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EASA Convention 2011 June 25, 2011
Electrical Testing
of Three-Phase Motors
Presented by Electrical Apparatus Service
Tom Bishop, P.E. Association
St. Louis, MO
2011 EASA Convention • Denver, CO
Introduction
• Focus/scope: Electrical testing of three-
phase squirrel cage induction motors in
the service center
• Testing that will be covered includes:
Incoming tests
Post disassembly tests
In process tests – overhaul
In process tests – rewind
Pre-assembly tests
Post assembly tests
Denver, CO 1
Purpose
• Purpose: Provide overview of common
(and some uncommon) electrical tests for
most AC squirrel cage three-phase motors
Can be used as a tutorial for training of
technicians and others in service center
Recorded test results can be used to provide
an electrical condition repair benchmark (birth
certificate) for end user
Electrical testing -- safety

• All applicable safety-related work practices
must be followed during electrical testing
• This includes but is not limited to
Wear proper personal protective equipment
Insulate electrical connections
Isolate test area
Denver, CO 2

• Wear proper
personal protective
equipment (PPE)

• Insulate electrical
connections
Exposed rotating parts
such as shaft
extensions should
have guards
Denver, CO 3

• Isolating test area such
that only qualified test
personnel can enter
Detailed
Flow
chart –
Overall
process
Denver, CO 4
Test types
• R = Routine test
• O = Optional test
• C = Conditional test
Test types -- routine

• R = Routine test
Normally applied to all motors
as part of category of tests
being performed
Example: Insulation
resistance test is performed
on all motors during incoming
static tests
Denver, CO 5
Test types -- optional

• O = Optional test
A test that may be
performed on a motor
• If service center
management desires it
• Or is required by the
customer
Example: Single phase
rotor test as part of
incoming static tests
Test types -- conditional

• C = Conditional test
Performed if conditions
warrant it
Example: Incoming dynamic
test run
• Performed if the motor is
deemed capable of operating
• Not run if static incoming tests
such as insulation resistance
test do not have acceptable
values
Denver, CO 6
Incoming tests -- static
Insulation resistance (IR) test

• [R]* Insulation resistance
(IR) test
• Megohmmeter or “megger”
test
1 minute (60 seconds) duration
500 or 1000 volts most
common test voltages
*[R] Routine
[O] Optional
[C] Conditional
Denver, CO 7

• Machine rated voltage
versus IR test voltage
Winding rated voltage Insulation resistance

AC or DC test voltage DC
< 1000 500
1000 - 2500 500 - 1000
2501 - 5000 1000 - 2500
5001 - 12000 2500 - 5000
>12000 5000 - 10000

• IR test insulation
resistance versus
temperature
• Minimum IR value
doubles for every 10 °C
decrease in temperature
• Hot windings: Allow to
cool to ≤ 60 °C before IR
testing
Denver, CO 8

• Formula for temperature correction factor:
Kt = (0.5) (40-T)/10
• Kt -- Factor to multiply T by to obtain insulation
resistance corrected to 40 °C
• T -- Temperature in °C at which insulation
resistance was measured

• Calculation example for a winding tested
at 35 °C:
Kt = (0.5) (40-35)/10 = (0.5) 5/10 = (0.5) 1/2
= 0.707
• If measured IR is 100 MΩ at 35 °C,
corrected megohms are:
100 x 0.707 = 70.7 or about 71 MΩ at 40 °C
Denver, CO 9


• IR test minimum
acceptable megohm
values
• If IR is below minimum
Do not apply high-
potential tests
• Surge
• Hipot
Do not energize winding
Denver, CO 10

• IR test example
Random wound three-phase motor rated 460 volts
• IR of 47 MΩ at 25 °C
• Use temperature correction factor formula
Kt = (0.5) (40-25)/10 = (0.5) 15/10 = (0.5) 1.5
= 0.354
• Corrected megohm value (original MΩ x Kt)
47 x 0.354 = 16.6 MΩ > 5 MΩ IEEE 43 minimum
– Conclusion: satisfactory test result
• If result was unacceptable
– Clean and retest
– Consider rewind
Polarization index (PI) test

