TESTING OF DC MACHINES

Reference Book: Compiled By:

B.L. Theraja Prof. S. N. JANI & Prof. S. S. SHAH
ELECTRICAL TECHNOLOGY INSTITUTE OF TECHNOLOGY
PART-2 : AC, DC MACHINES NIRMA UNIVERSITY

08/01/2020 1
 Some Basic

08/01/2020 2
EFFICIENCY OF DC MACHINE
• Efficiency can be determine by finding losses in the equipment, input
given and the output using below equation:

𝑜𝑢𝑡𝑝𝑢𝑡
𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 𝑖𝑛 % = ∗ 100
𝑜𝑢𝑡𝑝𝑢𝑡 + 𝑙𝑜𝑠𝑠𝑒𝑠

• The efficiency is calculated at 25%, 50%, 75%, 100% and 125% rated
load.

08/01/2020 3
Losses in the Equipment
• Friction and Windage Loss
• Iron Loss
• Armature Copper Loss
• Series Winding Copper Loss
• Inter-pole Winding Copper Loss
• Brush Contact Loss
• Shunt Field Copper Loss
• Stray Load Loss

08/01/2020 4
• Friction and Winding Loss: Separated by light load test
• Iron Loss: By separation of iron and friction loss by light load test
• Armature Copper Loss:
- Measure armature resistance
- Convert that to at 75˚C
- Find armature current at the load required
- Calculate 𝐼 2 ∗ 𝑟𝑎
• Series Winding Copper Loss:
- Measure series winding resistance
- Calculate 𝐼𝑠𝑒 2 ∗ 𝑅𝑠𝑒 at 75˚C and at the load required
• Inter-pole Winding Copper Loss: Same procedure to calculate 𝐼𝑐𝑝 2 ∗ 𝑟𝑐𝑝
08/01/2020 5
• Brush Contact Loss:
- 1 V per brush or a total 2 V voltage drop
- (2 V * Current) = Watts in brush contact loss
• Shunt Field Copper Loss:
- Measure shunt field resistance
- Convert it to 75˚C and find normal field current at the loading condition
- Calculate 𝐼𝑓 2 𝑅𝑓
OR shunt field copper loss = (voltage across shunt winding * field current)
• Stray Load Loss: It can’t be measured accurately, approximately it is taken 1%
of output

08/01/2020 6
 Brake Test

08/01/2020 7
Brake Test
• Direct Method

• In which applying brake to water cooled pulley

mounted on the motor shaft as shown in fig.. This
method is mainly used for small DC motor.

• In which one end is connected with earth via spring

balance and another with the suspended weight.
And the load over the motor adjusted till it carries
the full load current.

08/01/2020 8
Torque developed Tsh = (W1 – W2) * R kg-m or 9.81(W1-W2)R N-m
Output Power = Tsh * 2πN or Tsh * ω watt
Input Power =V*I watt

61.68 𝑁 𝑊1 −𝑊2 𝑅
Efficiency =
𝑉𝐼

Where, W1 = Suspended weight in kg

W2 = Reading on spring balance in kg
R = Radius of the pulley in meter
N = motor or pulley speed in RPS || ω = Angular velocity
V = Supply Voltage || I = Full load current taken by motor
08/01/2020 9
• Previous brake test is applied only
for small DC motor as there is
problem of dissipation of large
amount of heat generated at the
brake for large DC motor.

• For that another method is used

which is called Pony Brake. In
which rope is wound round along
the pulley and both ends are
connected to individual spring
balance (S1 and S2).
61.68 𝑁 𝑆1 −𝑆2 𝑅
Efficiency =
𝑉𝐼

08/01/2020 10
• Here a rope is wound around the pulley and its two ends are attached
with the spring balance 𝑆1 and 𝑆2 .

• Tension on this rope can be adjusted by means of adjustment of

swivels. And the force acting tangentially on the pulley is equal to the
difference between the readings of spring balance.

• Force acting on the pulley

= Difference between reading of spring balance =
= reading of 𝑆1 - reading of 𝑆2

08/01/2020 11
 Swinburne’s Test

08/01/2020 12
Swinburne’s Test
• It is also know as No load test or Losses Method.

• It is simple method in which losses are measured separately and from

their knowledge efficiency can be measured at any desired load.
Separately test required is only running no load test.

• This test is only required where the flux in the stator is remaining
practically constant.

08/01/2020 13
• At no load, the speed is being
regulated to its rated speed by
use of shunt regulator.

