all-
purpose, constant speed motor applications. Without a
doubt, the squirrel-cage motor is the workhorse of the
industry.

The Squirrel Cage Induction Motor has certain advantages

over the DC motor.

• There are only two points of mechanical wear on the

squirrel cage motor: the two bearings.
• Because it has no commutator, there are no brushes to
wear. This keeps maintenance minimal.
• No sparks are generated to create a possible fire
hazard.

Three- Phase Motor

An induction motor depends upon an electrically rotating

magnetic field, not a mechanically rotating one. (A
mechanically rotating field would work, but an electrically
rotating magnetic field has significant advantages.) How is
an electrically rotating field obtained? It all starts with the
phase displacement of a three-phase power system.

9
Three-phase power can be thought of as three different
single-phase power supplies. They are called A, B, and C. In
the three-phase motor, each phase of the power supply is
provided with its own set of poles, located directly across
from each other on the stator, and offset equally from each
of the other two phases’ poles.

FIG: THREE PAIRS OF FIELD COILS ON THE STATOR, SET 120

DEG APART

The three currents start at different times. Phase B starts

120° later than phase A and phase C starts 120° later than
phase B. This is shown on the sine wave graph in Figure,
which indicates the way the magnetic field will point at
various times in the cycle.

FIG: Magnetic Field Rotation Providing Torque To Turn The

Motor

Introducing these different phase currents into three field

coils 120° apart on the stator produces a rotating magnetic
field, and the magnetic poles are in constant rotation. The

10
magnetic poles chase each other, simultaneously inducing
electric currents in the rotor (generally, bars of copper
imbedded in a laminated iron core). The induced currents set
up their own magnetic fields, in opposition to the magnetic
field that caused the currents. The resulting attractions and
repulsions provide the torque to turn the motor, and keep it
turning.

Walking through one revolution of the motor

First, the A poles of the stator are magnetized by phase A.

Then, the B poles are magnetized by phase B. The rotor
turns, due to the induced current. Then, the C poles are
magnetized by phase C. The rotor turns, due to the induced
current. The rotor has completed one-half turn at this point.

FIG: Rotating Magnetic Field Turns the Motor

Now, the A poles of the stator are magnetized again, but the
current flow is in the opposite direction. This causes the
magnetic field to continue to rotate, and the rotor follows.
Then, the B poles are magnetized by phase B. The rotor
turns, due to the induced current. Then, the C poles are
magnetized by phase C. The rotor turns, due to the induced
current.

FIG: Rotating Magnetic Field Turns the Motor

11
The rotor has completed one full revolution at this point, and
the process repeats itself.

CONSTRUCTION OF THREE
PHASE MOTORS
The three-phase motor is probably the simplest and most
rugged of all electric motors. To get a perspective on how
important the three-phase motor is, all you need to know is
that this motor is used in nine out of ten industrial
applications.

All three-phase motors are constructed with a number of

individually wound electrical coils. Regardless of how many
individual coils there are in a three-phase motor, the
individual coils will always be wired together (series or
parallel) to produce three distinct windings, which are called
phases. Each phase will always contain one-third of the total
number of individual coils. As we mentioned, these phases
are referred to as phase A, phase B and phase C.

Three-phase motors vary from fractional KW size to several

thousand KW. These motors have a fairly constant speed
characteristic but a wide variety of torque characteristics.
They are made for practically every standard voltage and
frequency.

12
 CHOSING THE CORRECT TYPE
OF MOTOR
In order to select the correct motor type for a given
application, it is necessary to understand the load
requirements first. To understand these requirements, you
need to be familiar with the concepts of force, work, torque,
power and KW, and how they relate to speed.

Force, Work and Torque

Work is done when a force overcomes a resistance.

Work = Distance x Force

In the case of an electric motor, force is not exerted in a line,

but in a circle, about a cylindrical shaft. This turning force is
called torque.

Torque = Radial Distance x Force

Power and KW

Power takes into consideration how fast work is

accomplished. It is the rate of doing work.

Power = Work/Time

The reason for this difference is the amount of work that can
be delivered in a given amount of time. Obviously, a larger
motor should be able to deliver more work in a given time
than one that is considerably smaller. It is this difference
that determines the power rating of the motor.