• [O] PI is 10:1 minute IR ratio
PI ≥ 2.0 indicates clean and dry insulation
If IR > 5000 MΩ PI test not necessary/meaningful
• PI is variation of dielectric absorption ratio (DAR)
test
Ratio of long time period to short time period
• e.g., 60 to 30 seconds
Denver, CO 11

• If hipot is used for PI or DAR
Divide short time microamps (μa) by long time μa

• PI test example plot of results
10:1 minute IR ratio
Polarization index (PI) PI = 1.45/0.51 = 2.84
4
Microamps
0
0 100 200 300 400 500 600 700
Seconds
Denver, CO 12
Insulation power factor test

• [O] Also termed
dissipation factor test
Typically for windings rated
> 5kv with stress grading
tape or paint
Higher power factor = higher
insulation system losses
Customer typically specifies
acceptance criteria
Winding resistance test

• [R] Lead to lead, or
winding resistance test
• Record winding
temperature for accurate
comparison of present
value to:
Future resistance readings
at other temperatures
Original factory value
Denver, CO 13

• Use a bridge type instrument
4 leads
• 2 for volts
• 2 for amps
Milliohmmeter or
microohmmeter
• Resistance balance
tolerances
Random windings 2%
Form coil windings 1%

• Bridge type instruments
Importance of calibration
Accurate and repeatable
measurements
Denver, CO 14
High potential (hipot) test

• [O] Hipot test
Per AR100 do not hipot windings that
are not clean and dry
• AC or DC test voltage
Good practice: Record temperature
and humidity
• Demonstrates suitability of winding
for service
Apply maximum voltage for 1 minute
Pass/fail – go/no-go

• Hipot test -- AC
• Typically at 50 or 60Hz
New winding test level
• 2E + 1000 volts
• E = rated voltage
Non-rewind test level
• (2E + 1000) x 0.65 volts
Denver, CO 15

• Example of 350 kv
AC hipot
• Larger machines
require larger hipot
What matters is kva
not kv

• Hipot test -- DC
New winding test level
• (2E + 1000 volts) x 1.7
• (2E + 1000 volts) x 1.7 x 0.65
= (2E + 1000) x 1.11 volts
Denver, CO 16

• Example hipot test values
AC New winding test
• Rated 460 volts
• [(2 x 460) + 1000)] x 1.7 = 1920 x 1.7
= 3264 volts
• Rated 460 volts
• [(2 x 460) + 1000)] x 1.7 x 0.65
= 1920 x 1.11 = 2131 volts

• Ramp method
Slowly increase applied voltage
Monitor current for rapid increase (stop test)
Hipot test - ramp method
12
10
8
Microamps
0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
Volts
Denver, CO 17

• Ramp method

• Impending failure – ramp method example
Test terminated
Hipot test -- impending failure
12
10
8
Microamps
0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
Volts
Denver, CO 18

• Step voltage test
Typically used for windings rated > 2400 volts
Hipot test -- Step voltage
12
10
8
Microamps
4
2
0
0 2000 4000 6000 8000 10000 12000 14000 16000 18000
Volts

• Step voltage test
Denver, CO 19

• Safety -- Discharge
winding to ground after test
Ground for:
• At least 15 minutes
• Or 4 times length of test
• Whichever is longer
Discharges capacitive
voltage charge in windings
Surge test
• [O] Surge test can identify
Shorted turns
Misconnections
Grounds and open circuits
• Typical test level: Twice
rated voltage plus 1000
volts
Denver, CO 20
Surge test
• Assembled motor versus stator
only surge test
Requires much greater energy
(joules)
• Stator-rotor coupling may make
interpretation difficult
Transformer effect between stator
(primary) and rotor (secondary)
Offset surge test patterns
Rotate rotor to align surge
patterns
Surge test
• Instrument is high energy pulse
generator and cathode ray tube
(CRT)
• Pulse rise time and repetition
rate produce a resonant
response in coils under test
If response is stable as voltage is
increased coils are not shorted
• Result can be saved using the
tester software, if applicable,
and compared to other coils
Denver, CO 21
Surge test
• It is a comparison test
Positive result when windings
are symmetric
• Apparent single trace
Does not detect all anomalies
• Such as winding connected
for wrong number of poles
Surge test
• Unacceptable pattern
Surge is actually 2 or 3
overlayed waveforms
When surge is satisfactory
only 1 waveform is apparent
When surge is faulty 2 or 3
waveforms appear
• Short shifts 1st peak to left
• Magnetic dissymmetry can
affect result
Denver, CO 22
Surge test
• 3 phase
Single phase rotor test