No load current = 𝐼0

(measured by ammeter 𝐴1 )
Shunt Field Current = 𝐼𝑠ℎ
(measured by ammeter 𝐴2 )
No load armature current =𝐼0 - 𝐼𝑠ℎ
= 𝐼𝑎0
If supply voltage=V then i/p=V ∗ 𝐼0
Power i/p to armature = V * (𝐼0 - 𝐼𝑠ℎ )
Power i/p to shunt = V * 𝐼𝑠ℎ

08/01/2020 14
• No load power i/p to armature supplies
the following:
1. Iron losses in core
2. Friction Loss
3. Windage Loss
4. Armature Cu loss = (𝐼0 − 𝐼𝑠ℎ )2 *𝑅𝑎 = 𝐼𝑎0 2 *𝑅𝑎
• While calculating the Cu loss ‘hot’
resistance need to be considered. Which
can be find by measuring resistance at
room temperature and then calculate
resistance for some temp. rise.
• Ex.: Room Temp. = 15 ˚C , ∝0= (1 234.5) and Temp. Rise = 50 ˚C
So, 𝑅15 = 𝑅0 ∗ 1 + 15 ∝0 and 𝑅65 = 𝑅0 ∗ 1 + 65 ∝0
𝑅65 = 1.2 * 𝑅15

(Here, armature current will be found decrease with increase on armature

resistance as shown in fig. due to brush contact resistance as it is inversely
proposal to armature current.)

08/01/2020 15
• Now subtracting the armature Cu loss it can be easily found out the
constant losses.
𝑊𝑐 = 𝑉 𝐼0 − 𝐼0 − 𝐼𝑠ℎ 2 ∗ 𝑅𝑎

• After which at any load point efficiency can be find out.

For which, armature current 𝐼𝑎 = I − 𝐼𝑠ℎ (for motoring action)
= I + 𝐼𝑠ℎ (for generating action)

𝑖𝑛𝑝𝑢𝑡 −𝑙𝑜𝑠𝑠𝑒𝑠 𝑉 𝐼 −( 𝐼 − 𝐼𝑠ℎ 2 ∗𝑅𝑎 ) − 𝑊𝑐

• Efficiency as a motor = Ƞ𝑚 = =
𝑖𝑛𝑝𝑢𝑡 𝑉𝐼
𝑜𝑢𝑡𝑝𝑢𝑡 𝑉𝐼
• Efficiency as a generator = Ƞ𝑔 = =
𝑜𝑢𝑡𝑝𝑢𝑡+𝑙𝑜𝑠𝑠𝑒𝑠 𝑉 𝐼 + 𝐼+ 𝐼𝑠ℎ 2 ∗𝑅𝑎 + 𝑊𝑐

08/01/2020 16
 Advantage
• This method is convenient and
economical as it needs small
power equal to no load input
power.
• Efficiency can be predetermined
at any load condition as
constant losses are known.
08/01/2020
Disadvantage
• No account of change in iron loss
is taken into consideration from
no load to full load. At a full
load, due to armature reaction
flux is being distorted which
increases the iron losses in some
case it is being gone up to 50%.
• As in this test only no load test is
done so no data of satisfactory
commutation and temp. with in
specific limit can be found.
17
 Regenerative or Hopkinson’s Test

08/01/2020 18
Regenerative or Hopkinson’s Test (Back to Back Test)
• In this method full load test is being carried out. Between two
identical ones shunt machines.

• Without wasting each others energy by using mechanical

coupling between each other and electrical coupling is such that
one is being used as motor and another one as generator.

• So by which mech. o/p of motor is being use to drive the

generator and electrical o/p of generator is being use to drive the
motor.

08/01/2020 19
08/01/2020 20
• Ideally each can fulfil demand of other but as due to losses there is need of
external force.

• Which can be fulfil by mechanically by attaching extra motor to belt

connection or by electrically supply from the mains.

• Procedure:
o Machine M start from the supply mains and main switch S of the another machine is open.
o Speed is adjusted to normal value by means of field regulator.
o Machine M drives machine G as generator and its voltage can be measured from voltmeter 𝑉1 .
o Voltage of machine G is adjusted by field regulator until voltmeter 𝑉1 reads zero, thereby voltage wll be same in
magnitude and polarity as that of the mains supply.
o Thereafter S is closed to parallel the machines.
o By adjusting the respective field regulators any load can be thrown on the machines.
o Gen. current 𝐼1 can be adjusted to any desired value by increasing the excitation of G or by reducing the excitation
of M.
o The electrical o/p of the Gen. + the small power taken from the supply by the motor = mech. power after
supplying the motor losses.

