MOTOR INSULATION & ITS CARE.

Preventive attention is better than cure.

PERFECT ELEKTRO MEK PAKISTAN (Regd.) Suit # 5, 2
nd
floor, Business arcade, Walton road, Lahore Cantt.
Perfection with convenience. Ph. 042-668-0902/03. Fax: 042-668-6685.
A. MOTOR INSULATION:

The most important item in the maintenance of electric apparatus is taking care of the
insulation. Commutator, collectors, and bearings require periodic attention; meters,
regulators, etc., While requiring adjustments, can usually continue in service until a planned
shutdown takes place. However, when insulation fails, you are extremely fortunate if only a
temporary shutdown occurs. In order to be able to cope with insulation problems arising
today, it is important to understand the qualities of insulating materials in order to discover
incipient trouble before it becomes major. In other words, preventive attention is better than
cure.

A major insulated for damp applications might fail very soon if applied where ambient
temperatures are high, and vice versa. The application of the motor should determine the
class of insulation, and repairs should be made, using best grade of materials to suit the
application.

The American Standards Association publishes the various symbols used in
classifying and identifying insulation materials, and these standards should be consulted.
Standards have also been formulated and published on allowable temperatures that various
insulations should be limited to in operation. For convenience, below are listed the limiting
temperatures (Sometimes called hottest-spot temperatures) to be used as a reference.

Material Temperature, deg. C
Class O 90
Class A 105
Class B 130
Class C No limit selected as yet
Class H 180

In actual practice, it is advisable to keep the operating temperature below the limit in order to
prolong the life of the insulation. Practically all insulation on coils has a binder, which is
used to band the insulating material to the conductors. This binder keeps the insulation
alive and pliable, and as long as the flexibility remains, the insulation will have long service
life under normal operating conditions. Operation for extended periods at high temperatures
or unfavorable atmospheric conditions affects this binder and shortens insulation life.

A check of the condition of insulation should be made periodically to indicate the
presence of dirt, carbonized material, and moisture. Tests to indicate this that do not damage
or break down the insulation are the most satisfactory for maintenance testing.
(Page # 1/3)
MOTOR INSULATION & ITS CARE.
Preventive attention is better than cure.

PERFECT ELEKTRO MEK PAKISTAN (Regd.) Suit # 5, 2
nd
floor, Business arcade, Walton road, Lahore Cantt.
Perfection with convenience. Ph. 042-668-0902/03. Fax: 042-668-6685.
The test most generally applied is that to determine the resistance of the insulation.
Special conditions may justify other tests such as dielectric tests, over-potential tests, high-
frequency tests, or power-factor tests. In some unusual cases chemical, physical, or
laboratory tests may be needed in checking into insulation failure.

The resistance test gives a good indication of the condition of the insulation,
particularly from the standpoint of moisture and dirt. The actual value of the resistance
Varies in different apparatus depending on type size, voltage rating etc. However the
importance of these values lies in the relative readings of insulation values taken under
similar conditions at various times They usually indicate how well the maintenance
department has done its work.

High insulation resistance values, however, do not assure high dielectric strength,
although low insulation resistance may indicate low dielectric strength. Coil insulation that is
wrinkled or that has been damaged mechanically may have a high resistance but could fail at
a relatively low value of dielectric test voltage. Insulation resistance varies inversely with the
temperature, a rough check being that the insulation resistance will be halved for every 10 C
rise in temperature of the apparatus.

Insulation resistance can be measured by a self-contained instrument such as the
familiar Megger, either hand-or motor-operated; by the electronic type; with a resistance
bridge; or with a millimeter, a voltmeter, and a d-c supply. Any of these instruments used in
insulation testing must be well maintained to be sure that the readings taken will be factual.

Insulation resistance of apparatus in service should be checked periodically at
approximately the same temperature and under similar conditions of humidity to determine
possible insulation deterioration. If such measurements show wide variations, the cause
should be determined and corrective measures taken to forestall an insulation failure.

Now new equipment should be placed in service with insulation resistance less than
1megohm. A good rule to follow on equipment in service is that the insulation resistance should
be approximately 1megohm for each 1,000volts of operating voltage with a minimum value of
1megohm.

DIE ELECTRIC TEST OF MOTOR:
The purpose of dielectric tests is to determine if the insulation on the machine can
withstand the voltage stresses set up during normal and possible abnormal conditions
during operation.

(Page # 2/3)

MOTOR INSULATION & ITS CARE.
Preventive attention is better than cure.

PERFECT ELEKTRO MEK PAKISTAN (Regd.) Suit # 5, 2
nd
floor, Business arcade, Walton road, Lahore Cantt.
Perfection with convenience. Ph. 042-668-0902/03. Fax: 042-668-6685.
The application of the a-c high voltage necessary to make a dielectric test presents
hazards in that not only can the a-c voltage used puncture or breakdown the insulation
but often severe burning of the machine laminations occurs, because the capacity
needed to test larger machines is such that in case of breakdown, a large amount of
power follows in the arc established. However, in many cases, the risk involved does not
outweigh the possible long outage that might occur if the insulation failed while on an
operation driving an important load.

The test voltage applied to new machines or to the winding of machines completely
rewound with new coils and insulating material is specified by AIEE and ASA standards
as twice rated voltage plus 1,000volts held for 60sec, with the exception of field windings
of synchronous motors, which are given a test voltage of 10 times the exciter voltage but
not less than 1,500volts. For machines in commercial operation or for repaired
machines, No standards have been set, but established practice is to use an a-c test
voltage between 65 and 75 percent of the test voltage for new windings. The lower value
should be used for older windings.

Within recent years, high-voltage d-c testing has become more and more accepted. It
has numerous advantages over a-c testing. The capacity used is small, and the test
effect in searching out weak insulation is comparable to a-c testing. The unit used is
considerably smaller physically than the test transformer, the equipment needed to test
the largest machine being easily transported in a car, whereas the transformer requires
a large truck. The device is electronic and consists essentially of a high-voltage
rectification circuit. Instruments measure the current and voltage. Another advantage,
Which is of prime importance, is that in case of an insulation failure during test, no
iron burning results because of the small amount of power used. The test equipment
operates from the 60-cycle lighting circuit. Test values have been established whereby a
d-c test voltage is applied 60 per cent greater than the a-c test voltage ordinarily used.
The cost of the d-c test outfit can be used to test the windings of machines, from the
smallest to the largest.

A relatively new test has come into use check turn-to turn insulation in machine
windings. The device is a surge comparison tester and is used to locate insulation faults
and winding dis-symmetries in all classes of equipment regardless of size. It is an
electronic device and id portable, so that it can be used for maintenance work as well as
shop work. High turn-to-turn voltages are applied without excessive winding to ground
stresses, and the testing is nondestructive.