• [O] Single phase test set up
(assembled motor)
Apply ~1/8 to 1/4 rated
voltage to 2 motor line leads
Expected current ~75 to 125%
rated amps
• Increase voltage & current if
<50% rated amps
Denver, CO 23

• Rotate shaft and rotor
slowly
Monitor current
Measure current

• Single phase rotor test assessment
If amps vary >3% rotor is probably open
Note variations in
• Torque (cogging)
• Noise (changes in synch with torque change)
• Will match winding poles
• Example
Measured 10.8 to 10.3 amps
Variation 10.8/10.3 = 1.049 = 4.9% > 3%
Indication is possible open rotor
Denver, CO 24
Shaft magnetization test

• [O] Measure shaft
magnetization with a
gaussmeter
Magnetized shaft can cause
shaft currents
• Perform test if
Bearings noisy
Motor used on VFD

• Residual magnetization limits
Disassembly can change magnetic field strength
Measured values may be lower than levels inside
component
Maximum allowable residual magnetic field levels

(measured in free air)
2 gauss Bearing components, bearing journals;
seals, gears and coupling teeth.
4 gauss Bearing housings.
6 gauss Mid-shaft and rotor core area.
Denver, CO 25
Incoming tests – dynamic
Test run no load

• [C] Test run no load if safe
• Mount motor on baseplate
Bolt to make rigid
Place on resilient pads
• Measure and record volts
and amps
Consider measuring watts as
benchmark for future re-testing
• Assess effect of prior repairs
on efficiency
Denver, CO 26
Test run no load

• Evaluate no load current
Shaft to frame voltage test

• [O] Shaft to frame voltage
indicates probability of
bearing current
• Check large motors and
motors used on VFDs
Large motor: core OD > 48”
Also check for magnetized shaft
• Post-disassembly: Inspect
bearings for evidence of shaft
currents
Denver, CO 27

• Measure with true RMS AC
voltmeter
• Tolerance limits
Ball or roller bearings 100 mv
Sleeve bearings 200 mv
• If measured values exceed
limits
Inspect bearings after
disassembly for evidence of
shaft currents
Check shaft for residual
magnetism
Partial discharge test

• [O, C] Test for partial
discharge (PD) activity
aka Corona
• PD/corona
Air becomes ionized =
conductive
Ozone (O3) gas is generated
• Erodes winding insulation
• Ferrous parts (e.g., core)
oxidize
Denver, CO 28

• Specialized test
equipment required
For details of testing, see
• IEEE 1415 IEEE Guide for
Induction Machinery
Maintenance Testing and
Failure Analysis
• IEEE 1434 IEEE Guide to
Measurement of Partial
Discharges in Rotating
Machinery
Detailed Status
Flow check:
chart – Where
are we in
Overall the
process process?
Denver, CO 29
Post-disassembly
Growler test
• [R] Principle of operation:
Transformer effect
Growler is primary
Rotor being tested is
secondary
• Place hacksaw blade on
rotor
Vibrating blade = bar intact
No vibration = open
Denver, CO 30
Growler test
• Other growler test
methods
• Magnetic paper
Open or cracked bar
= weak trace
• Iron filings
Open or cracked bar
= weak path
Bearing insulation test

• [C] Bearing insulation
used on:
Large motors with
magnetic dissymmetry
Motor used with VFDs
• Prevents/reduces shaft
and bearing current
Denver, CO 31

