PT.

BINTANG LESTARI PERSADA Electro Mechanical Workshop

ELECTRO MOTOR TESTING PROCEDURE

AC LOW – MEDIUM VOLTAGE
1. Record name plate and perform visual inspection and reporting.
1.1. Part listing (terminal, fan, pulley / coupling, thermostat, etc).
1.2. Rotate shaft with hand (noise, jammed part, foreign object).
1.3. Cooling device (damage, crack, leak)
1.4. Complete condition
2. Perform Insulation Resistance test.
2.1. The recommended insulation resistance to ground, R min, when measure at or corrected to
40° C is given by :
R min : n + 1,
in Megohm. When n is the rated machine potential in kilovolt. A 500V Megohmmeter is
suitable for testing of machine rated up to 2400V. above that voltage, a 1000V Megohmmeter
is recommended. Test voltage should be applied for one minutes ( ref IEEE std. 43).
2.2. If test are pass, continue to step 3
2.3. If test are fail, follow this step :
2.3.1.Dismantling electro motor to perform complete inspection.
2.3.2.Measuring Insulation resistance of Stator after rotor has been removed
2.3.3.Perform inspection and documented for evidence of damage or degradation such as :
1. Puffiness, cracking, separation or discoloration as indication of thermal aging.
2. Contamination of coil and connection surface.
3. Abrasion or other mechanical stresses.
4. Evidence of partial discharge (Corona).
5. Loose wedge, filler, ties, banding, or surge rings.
6. Fretting of supports, Bracing, or Crossings (an indication of looseness and
movement).
( ref IEEE std. 432 sec. 5. )
2.3.4.Turn to Turn resistance or phase balance test (must equal, tolerance is ± 0,3 Ω).
2.3.5.Surge test wave form
Using wave diagram as describe below to analyze winding condition.
BAKER Surge Winding Analyzer ( ref BAKER Tech – Surge Test ).

2.3.6.Perform Interlaminar insulation test with growler test.

2.3.7.Polarity and ball rotation test.
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Low-Med Voltage AC Motor Rev. 1.1 - 2009
By. Mirza Aminudin
PT. BINTANG LESTARI PERSADA Electro Mechanical Workshop

2.3.8.Complete reporting of electrical condition

3. Polarization Index (P-I) test.

3.1. P-I test should be performed at the same voltage as the test in paragraph 2.1 for 10 minutes.
The recommended minimum value of polarization index for winding rated class B and higer is
2.0.
PI=10 Minute Result1 Minute Result= ≥2.0
( ref : IEEE std. 43 sec 9.2 )
3.2. P-I test below 2.0 is acceptable if insulation resistance result is more than 5000 Megohm
( ref : IEEE Std. 43.2000. 12.2.2.2 )
4. Surge Test – Winding analyzer.
Reference to paragraph 2.3.5. from the wave graphic we can determine is winding are in good
condition. Perform full reporting with print out or photograph of the result.
5. Perform No-Load Test.
5.1. Speed
No-load running test should be made at rated voltage and frequency. Measure and compare
with nameplate speed.
5.2. Current
No-Load current should be compared with full load current.
5.3. Cooling system
The cooling system must be verified as being operational
5.4. Sound level
Test may be made for sound level as an indication of fault or as an irritation to those in the
machine ambient.
( ref. NEMA stds. MG 1-12.53, 1-12.81, and 1-20.50 )

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Low-Med Voltage AC Motor Rev. 1.1 - 2009
By. Mirza Aminudin
PT. BINTANG LESTARI PERSADA Electro Mechanical Workshop

5.5. Bearing temperature

Ambient and bearing housing temperatures may be measured periodically until temperatures
are stabilized.
5.6. Frame temperature
Ambient and Frame temperatures may be measured periodically until temperatures are
stabilized.
5.7. Vibration test
The vibration test should be in accordance
with NEMA std. MG 1-7 for standard
machine, as arrange with customer, or as
necessary to check the operating
characteristics of the machine. When there
are special requirements, NEMA std. MG 1-7
for special machine is recommended.
The unfiltered vibrations limits for resiliently
mounted on standard machine (having no
special vibration requirement), and based on
rotational speed, are shown in next table.
Vibration levels for speed above 1200 rpm
are based on peak velocity of 0.15 inch/s (3.8 mm/s). Vibration limit for speed below about
1200 rpm, are based on the peak-to-peak velocity equivalent of 0.0025 inch (0.0635 mm)
peak-to-peak displacement. For machine with rigid mounting, multiply the limiting value by
0.8.
To obtain approximate metric rms equivalent, multiply the peak vibration in in/s by 18.
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Low-Med Voltage AC Motor Rev. 1.1 - 2009
By. Mirza Aminudin
PT. BINTANG LESTARI PERSADA Electro Mechanical Workshop

( ref. NEMA std. MG 1-7.08.).