13
Motors are rated in KW (HP). One KW is equal to 746 watts.

Putting it all together, Torque, KW, and speed are all

interrelated when turning a load. KW is proportional
to torque and speed. The following formula ties
them all together:

T=974*KW/rated speed

This means that if either speed or torque remains constant

while the other increases, KW increases. Conversely, if either
torque or speed decreases while the other remains constant,
KW will decrease.

Below is a chart that shows the relationship of KW, torque

and speed.

Speed Increases
KW Increases
Torque Constant

Speed Decreases
KW Decreases
Torque Constant

Speed Constant
KW Increases
Torque Increases

Speed Constant
KW Decreases
Torque Decreases

Speed Increases
KW Increases
Torque Decreases

Speed Decreases
KW Decreases
Torque Increases

14
Speed Control for an AC Motor

Because each motor type has its own characteristics of KW,

torque and speed, different motor types are more suited for
different applications.

The basic characteristics of each AC motor type are

determined by the design of the motor and the supply
voltage used.

The induction motor is basically a constant speed device.

The speed at which an induction stator field rotates is called
its Synchronous Speed. This is because it is synchronized to
the frequency of the AC power at all times. The speed of the
rotating field is always independent of load changes on the
motor, provided the line frequency is constant.

Synchronous speed is determined by the number of poles

that the motor has, and the frequency being supplied to it.
The equation for determining the synchronous speed of a
motor is:

N = 120f/P

Where:
N = the synchronous speed of the motor in revolutions per
minute (RPM)
f = the frequency supplied to the motor in Hertz (Hz)
P = the number of poles the motor has

15
Motors designed for 50 Hertz use (standard in the INDIA)
have synchronous speeds as follows:

Poles RPM
2 3000
4 1500
6 1000
8 750
10 600

Induction motors do not run at synchronous speed; they run

at Full Load Speed, which is the rotational speed of the rotor.
Full load speed is always slower. The percent reduction in
speed is called Percent Slip. The slip is required to develop
rotational torque. The higher the torque, the greater the slip.

The motor speed, under normal load conditions, is rarely

more than 10% below synchronous speed. If the motor is not
driving a load, it will accelerate to nearly synchronous speed.
As the load increases, the percent slip increases.

For example, a motor with a 2.8% slip and 1800 rpm

synchronous speed would have a slip of 50 rpm, and a full
load speed of 1750 rpm (1800 - 50 = 1750 rpm). It is this full
load speed that will be found on the motor's nameplate.

From the formula, it is evident that the supply frequency and

number of poles are the only variables that determine the
speed of the motor .

Varying the voltage is not a good way to change the speed

of the motor. In fact, if the voltage is changed by more than

16
10%, the motor may be damaged. This is because the
starting torque varies as the square of the applied voltage.

Because the frequency or number of poles must be changed

to change the speed of an AC motor, two methods of speed
control are available. These are:

• Changing the frequency applied to the motor

Changing the frequency requires a device called an

Adjustable Frequency Drive to be inserted upstream from
the motor. This device converts the incoming 50 Hz into any
desired frequency , allowing the motor to run at virtually any
speed.
For example, by adjusting the frequency to 30 Hz, the motor
can be made to run only half as fast.

• Using a multi-speed motor

Multi-speed AC motors are designed with windings that may

be reconnected to form different numbers of poles. They are
operated at a constant frequency.

Two-speed motors usually have one winding that may be

connected to provide two speeds, one of which is half the
other. Motors with more than two speeds usually include
many windings. These can be connected many ways to
provide different speeds.

Starting the Motor

A Starter is a device that is used to start a motor from a

stop. The across-the-line starter is by far the most common.
This type of starter places the motor directly across the full
voltage of the supply lines, hence the name: “across-the-
line.” When an induction motor is placed across-the-line, it
will accelerate to full speed in a matter of seconds.

17
Reversing the Motor

To reverse a motor all we need to do is reverse the order in

which the Line Power is fed to the motor. This wiring change
is accomplished by “swapping” two of the phases of power.
In short, A motor wired with phases ABC to run forward,
would have its phases wired CBA to run in reverse

Braking the Motor

Two common methods used for breaking a motor are DC

Injection Braking and Dynamic Braking.

i) DC Injection Braking:

DC injection braking is a method of braking in which direct

current (DC) is applied to the stationary windings of an AC
motor after the AC voltage is removed. This is an efficient
and effective method of braking most AC motors. DC
injection braking provides a quick and smooth braking action
on all types of loads, including high-speed and high-inertia
loads.

ii) Dynamic Braking:

Dynamic braking is another method for braking a motor. It is

achieved by reconnecting a running motor to act as a
generator immediately after it is turned off, rapidly stopping
the motor. The generator action converts the mechanical
energy of rotation to electrical energy that can be dissipated
as heat in a resistor.