08/01/2020 21
oSupply voltage = V
oGenerator output = V 𝐼1
oMotor input = V (𝐼1 + 𝐼2 )
(Here 𝐼2 is current taken from the supply)
Assumption: Both machine have same efficiency (Ƞ)
oOutput of motor = Ƞ * i/p = Ƞ * V (𝐼1 + 𝐼2 )
oOutput of generator = Ƞ * i/p = Ƞ * Ƞ * V (𝐼1 + 𝐼2 ) = Ƞ2 * V (𝐼1 + 𝐼2 )
= Ƞ * V 𝐼1
𝐼1
Ƞ=
𝐼1 + 𝐼2

08/01/2020 22
However there can not be equal efficiency of both machine as the
armature current and excitation in both machines are different.

Let,
𝑅𝑎 = 𝑎𝑟𝑚𝑎𝑡𝑢𝑟𝑒 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑜𝑓 𝑒𝑎𝑐ℎ 𝑚𝑎𝑐ℎ𝑖𝑛𝑒
𝐼3 = 𝑒𝑥𝑐𝑖𝑡𝑖𝑛𝑔 𝑐𝑢𝑟𝑟𝑒𝑛𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑜𝑟
𝐼4 = 𝑒𝑥𝑐𝑖𝑡𝑖𝑛𝑔 𝑐𝑢𝑟𝑟𝑒𝑛𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑚𝑜𝑡𝑜𝑟

Armature Cu loss in generator = (𝐼1 + 𝐼3 )2 ∗ 𝑅𝑎

Armature Cu loss in motor = (𝐼1 + 𝐼2 − 𝐼4 )2 ∗ 𝑅𝑎
Shunt Cu loss in Generator = V * 𝐼3
Shunt Cu loss in Motor = V * 𝐼4
As Total generator and motor losses are equal to the power supplied by the mains.
Power drawn from supply = V * 𝐼2

08/01/2020 23
Stray Losses for the set:
= V * 𝐼2 − [ 𝐼1 + 𝐼3 2 ∗ 𝑅𝑎 + 𝐼1 + 𝐼2 − 𝐼4 2
∗ 𝑅𝑎 + 𝑉 ∗ 𝐼3 +𝑉 ∗ 𝐼4
= 𝑊𝑠𝑡𝑟𝑎𝑦

Assumption: Stray loss is equally distributed between two machines.

So, stray losses per machine = 𝑊𝑠𝑡𝑟𝑎𝑦 /2

For Gen.:
V ∗ 𝑰𝟏
Total losses 𝑊𝑔 = 𝐼1 + 𝐼3 2
∗ 𝑅𝑎 + 𝑉 ∗ 𝐼3 + (𝑊𝑠𝑡𝑟𝑎𝑦 /2) Ƞ𝒈 =
V ∗ 𝑰𝟏+ 𝑾𝒈
Output = V * 𝐼1

For Motor:
V ∗ (𝑰𝟏+𝑰𝟐) −𝑾𝒎
Total losses 𝑊𝑚 = 𝐼1 + 𝐼2 − 𝐼4 2
∗ 𝑅𝑎 + 𝑉 ∗ 𝐼4 + (𝑊𝑠𝑡𝑟𝑎𝑦 /2) Ƞ𝒎 =
V ∗ (𝑰𝟏+𝑰𝟐)
Input = V * (𝐼1 +𝐼2 )

08/01/2020 24
 Advantage
• Power required for to do this
test is small as compared to full
load test of the two machines.
Disadvantage
• Two identical machines are
required which is the main
disadvantage or demerit of this
test.

• As in this test machines are

working on full load, temp. rise
and commutation qualities can
be observed.

• Any change in iron loss due to

flux distortion at the full load is
being taken into account.

08/01/2020 25
 Field’s Test

08/01/2020 26
Field’s Test
• Applicable only for two similar series
motors.

• Two machines are coupled mechanically,

one machine runs normally as a motor and
drives a generator whose o/p is wasted in
variable resistor.

• Here the iron and friction loss of two

machines made equal.

08/01/2020 27
• How to make iron and friction loss of the two machines equal for
field’s test?
oBy joining the series field winding of the generator in the motor
armature circuit so that both machines are equally excited.
oBy running them at equal speed.

• Adjust the value resistor R such that the reading of 𝐴1 notes full load
current.

• And note the value at various voltmeter and ammeter.