• Use IR test method
500 VDC test level – 1MΩ
minimum
Disassembled motor test
from end bracket to bearing
seat
Assembled motor test from
end bracket to shaft
• Check for leakage paths
through piping and
instrument connections
Stator core loss or loop tests

• [R] Test assesses condition of
laminations and lamination
insulation
Usual flux level 85kl/in2
• Commercial core tester and
loop test give equivalent results
Core tester 1 turn and high amps
Loop test multiple turns and lower
amps
Denver, CO 32
Stator core loss or loop tests

• Assess core condition
Hot spots > 27 °F (15 °C)
• May indicate degradation
• Check with temperature
detector
– Do not use hand to check
Loss > 4 watts/pound
• May indicate degradation
Surge test
• [R] Surge test can identify
Shorted turns
Misconnections
volts
• More probing than with
assembled motor
Denver, CO 33
Phase balance test

• [O] Performed on stator
Checks for balanced windings
• Test parameters
Balanced 3 phase power
About 1/6 rated voltage
Expect about full rated amps
Amp balance ~5-6% for
voltage balance within 1%
• Example
460 volt stator rated 100 amps
Apply about 80 volts and
expect about 100 amps per
lead
Post-disassembly – Suspected
open rotor
Denver, CO 34
Growler & magnetic paper or

iron filings test
• [R] Magnetic paper
Open or cracked bar
= weak trace
or
• [R] Iron filings
Open or cracked bar
= weak path
Core tester & infrared

thermography
• [O] Core loss test rotor
• Core tester with shaft
clamps to energize rotor
Duration of 15 – 60 minutes
may be required
Infrared thermographic
temperature detector
• Caution: Keep infrared
detector at least 3ft from
rotor core
• Assessment
Weak or high-resistance joint
= hot spot
Open = cold spot
Denver, CO 35
Detailed Status
Flow check:
chart – Where
are we in
Overall the
process process?
In process tests – overhaul –

after cleaning and baking
Denver, CO 36
In process tests – overhaul –

after cleaning and baking
• [R] Insulation resistance
(IR)
• [O] High potential
At 65% new winding level
Obtain customer approval
• [R] Surge test
• Some instruments can

perform all 3 tests
In process tests – rewind –

before and after burnout
Denver, CO 37
Stator core loss or loop test

• [R] Stator core loss
or
• [R] Stator loop test
• Limits before burnout:

≤ 4 watts/pound (8.8 w/kg)
≤ 27 °F (15 °C) hot spot
rise above ambient
Burnout process
• [--] Test stator core
before and after
burnout process
Denver, CO 38
Stator core loss test
Stator loop test
Denver, CO 39
Stator core loss or loop test

• [R] Stator core loss
or
• [R] Stator loop test
• Limits after burnout:

Watts loss after burnout
≤ 1.2x loss before burnout
≤ 4 watts/pound (8.8 w/kg)
≤ 27 °F (15 °C) hot spot
rise above ambient
In process tests – rewind –

before impregnation
Denver, CO 40

• [R] Machine rated voltage
versus IR test voltage
< 1000 500
1000 - 2500 500 - 1000
2501 - 5000 1000 - 2500
5001 - 12000 2500 - 5000
>12000 5000 - 10000

• Insulation resistance
(IR) test minimum
acceptable values
Denver, CO 41

• [R] Lead to lead, or
winding resistance test
Milli- or microohmmeter
• Resistance balance
tolerances
Random windings 2%
Form coil windings 1%

• [R] Random
2x rated voltage plus 1000
volts AC
(2x rated voltage plus
1000 volts) x 1.7 DC
• [R] Form wound

untreated “green coils”
Check with coil supplier
DC at no more than 1.7x
rated voltage
Denver, CO 42
Surge test
• [R] Surge test can identify
Shorted turns
Misconnections
volts
In process tests – rewind – after

impregnation
Denver, CO 43
High potential test – random

wound
• [--] If hipot tested before dip & bake
Hipot not needed
• Test levels DC if hipot test is desired