18
 WINDING
A very brief explanation of the winding process has been
provided below according to the different stages the motor
goes under this process.

1. Coil making – Copper wires are arranged in order to

form coils according to the specifications demanded by
the customer. These include number of wires used,
thickness of the wire and number of turns of these
wires.

2. Mounting / Coil insertion – These copper coils are then

manually inserted into the depressions of the rotor
accordingly to distinguish the three different phases.
Insulation paper is also inserted between each coil to
provide prevention from short circuits.

3. Connection – The three phases are then produced

upwards to the control panel where they are fitted with
the help of PVC insulation and screws. Shaping and
pressing of the coils is also done in this stage of the
process.

4. In-process testing – A few tests are also performed

before the motor is sent in for impregnation. These
include:

a) DCR test – Used to test the resistance of the copper

coils inserted into the rotor.

b) Surge test – This checks if there is any fault in the

insulation between the coils.

c) HV test – This is used to check if the motor breaks

down if high voltage is applied to its ends.

19
5. Impregnation – There are two basic types of
impregnations.

a) Flood impregnation - Once fitted with its (un-

impregnated) coils and provided with all necessary
winding overhang supports and end winding
connections, the entire stator assembly is flooded with
resin and then cured at elevated temperature.

b) Vacuum Pressure impregnation - This method is

employed to obtain a nearly 100 % filling of the voids
in the slot guaranteeing the excellent moisture and
mechanical strength.

6. Baking – This is the final stage of winding under which

the motor is placed in an oven and is heated at a
temperature of 145 to 155 degrees C for 6 hours. This
is done to increase insulation by hardening the liquid
produced from the previous stage.

20
 USES OF MOTORS
A few examples showing the different uses and purposes of
electrical motors have been provided below.

1. Roller Table Motors -

Introduction

In Rolling Mills, the stock is fed to the rolling stands and

removed from them by roller tables, the rollers of which
are driven either in groups by a common motor or
individually, each roller having its own motor. Roller
table motors are special purpose motors, with special
torque speed characteristics to meet severe conditions
of frequent starts and reversal. In addition, the high
ambient temperature, humidity and risk of fine dust
particles from the process infiltrating the motor are
constant threat to system reliability.

Classification

They can be generally classified into two groups:

i) Constant speed roller table motors:

These motors are switched directly on the line and
designed for frequent start, stops and reversal. The
acceleration factor B is a characteristic figure that
describes the behavior of the motor when frequently
switched. Its value is determined as the product of total
inertia (expresed in GD2) to be accelerated and the
maximum no. of starts per hour of the motor without
exceeding the permissible temperature limit.

21
ii) Variable speed roller table motors:
These motors are fed through PWM frequency
converter. A PWM converter has many advantages e.g.
minimum reactive power consumption, less converter
loss, multi-drive applications, etc. The greatest
advantage of using frequency controlled ac roller table
is a possibility to avoid a gear box by optimal selection
of the pole number and the nominal frequency.

Special Features

Mechanical features:

• Stator frames and end-shields are of cast iron

grade FG- 260 or higher.
• Degree of protection IP55 or IP56
• Mounting B3 or B5 or B35
• Cooling IC 0041 (surface cooled)
• Circular Cooling ribs (for better heat transfer)
• 63 series single row deep groove ball bearings,
roller bearing on DE and ZZ bearing on request
• Epoxy Paint
• Plug and socket arrangement (on request)

Electrical Features

• High starting torque design( constant speed)

• Low starting current (constant speed)
• High stall time (constant speed)
• High pull out torque (variable speed)
• Nominal Frequency selection according to required
speed range (variable speed)
• Special care for PWM frequency converter supply
• Star connection
• Insulation class F or H
• Voltage range 380 to 660 V

22
2. Textile Motors –

Introduction

These motors, also known as ring frame motors are

used for driving spinning frames in textile industries.
Rating of these motors are as per IS:2972 part III and
are available in both single speed and double speed.
The starting torque and the speed-torque
characteristics of the spinning frame motor is typical
since it should be neither too high nor too low. If it is
too high, the acceleration will be rapid and there will be
snatch and break-up of the yarn. If it is too low, the
tension of the yarn is insufficient and as such the yarn
gets entangled and cause breakage. The torque values
of the motors have therefore to be very carefully
specified by suitably matching with that of the load.