08/01/2020 28
V = Supply Voltage 𝑉2 =Terminal potential drop of Generator
𝐼1 = Motor Current 𝐼2 = Load Current

Intake of the whole set = 𝑉 ∗ 𝐼1 Output = 𝑉2 ∗ 𝐼2

Total losses in the set, 𝑊𝑡 = 𝑉 ∗ 𝐼1 − 𝑉2 ∗ 𝐼2

Armature and Field Cu losses, 𝑊𝐶𝑢 = 𝑅𝑎 + 2 𝑅𝑠𝑒 𝐼1 2 + 𝐼2 2 𝑅𝑎
𝑅𝑎 = 𝐻𝑜𝑡 𝑎𝑟𝑚𝑎𝑡𝑢𝑟𝑒 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑜𝑓 𝑒𝑎𝑐ℎ 𝑚𝑎𝑐ℎ𝑖𝑛𝑒
𝑅𝑠𝑒 = 𝐻𝑜𝑡 𝑠𝑒𝑟𝑖𝑒𝑠 𝑓𝑖𝑒𝑙𝑑 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑜𝑓 𝑒𝑎𝑐ℎ 𝑚𝑎𝑐ℎ𝑖𝑛𝑒
Stray losses for the set = 𝑊𝑡 − 𝑊𝐶𝑢
𝑊𝑡 − 𝑊𝐶𝑢
Stray losses/ machine, 𝑊𝑠 = (Assumption: Stray losses are equally divided)
2

08/01/2020 29
• Motor Efficiency
Motor input = 𝑉1 𝐼1
Motor losses = armature + field Cu loss + Stray loss = (𝑅𝑎 + 𝑅𝑠𝑒 )𝐼1 2 + 𝑊𝑠 = 𝑊𝑚

𝑽𝟏 𝑰𝟏 − 𝑾𝒎
Ƞ𝒎 =
𝑽𝟏 𝑰𝟏

• Generator Efficiency
Generator output = 𝑉2 𝐼2
Field Cu loss = 𝐼1 2 𝑅𝑠𝑒 Armature Cu loss = 𝐼2 2 𝑅𝑎
Stray Losses = 𝑊𝑠
Total Losses = 𝐼1 2 𝑅𝑠𝑒 + 𝐼2 2 𝑅𝑎 + 𝑊𝑠 = 𝑊𝑔
𝑽𝟐 𝑰𝟐
Ƞ𝒈 =
𝑽𝟐 𝑰𝟐 + 𝑾𝒈

08/01/2020 30
 Retardation Test

08/01/2020 31
Retardation Test or Running Down Test
• It is used for finding out stray losses of shunt wound DC motor.
• In this method, machine under test is being speed up slightly more than
normal speed and then supply to the armature is cut off.
• Due to which armature slows down and its kinetic energy will be used for
meeting rotational losses (Stray Loss).

08/01/2020 32
 1
Kinetic energy of the armature = 𝐽 𝜔2
2
𝐽 = 𝑚𝑜𝑚𝑒𝑛𝑡 𝑜𝑓 𝑖𝑛𝑒𝑟𝑡𝑖𝑎 𝑜𝑓 𝑎𝑟𝑚𝑎𝑡𝑢𝑟𝑒
𝜔 = 𝑎𝑛𝑔𝑢𝑙𝑎𝑟 𝑠𝑝𝑒𝑒𝑑 𝑎𝑡 𝑡ℎ𝑒 𝑖𝑛𝑠𝑡𝑎𝑛𝑡

𝜕 1 2 𝜕𝜔
Rotational losses, 𝑃𝑠 = 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑐ℎ𝑎𝑛𝑔𝑒 𝑜𝑓 𝐾. 𝐸. = 𝐽𝜔 = 𝐽𝜔
𝜕𝑡 2 𝜕𝑡

2𝜋𝑁
𝜔= N = Speed of armature in rpm at that instant
60

2𝜋𝑁 𝜕 2𝜋𝑁 2𝜋 2 𝑑𝑁
Rotational Losses, 𝑃𝑠 = 𝐽 = 𝐽𝑁
60 𝜕𝑡 60 60 𝑑𝑡

08/01/2020 33
 𝝏𝑵
Determination of
𝝏𝒕
• Voltmeter connected across armature to find instantaneous back emf. Which is
directly in proportion to speed N.
• Voltmeter is calibrated such that it shows speed.
• When supply to armature is cut off speed of the motor decreases.

