UNIT-III

TESTING OF D.C. MACHINES

by
Kumar Saliganti
Assistant Professor (C)
skjntum@gmail.com

Department of Electrical and Electronics Engineering

JNTUH University College of Engineering Manthani
TESTING OF D.C. MACHINES
CONTENTS :
❑ Objectives Of Testing
❑ Methods of Testing – direct, indirect and
regenerative testing
❑ Brake test
❑ Swinburne’s test
❑ Hopkinson’s test
❑ Field’s test
❑ Separation of stray losses in a d.c. motor test
 OBJECTIVES OF TESTING :
A DC machine has to be tested for
proper fabrication and trouble free
operation.
 From the tests one can determine the
external characteristics needed for
application of these machines.
 Also, one can find the efficiency, rating
and temperature rise of the machine.
 METHODS FOR TESTING
 There are different methods for testing of
DC Machines. They are :
1. Direct Method
2. Indirect Method
3. Regenerative method
(1) DIRECT METHOD :
 In this method, the DC machine is loaded
directly by means of a brake applied to a
water cooled pulley coupled to the shaft of
the machine.
 It is not practically possible to arrange
loads for machines of large capacity. So this
method is used only for testing of small dc
machines .
 Brake Test is an example of direct test.
(2) INDIRECT METHOD :
• In this method of testing, the losses are
determined without actual loading of the
machine.
• If the total losses in the machine are known,
the efficiency can be calculated.
• Swinburne’s Test is an example of Indirect
Test.
(3) REGENERATIVE METHOD :
• This method requires two identical dc machines.
One of the machines is operated as a motor and
drives the other machine as a generator.
• The electrical output of the generator is feedback
into the supply.Thus the power drawn from the
supply is small only to overcome the losses of
two machines.
• Hence the large machines can be tested at rated
load without consuming much power from the
supply.
• Hopkinson’s Test is an example of Regenerative
Method .
 BRAKE TEST OR LOAD TEST:
 To assess the rating of a machine a load test has to be
conducted.
 When the machine is loaded, certain fraction of the
input is lost inside the machine and appears as heat,
increasing the temperature of the machine.
 If the temperature rise is excessive then it affects the
insulations, ultimately leading to the breakdown of the
insulation and the machine.
 The load test gives the information about the efficiency
of a given machine at any load condition.Also, it gives
the temperature rise of the machine.
 The load test alone can give us the proper information
of the rating and also can help in the direct
measurement of the efficiency.
 Brake Test

Precaution: While performing this test with series machines care should be
taken that brake applied is tight failing Which the motor will attain
dangerously high speed and get damaged
Let , V= supply voltage measured by voltmeterV
I = Input current measured by ammeter A
W1 and W2 = Spring balance reading in Kg

N = Speed of armature in rpm

r = Radius of pulley
The net force acting on pulley is (W1−W 2) Kg OR

9.81(W 1 − W 2 ) Newton
Therefore, the torque developed by the motor
T = (W1−W 2 )* r kg-m OR

T =9.81*(W1−W2)*r N-m

Output of the Motor = T * w

2 N …..............(1)
= 9.81* (W1 −W 2)* r * watt
60

Input to motor =V IL……………................................ (2)

Efficiency of Motor= output/input,

 = 2N * 9.81 * (W 1 − W 2) * r
60 *VIL
LIMITATIONS :
1. Large amount of power is required to test a large
machine and the entire output power is wasted at the
mechanical brake.
2. Non- availability of large capacity load for testing large
motors in the laboratories.
Indirect method of Testing
● In this method, the m/c under test is not directly
loaded for determining its efficiency but its
performance characteristics is determined by using the
data obtained in no load test performed on the m/c.
Swinburne's test
● In this test, the machine under test is run as a motor
although it may be generator
● At no load, we apply the rated voltage across its terminals
and adjust its field current to run the motor at its rated
speed
● Under this condition its
1. No load line current Io
2. Field current Ish
3. Rated voltageVL are recorded
From which either constant losses or stray losses are
computed.
Swinburne's test
No load arm current of the motor is Iao = Io − Ish

Constant losses (Pc)=No load input – No load arm

copper loss
= V* Io− Iao 2 Ra
Extra:
Therefore,
stray losses = input on no load – shunt field copper
loss – armature copper loss

=V*Io−Ish2Rsh−Iao2Ra
From the detail plate of m/c, its full load current is known.
So ,let full load line current is IL
Then, input to motor on full load = VI L watts

Its armature current on full load, I a = I L − Ish

Full load armature copper loss = Ia 2 Ra
= ( I − Ish ) 2 Ra
L

Efficiency of the motor on full load = (input-losses)/input

V IL − Pc − (IL − Ish)2 Ra
=
V IL
 If machine under the test is generator having IL its full load
output current and V is the load voltage or terminal voltage

Then, output of generator on full load = VIL watts

Its armature current on full load, I a = I L + Ish
Full load armature copper loss = Ia 2 Ra
= ( I + Ish ) 2 Ra
L

Efficiency of the generator on full load = output/(output+losses)

V IL
=
V I L + Pc + (IL + Ish ) 2 Ra
Hopkinson's test
This is a regenerative test which requires two identical dc shunt
machines coupled mechanically and connected electrical in parallel.
One of the machines is operated as a motor and other as a
generator.
In this test, the mechanical power output of the motor is given to
the generator and the electrical power output of the generator is
given to the motor. Hence, this test is also called regenerative test or
back-to-back test.
The power input from the supply is only to meet the losses.
Therefore, this test is economical.
In this test stray losses are measured.
Hopkinson's test