Classification

Spinning frame motors are generally available in 4 pole

and 6 pole single speed application and 6/4 and 8/6
pole two speed applications.

Special Performance Requirement

Following Values of various torque characteristics for

spinning frame motors have been stipulated taking into
consideration their performance requirements when
started at rated voltage.

• Starting torque: 150 to 200% of full load torque

• Pull Out torque: 200 to 275 % of full load torque

23
3. Crane Duty Motors –

Introduction

ABB Crane Duty Squirrel Cage Induction Motors

incorporating State-of-the-art technology, are specially
designed to service the cranes and hoists. These
motors have unique torque-speed characteristics, which
results in rapid acceleration causing minimum heat
losses in rotor circuit. ABB crane duty motors are robust
in construction and extremely sound in electrical and
mechanical design. These motors can also be used for
similar applications in intermittent duty. These motors
have high starting torque with low starting current and
are suitable for frequent starts, stops and reversing
operation. Further, rapid acceleration is achieved by
high pull out torque/ rotor inertia ratio.

Special Features

The ABB Crane Duty Motors stand apart for many

reasons:

• High starting torque

• Low starting current
• Frequent Starts/Stops and Reversals
• High Pull out torque
• Low Rotor Inertia
• Extra thermal endurance

24
4. Dual Speed Motors –

Introduction
A double speed motor permits operation of the loads at
speeds corresponding to two different pole numbers.
These motors are preferred in applications such as fan,
pump, blower, where adjustable speed operation leads
to substantial energy saving. These motors also find
applications in machine tools where it is required to
achieve different torque and speed combinations from
operation point of view.

Classification
These are classified according to the different speed
ratios. The desired speed ratio from a double speed
motors could be an integer or a fraction.

i) Integral Speed Ratio Motors:

4/2 and 8/4 pole combinations give integral speed ratio.
Integral speed ratio can be obtained by two types of
winding configuration.

Separate Winding: The stator contains two separate

windings placed one above another, each
corresponding to the two pole numbers. Only three
leads are brought out from each windings.

Dahalander Winding: The stator is wound for one speed

and provision is given for reconnecting the same
winding for the second speed. All the six ends of the
winding are brought out to the terminals and a
connection diagram is provided to facilitate change in
the speed of the motors.

ii) Fractional Speed Ratio Motors:

Pole combination 8/6 and 6/4 give fractional speed
ratio. These motors are wound with two separate
windings, as described in integral speed ratio above.

25
 TESTING
Testing can be categorized into 2 types, Routine and
Type tests. Routine tests are performed on every motor
after it is assembled since these are the requirements
according to ‘IS:325’ standards. Type tests are
performed usually to one of the motors of a series of
similar motors or by a request of the customer. These
are needed if the motor will run in special conditions.

The various routine tests are briefly explained below:

1. Visual inspection:
During the visual inspection the following points are
checked:
• The rating plate values.
• Fans, fan motors, main terminal box, terminal
blocks and other auxiliary devices are of correct type.
• Paint, if for client inspection, is of correct type.
2. High-voltage test:
High-voltage test is carried out for windings,
temperature detectors and space heaters to ensure
that there are no weak points in insulation. The
measuring principle for windings is shown in fig. 1.

U
V
kV W

Detector,
heater
A B
Fig. 1. High voltage test arrangements for the stator
phase U.

26
By standard motors, and when the star point is
available, the windings can be tested separately as in
figure 1A. In other cases all the phases are tested
together as shown in figure 1B.
The test voltages used are at least equal to values
given in IS 4029. Measuring voltage of phase windings
is 2000 V (2 x UN + 1000 = 2000 V for all sizes ≤ 690 V)
for two minutes. For auxiliaries test voltage is usually
1500 V and testing time is 15 seconds.

3. Insulation resistance measurement:

The purpose of this measurement is to check that the
insulation level of windings and auxiliary devices of the
motor is high enough to ensure safe operation of the
motor.
The insulation resistance of windings is measured as
shown in fig. 2. The measuring voltage is 500 VDC. For
type tested motors this measurement is done after the
temperature rise test. For routine tested motors the
test is done at the ambient temperature.
Also space heaters and temperature detectors are
tested with 500 VDC.