(2x rated voltage plus 1000 volts) x 1.36
• If not already tested at 80% (0.8) level
• If already tested at 80% (0.8) level
Notes:
• Test level AC if hipot test is desired 1.7 x 0.8 = 1.36
(2x rated voltage plus 1000 volts) x 0.8 1.7 x 0.65 = 1.11
High potential test – random

wound
• Hipot trip
Denver, CO 44
High potential test – form coil

• [R] Hipot test level
2x rated voltage plus 1000
volts AC
(2x rated voltage plus 1000
volts) x 1.7 DC

Ground for:
Denver, CO 45
Phase balance test

• [O] Perform test on stator
Checks for balanced windings
• Test parameters
Balanced 3 phase power
About 1/6 rated voltage
Expect about full rated amps
Amp balance ~5-6% for voltage
balance within 1%
• Example
460 volt stator rated 100 amps
Apply about 80 volts and expect
about 100 amps per lead
Phase balance test

• Actual example: 9000hp
4160 volt 1390 amp motor
• At 233-234 volts measured
299-305 amps per line
Denver, CO 46
Bearing ball rotation test

• [O] Bearing or large
bearing ball inserted
in stator bore
Stator energized at
reduced voltage
• Dummy rotor can be

more effective
Garage door roller
can be used
Bearing ball rotation test

• Dummy rotor
Denver, CO 47
Polarity test
• [O] Polarity test using
high current DC supply
Battery charger or welder
Apply to two motor
winding line leads
Polarity test
• Identify coil group polarity
with compass
Alternating = salient pole
• # of poles = # of groups per
phase
Same = consequent pole
• # of poles = 2x # of groups per
phase
• Photos at right:
Red light = south
Green light = north
Denver, CO 48
Polarity test
• Identify coil group polarity
Detailed Status
Flow check:
chart – Where
are we
Overall in the
process process?
Denver, CO 49
Pre-assembly tests

• [C] Apply test if one or
both bearings insulated
Insulation prevents or
reduces shaft current
If both bearings insulated
= test after assembly
• Use IR test
500 VDC test level – 1MΩ
minimum
Denver, CO 50

• [O] Measure shaft
magnetization with a
gaussmeter
• Perform if shaft was
welded during repair
Maximum allowable residual magnetic field levels
(measured in free air)
2 gauss Bearing components, bearing journals;
seals, gears and coupling teeth.
4 gauss Bearing housings.
6 gauss Mid-shaft and rotor core area.
Insulation power factor test

• [O, C] Also termed
dissipation factor test
Typically for windings
rated > 5kv with stress
grading tape or paint
Provides a baseline value
for future testing
Customer typically
specifies acceptance
criteria
Denver, CO 51
Post assembly tests -- static

• [R] Insulation resistance
(IR) test
Check that assembly did
not cause winding to
ground contact
< 1000 500
1000 - 2500 500 - 1000
2501 - 5000 1000 - 2500
5001 - 12000 2500 - 5000
>12000 5000 - 10000
Denver, CO 52

• Record final IR test result
Repair product safety
Reduce liability

• High potential testing
AC or DC
Rewound or not rewound
Denver, CO 53
High potential (hipot) test --

rewound
• [O, C] Hipot test level AC -- rewound
(2x rated voltage plus 1000 volts AC) x 0.8
High potential (hipot) test --

rewound
• [O, C] Hipot test level DC -- rewound
(2x rated voltage plus 1000 volts) x 1.7 x 0.8 DC
(2x rated voltage plus 1000 volts) x 1.7 x 0.65 DC
Notes:
• 1.7 x 0.8 = 1.36 1.7 x 0.65 = 1.11
Denver, CO 54
High potential (hipot) test – not

rewound
• [O, C] Hipot test level AC – not rewound
• [O, C] Hipot test level DC – not rewound
(2x rated voltage plus 1000 volts) x 1.11 DC

Ground for:
Denver, CO 55
Surge test
• [O] Assembled motor
versus stator only
surge test
Requires much greater
energy (joules)
Surge test
• Stator-rotor coupling
may make interpretation
difficult
Transformer effect
between stator (primary)
and rotor (secondary)
Offset surge test patterns
Rotate rotor to align surge
patterns
Denver, CO 56
Post assembly tests -- dynamic
Test run no load