Fig. Circuit diagram for performing Hopkinson's test on two dc shunt machines
Observation Table

Input Current Gen. Motor Motor Gen.

voltage v drawn Arm. Arm. field Field
volts from the Current Current Current Current
supply I2 A (I1+I2) A I3 A I4 A
I 1A

Total losses in both machines = VILo

VILo = Iag2Rag + Iam2Ram + stray losses in both machines
Stray losses (Ws) = VILo - Iag2Rag - Iam2Ram
Stray losses for each machine = Ws/2
Efficiency of the generator = output / (output+losses)

V I ag
=
V I ag + Iag2Rag + Ishg2Rshg + Ws/2

Efficiency of the motor = (input - losses) / input

V (Iam +Ishm) − Iam2Ram − Ishm2Rshm − Ws/2

=
V (Iam +Ishm )
❑ Advantages of Hopkinson’s test

➢ The temperature rise can be estimated during the test.

➢ The efficiency of the machine can be accurately determined at
various loads.
➢ The commutation conditions can be checked under rated load
conditions.

❑ Disadvantages of Hopkinson’s test

➢ Availability of two identical dc machines.

➢ It is impossible to separate out iron losses of the two machines
which are different because of different excitations.
 Field's test (for series motors)

Fig. Circuit diagram for performing Field’s test on dc series machines

By above fig. small series machines can be tested by direct load test, but the large series
machines cannot be tested by Swinburne’s test because series motor can not run at
No- load due to dangerously high speed .
Field’s test is applicable to two similar series machines. These two machines are
mechanically coupled and electrically isolated. One of machines are run as a motor
and drives the other machine as a generator.
A variable load is connected across the generator terminal.The output power of the
generator is wasted in a variable load resistance .This load resistance is varied till the
motor carries its full load rated current.
Observation Table
Supply Motor Generator Generator Motor
Voltage Armature Armature Output Voltage
V Current Current Voltage V1
I1 I2 V2

Let V = Supply voltage

I1 = Current taken by motor
I2 = Load current
V2 = Terminal p.d. of generator
Ra, Rse = Armature and series field resistance of each machine
Power taken from supply = VI1
Output obtained from generator = V2 I2
Total losses in both the machines, W T = VI1 - V2 I2
VI1 - V2 I2 = Iam2 (Ram + Rsem + Rseg ) + Iag 2Rag + stray losses in both machines
Stray losses (Ws) = VI1 - V2 I2 - Iam2 (Ram + Rsem + Rseg) - Iag2Rag
Stray losses for each machine = Ws/2
The stray losses are equally divided between the machines because of
their equal excitation and speed.

Generator Efficiency
Efficiency of the generator = output / (output + total losses)

V2 I2
=
V2 I2 + Iag2Rag + Iam2Rseg + Ws/2

Motor Efficiency
Efficiency of the motor = (input - total losses) / input

V1 I1 − Iam2 (Ram + Rsem) − Ws/2

=
V1 I1
❑ Advantages of Field’s test

➢ The actual performance of the machine is verified, i.e temperature

rise and commutation. Stray losses are considered and they are
equally divided, which is justified.
➢ The efficiency of the machine can be accurately determined at various
loads.

❑ Disadvantages of Field’s test

➢ Two identical dc series machines are required and hence, cost is high.
➢ The entire power drawn from the supply is wasted across load
resistance of generator.
Separation of stray losses in a d.c. motor test

3- POINT STARTER

DPST L Z A
FUSE 16A

300 Ω /2A (0-20A)

(0-2A) A A
A

1
220V DC
SUPPLY
(0-300V)
V 300 Ω /2A
M V
Min Z AA (0-300V)

2
16A ZZ
Observation Table
Field control method
Field current (If) Armature Voltage Armature Speed (N) Input Constant
S.No (Amps) (Va) Current (Ia) (r.p.m) VIa losses
(volts) (VIa-Ia2Ra)

Armature control method

Field current (If) Armature Voltage Armature Speed (N) Input Output
S.No (Amps) (Va) Current (Ia) (in r.p.m) VIa losses
(volts) (VIa-Ia2Ra)
At a given excitation, friction losses and hysteresis are proportional to
speed. Windage losses and eddy current losses on the other hand are
both proportional to square of speed. Hence, for a given excitation (field
current) we have,
Friction losses = AN Watts
Windage losses = BN2 Watts Hysteresis losses = CN Watts
Eddy current losses = DN2 Watts Where, N = speed.

For a motor on no load, power input to the armature is the sum of the
armature copper losses and the above losses. In the circuit diagram,
Power input to the armature = V*Io watts.
Armature copper losses = Iao 2*Ra watts
V*Io – Ia2*Ra = (A + C)N + (B + D)N
W/N = (A+C) + (B+D)N.
The graph between W/N & N is a straight line, from which (A+C) and
(B+D) can be found.
In order to find A, B, C and D separately, let the field current be changed
to a reduced value If and kept constant at that value. If, voltage is applied
to the armature as before,
we have ,
W = (A+C1) N + (B+D1) N2
(at the reduced excitation, friction and windage losses are still are AN and
BN2, but hysteresis losses become C 1N and eddy current losses become
D1N2. We can now obtain (A+C) and (B+D) as before.
Now,
C/C1 = (flux at normal excitation/flux at reduced excitation) D/D 1 = (flux
at normal excitation/flux at reduced excitation)
So, if we determine the ratio (flux at normal excitation/flux
at reduced excitation)
we can find
A, B, C, D, C1, & D1