U1
U2
V1 V2
MΩ
W1 W2

Fig. 2. Insulation resistance measurement of stator

windings.

4. Resistance measurement at the ambient

temperature:

27
Resistances of windings are measured at ambient
temperature
• to check that the connections of the windings are
correct
• to find out eventual unbalance between phases
• to measure the accurate ‘cold’ resistance value so
that the temperature rise can be determined after a
temperature rise test (type test)
The resistance values of the standard terminals are
measured between terminals U1-U2, V1-V2, W1-W2
regardless of the Y/D -connection of the motor.
Resistances are measured by ohmmeter with 4-wire
method.
Resistances of possible temperature detectors and
space heaters are measured from their terminal blocks.
All measured values are compared to the calculated
values.

5. Terminal markings and direction of rotation:

According to standard IS: 4728 the motors rotate
clockwise (facing to the drive-end of a motor) and the
phases of supply are connected to terminal box in order
L1, L2, L3 -> U, V, W. Should the motor rotate counter-
clockwise chance the place of two leads.

6. No load point at 50 Hz frequency:

The motor is driven at no load at 50 Hz frequency and
rated voltage (for standard 50 Hz ratings) with a free
shaft extension. The stator current, voltage and input
power are measured, recorded and compared to the
designed values.

7. Locked rotor point at 50 Hz frequency:

The rotor of the motor is locked mechanically. The 50
Hz voltage selected gives approximately the rated
current. The stator current, voltage and input power are

28
measured, recorded and compared to the designed
values.

Some of the type tests asked for by the customers are

also mentioned below:

1. No load test:
Motor is to be run at no load at rated voltage and
frequency with a free shaft extension. The stator
current, voltage and input power are measured,
recorded for different readings of voltages to calculate
the friction and windage and iron losses of the motor at
rated conditions.

2. Locked rotor test:

The rotor of the motor is locked. The voltage is being
adjusted in order to get the rated current, 1.5 times the
rated current and double of the rated current.

Temperature rise test:

The temperature rise test is carried out to determine
the temperature rise of the winding of the motor. For
EEx e, Ex nA and Ex N motors also the temperature rise
of the motor is determined.
An asynchronous machine as a motor is tested by
feeding it from the supply that gives the rated voltage
and current. It is also possible to test a machine as an
asynchronous generator with the ATEML testing
systems.

Performance of the temperature rise test

29
The temperatures of the motor are recorded during the
test. The motor is to run until all temperatures have
become stable, change of temperature less than 1°C
per hour as per IS:12802. After the motor has been
stopped the temperature rise of stator winding is
measured by the resistance method.
After the motor has been stopped, the resistance
values are read for a suitable time (approximately 2
minutes). The following table shows at which time latest
the resistance value for calculating the temperature
rise should be measured.

Rated power Time after

electrical disconnection
0-50 30 s
50-200 kW 90 s
200-5000 kW 120 s

The temperature rise for copper is determined as

R2
Θ = ( 235 + t 1 ) − t a − 235
R1

Where R2 = hot resistance value

R1 = cold resistance value
t1 = temperature for the cold resistance (°C)
ta = temperature of the cooling medium (°C)
235 = temperature coefficient of resistance for
copper

Acceptable temperature rises of the windings according

to the standard IS325/IEC 34-2 are
Θ = 80 K for insulation class B
105 K for insulation class F

4. Efficiency determination:
The efficiency is calculated from the total losses, which
are determined by summation of the loss components
in accordance with IS 4029/ IEC 34-2.

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5. Overload test:
Overload test is performed to check if the torque of the
motor is high enough to handle overloads for a short
period. Test is performed at 160% of rated torque for
15 seconds (IS 4029/ IEC34-1).

6. Over-speed test:
By ABB Motors the over speed test is normally carried
out at 120% of the synchronous speed at no load for
two (2) minutes.

7. Vibration level test:

The vibration level test is made in accordance with IS
12075/ IEC 34-14, under no load with motor in a state
of free suspension. Results can be expressed either as
vibration velocity (mm/s) or acceleration (mm/s²).

8. Sound level test:

By ABB Motors the A-weighted sound pressure level is
measured on a motor with free shaft extension. The
measurement is done at different points around the
machine and limits specified as per IS 12065.

9. Partial loads:
Partial loads are measured at 50% and 75% of the
rated load and the efficiencies are determined for these
loads. The other loading points can be determined as
per the requirement.

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