• [C] Test run no load if prior
tests satisfactory
• Mount motor on baseplate
Bolt to make rigid
Place on resilient pads
• Other non-electrical
parameters can be measured
Denver, CO 57
Test run no load

• Test run no load
Test run no load

• Measure and record volts
and amps
Consider measuring watts
as benchmark for future
re-testing
• To assess effect of prior &
future repairs on efficiency
Denver, CO 58
Test run no load

• Evaluate no load current
Test run no load

• Pre-load roller bearings
To prevent damage to
bearing rollers and races
Denver, CO 59

• [O] Shaft to frame voltage
indicates probability of
bearing current
• Check large motors and
motors used on VFDs
Large motor: core OD > 48”

• Measure with true RMS AC
voltmeter
• Tolerance limits
Ball or roller bearings 100 mv
Sleeve bearings 200 mv
• If measured values exceed
limits
Bearing(s) need to be
insulated or add shaft
grounding brushes
Denver, CO 60

• [O, C] Test for partial
discharge (PD) activity
aka Corona
Typically windings rated > 5kv
• PD/corona
Air becomes ionized =
conductive
Ozone (O3) gas is generated
• Erodes winding insulation
• Ferrous parts (e.g., core)
oxidize

• Specialized test
equipment required
For details of testing, see
• IEEE 1415 IEEE Guide for
Induction Machinery
Maintenance Testing and
Failure Analysis
• IEEE 1434 IEEE Guide to
Measurement of Partial
Discharges in Rotating
Machinery
Denver, CO 61
Post assembly tests --

performance
Full load test

• [O] Test with motor
securely mounted on
baseplate
• Connect to dynamometer
Denver, CO 62
Full load test

• [R] Measure and record
volts and amps
Supply must be balanced
Current should be within
10% of rated
Full load test

• [R] Measure watts as
benchmark for future
re-testing
Assess effect of prior
repairs on efficiency
Denver, CO 63
Full load test

• [--] Measure non-electrical
parameters such as speed
and torque
Full load test

• [--] Efficiency: Precise
and accurate efficiency
measurement is beyond
service center capability
Denver, CO 64
Be sure you have a copy of the

2011 Select Presentations CD-ROM
It contains most of the handouts plus many complete

technical papers from this year’s quality lineup of speakers!
If you did not receive a CD in your packet
as part of your registration, you may purchase a copy for only $40.
Visit www.easa.com for more information.
Denver, CO 65

Electrical Testing of Three-Phase Motors

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Electrical Testing of Three-Phase Motors

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2011 EASA Convention • Denver, CO

Electrical testing -- safety

Electrical testing -- safety

Electrical testing -- safety

Electrical testing -- safety

Test types -- routine

Test types -- optional

Test types -- conditional

Incoming tests -- static

Insulation resistance (IR) test

Insulation resistance (IR) test

Winding rated voltage Insulation resistance

< 1000 500

1000 - 2500 500 - 1000

2501 - 5000 1000 - 2500

5001 - 12000 2500 - 5000

>12000 5000 - 10000

Insulation resistance (IR) test

Insulation resistance (IR) test

Insulation resistance (IR) test

Insulation resistance (IR) test

Insulation resistance (IR) test

Insulation resistance (IR) test

Polarization index (PI) test

Polarization index (PI) test

Polarization index (PI) test

Insulation power factor test

Winding resistance test

Winding resistance test

Winding resistance test

High potential (hipot) test

High potential (hipot) test

High potential (hipot) test

High potential (hipot) test

High potential (hipot) test

High potential (hipot) test

High potential (hipot) test

High potential (hipot) test

Hipot test -- impending failure

High potential (hipot) test

Hipot test -- Step voltage

High potential (hipot) test

High potential (hipot) test

Single phase rotor test

Single phase rotor test

Single phase rotor test

Shaft magnetization test

Shaft magnetization test

Maximum allowable residual magnetic field levels

4 gauss Bearing housings.

6 gauss Mid-shaft and rotor core area.

Incoming tests – dynamic

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