• Speed or readings of the voltmeter is noted at different

interval and draw graph of speed and time as shown in
fig.
• Draw tangent of any point lying on the curve (P) which
meet X and Y axis at point A and B.

𝜕𝑁 = 𝑂𝐵 𝑖𝑛 𝑅𝑃𝑀
𝜕𝑡 𝑂𝐴 𝑖𝑛 𝑠𝑒𝑐
08/01/2020 34
Determination of Moment of Inertia
• First draw speed-time curve for which moment of inertia need to
found. Then key a flywheel with the shaft which has known moment
of inertia 𝐽1 and again draw speed-time curve.

𝜕𝑁 𝜕𝑁
• From the above two curves determine and .
𝜕𝑡1 𝜕𝑡2

• As due to flywheel in second case moment of inertia will be more

than in first case and losses will be same.

08/01/2020 35
 2𝜋 2 𝜕𝑁
Rotational losses in first case, 𝑃𝑠 = JN
60 𝜕𝑡1
2𝜋 2 𝜕𝑁
Rotational losses in second case, 𝑃𝑠 = (J + 𝐽1 )N
60 𝜕𝑡2

As the losses are same,

2𝜋 2 𝜕𝑁 2𝜋 2 𝜕𝑁
JN = (J + 𝐽1 )N
60 𝜕𝑡1 60 𝜕𝑡2
𝜕𝑁
𝐽1 𝜕𝑡
2
By simplifying above equation, 𝐽 = 𝜕𝑁 𝜕𝑁
−
𝜕𝑡1 𝜕𝑡2

08/01/2020 36
Second Method to determine of Moment of Inertia
• In this method, time is being noted down for slowing down of speed
by 5%. Take it as 𝑡1 sec.
• Now add an additional load known as retarding torque, mechanical or
electrical is applied and same way note the time taken for slowing
down by 5% (𝑡2 sec).
• As shown in fig., of retardation test double throw switch is closed
over terminal 1’ and 2’ to connect additional load just after
disconnection of supply to armature.
• Which will make K.E. energy of armature to supply the power to non
inductive resistor R (Ps’) along with the rotational loss.

08/01/2020 37
 2
2𝜋 𝜕𝑁
𝑃𝑠 = 𝐽𝑁
60 𝜕𝑡1
2𝜋 2 𝜕𝑁
So, 𝑃𝑠 + 𝑃𝑠 ′ = 𝐽𝑁
60 𝜕𝑡2

By taking ratio of above equation,

𝜕𝑁
𝑃𝑠 + 𝑃𝑠 ′ 𝜕𝑡2
=
𝑃𝑠 𝜕𝑁
𝜕𝑡1
𝜕𝑁
′ 𝜕𝑡1
𝑃𝑠 = 𝑃𝑠 ∗
𝜕𝑁 𝜕𝑁
−
𝜕𝑡2 𝜕𝑡1
08/01/2020 38
 Heat Run Test

08/01/2020 39
Heat Run Test:

• Back to back test is done for the temperature run also.

• Normal run for time for temperature run test for large machine is 6
hours.
• As the time span to reach the steady state value of temp. is very long
some short time span test is being done in between and ultimate
temp. rise of the machine determined.

08/01/2020 40
Temp. Rise = 𝜃𝑡
−𝑡
𝜃𝑡 = 𝜃𝑚 1 − 𝑒 𝜏
−1
Let, 𝑒 𝜏 =𝐾 Then, 𝜽𝒕 = 𝜽𝒎 𝟏 − 𝑲𝒕

When, t=1 𝜃1 = 𝜃𝑚 1 − 𝐾 Successive interval between two

readings is 30 min. or even smaller.
t=2 𝜃2 = 𝜃𝑚 1 − 𝐾 2
𝜃2 𝜃2 −𝜃1 K is the ratio of increase in temp. rise during two
=1+K → 𝐾= successive interval of time
𝜃1 𝜃1
Max. Temp. Rise = 𝜃𝑚
𝜽𝟏
𝜽𝒎 =
𝟏−𝑲
If initial temp. rise 𝜃0 = 0

08/01/2020 41
Cooling Curve
• Cooling curve is shown with heating
curve, mirror image of the other,
displaced by the 𝜃𝑚𝑎𝑥 .

• Eq. for Temp. for cooling curve

−𝑡
𝜃𝑡 = 𝜃𝑚𝑎𝑥 𝑒 𝜏 = 𝜃𝑚𝑎𝑥 𝐾 𝑡

• Constant will have the same constant

value as of heating curve.

08/01/2020 42