5.7.1.If the test pass, continue to next step
5.7.2.If the test fail, proceed to check from paragraph 2.3 then continue to paragraph 7
5.8. Performance test
Full load test may be made as arrange with the customer or as necessary to check the
operating characteristic of the machine.
( ref. IEEE std. 112 and 115 and NEMA std. MG-1 )

6. Complete of testing
6.1. Providing electrical and mechanical report to customer
To check and analyze result of testing or repair with customer, each report must be have
detailed item name plate, workshop ref number, and specific test or repair have been
perform. To give evidence that the specific repair are perform, must give photograph report.
6.2. Providing warranty letter to customer
6.3. Packaging as appropriate handing of electro motor

7. Mechanical check
After dismantling motor unit that not pass electrical or testing we should verified the problems, with
mechanical check we will find source of each failed criteria.
7.1. Shaft
Shaft should be check for wear, cracks, scoring and straightness.
7.1.1.Shaft Extension
Shaft extension should be smooth, polished and concentric with the shaft diameter.
Shaft extension diameter should be checked.
7.1.2.Diameter tolerance
7.1.2.1.NEMA Frame machine

7.1.2.2.IEC frame machine

7.1.3.Permissible Run-Out
7.1.3.1.NEMA Frame machine

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Low-Med Voltage AC Motor Rev. 1.1 - 2009
By. Mirza Aminudin
PT. BINTANG LESTARI PERSADA Electro Mechanical Workshop

7.1.3.2.IEC frame machine

7.1.4.Keyway width tolerance

7.1.4.1.NEMA Keyway

7.1.4.2.IEC Keyway

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Low-Med Voltage AC Motor Rev. 1.1 - 2009
By. Mirza Aminudin
PT. BINTANG LESTARI PERSADA Electro Mechanical Workshop

7.2. Bearing
7.2.1.Ball or Roller Bearing
Check when operated for temperature, noise and vibration condition. See reference to
each bearing manufacture standard for acceptance clearance.
7.2.2.Sleeve Bearing
Sleeve bearing should be uniform in diameter or proper fit in the housing, smooth
internally, and suitably grooved for adequate distribution of lubricant.
When sleeve bearing are remanufactured or replaced by new bearings, the diametral
clearance should be set to original equipment manufacturers specification if available.
Otherwise, the value in table below are provided as guide.

7.2.3.Sleeve bearing end thrust

Bearing of horizontal machine should be positioned on the shaft to eliminate end thrust
against either bearing.
7.2.4.Oil Ring
Oil ring should be true and rotate freely. Retainer, when provided, should be inspected or
replaced if necessary.
7.2.5.Seals

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Low-Med Voltage AC Motor Rev. 1.1 - 2009
By. Mirza Aminudin
PT. BINTANG LESTARI PERSADA Electro Mechanical Workshop

Seal clearance should be set to original equipment manufacturers specification if

available. otherwise the value in table below provided as a guide, measure the final seal
dimension.

7.3. Lubrication
7.3.1.Grease
Grease passage and pipe should be clean, grease inlet should be equipped with fittings.
Grease should be compatible with customer lubricant. In the absence of the machine
manufacturers lubrication instruction, the grease reservoir should be filled with
approximately 1/3 capacity
7.3.2.Oil
Oil should be compatible with customer’s lubricant, there should be a means to
determine oil level, such as oil sight gauge.
7.4. Frame and housing bearing
Frame and housing bearing should be examine for defects. Cracks and breaks should be
repaired and fits restored to manufacturers specification.
Mounting surface tolerance, eccentricity and face run-out

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Low-Med Voltage AC Motor Rev. 1.1 - 2009
By. Mirza Aminudin
PT. BINTANG LESTARI PERSADA Electro Mechanical Workshop

7.5. Lamination
The rotor lamination should not be loose on the shaft, sleeve or spider on which the
lamination stack is assembled. The fit should be restored if it is found to be loose. The outer
diameter of the rotor laminations should be true and concentric with bearing journals.
The stator lamination should not be loose in frame. The bore of stator laminations should be
true and concentric with the rabbet (spigot) diameter of the frame.

7.6. Unbalance
Dynamic balancing should be to the level specified by customer. In absence of requested
level, dynamic balancing to balance quality grade G 2.5 (ISO 1940/1) should enable the
machine to meet final vibration limits.
Locate balance weights so they do not interfere with other components.

7.7. Rotor center

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Low-Med Voltage AC Motor Rev. 1.1 - 2009
By. Mirza Aminudin
PT. BINTANG LESTARI PERSADA Electro Mechanical Workshop

Assemble both of housing bearing into frame and measure bearing to bearing length,
compare result with rotor bearing to bearing.

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Low-Med Voltage AC Motor Rev. 1.1 - 2009
By. Mirza Aminudin