Electrical/thermal final tests on rotating electrical machines

Everey completed machine is subjected to a routine test to check its function and to verify that
customer´s requirements are met. Measured values are registered and recorded by means of
instruments forming part of a calibrating system. Results of routine tests are compared to those
of type tests of identical machines. Measured values must be within the limit values obtained in
the type tests; in addition, the symmetry of currents is checked. On request, test reports are
prepared.

Type tests are carried out on new types of motor to verify that the machine meets the specified
requirements. They are also carried out as in-process sampling tests. Primarily, type tests serve
to determine the rated values of particular machine. Measured values are computer-processed
and are entered as test results in the type test certficate.

In the list below, routine tests are marked „R“ and type tests are marked „T“. Some tests are part
of both routine and type tests.

Tests

0 General
1 Measurement of winding resistance at cold condition R T
2 Checking of direction of rotation R T
3 No-load measurements
3.1 No-load measurements at UN and fN R
3.2 No-load characteristic T
4. Short-circuit measurements
4.1 Short-circuit point at reduced voltage R
4.2 Locked rotor characteristic at reduced voltage T
5. Run-up characteristic at reduced voltage T
6. Heat run test
6.1 Heat run test at PN, UN and fN T
7. Load characteristic T
7.1 Load characteristic at UN and fN T
8. Winding tests
8.1 Measurement of insulation resistance R T
8.2 High-voltage tests on windings and auxiliary equipment R T
8.3 High-voltage tests on auxiliary equipment, built in windings R T
9. Measurement of shaft voltage
9.1 No-load measurement of shaft voltage at no load, UN R T
9.2 Inspection of bearing isolation, if available R T
10. Accessories
10.1 Inspection of accessories R T
10.2 Measurement of SPM-values R T
10.3 Temperature measurements on machines with sleeve bearings R T
11. Vibration measurement (R) T
12. Noise measurement (R) T

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Description of tests

0 General

All measurements are carried out with calibrated instruments.

Instruments for measuring voltage and current are at least of Class 0.5. Voltage and current
transformers used in the measurements are of Class 0.1. Outputs are measured using the Aron
connection (two-wattmeter circuit) with Class 0.2 instruments. Resistances are measured via
digital measuring bridges (injected current) with four conductors up to the motor terminals. Slip is
measured by means of slip coils and mirror galvanometer. With this method, slip is determined
from the rotor frequency shown; with lower slip values, speed is measured directly.
For noise measurements, precision sound level meters to IEC 651, Class 1 are used.
Vibration measurements are carried out using instruments in accordance with ISO 2954.

1 Measurement of windings resistance at cold condition

The winding, connected in star or delta, is fed with a constant current via two terminals, and the
voltage is measured at the motor terminals. From this, the resistance between terminals
U-V, V-W, and U-W is determined. In addition, the winding temperature is measured. In the
test certificates, winding resistance is referd to 20 ° C, i.e. values measured at temperatures
other than 20 ° C must be converted accordingly.

Principle construction of measurement:

V
V A V A

W V

W V
Star connection Delta connection

Conversion of measured values:

(235+20)
Resistance at 20°C R 20 = *R mess
(235+Winding temperature)

2 Checking of direction of rotation

When connecting the supply cable L1 to U, L2 to V, and L3 to W, the direction of rotation must
be clockwise, viewed from the D-end.

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3 No-load measurements

3.1 No-load measurements at UN and fN

No-load measurements, i.e. voltages, currents, and outputs, are carried out at rated voltage
+ 1 %, with the motor in cold condition.

3.2 No-load characteristic

As part of the type test, no-load characteristic is plotted, with the motor at operating temperature.
This curve consists of 6 measuring points, i.e. 3 measuring points around rated voltage and 3
measuring points at lower voltages. The measurements around rated voltage allow the exact
determination of data at rated voltage, whereas the measurements at lower voltages are used,
by means of regression calculation, to determine the friction losses. From the rated no-load
current and the winding resistance, the winding losses can be calculated, i.e. losses can be
differentiated: friction, iron and winding losses.

No-load characteristic (Example)

9 Characteristic
V=f(U)
8 linearised
(V=f(U^2))
7
Losses e.g. in kW

5
Iron losses
4

Total losses
3

2
Copper losses
1
Friction losses
0
0 0,2 0,4 0,6 0,8 1 1,2

Voltage (U/Un bzw (U/Un)^2)

4 Short-circuit measurements

4.1 Short-circuit measurements at reduced voltage

With the machine blocked by means of a defined lever (locked rotor) and energized with reduced
voltage, the following measurements are made: voltage, current and output. The force of the
lever is measured by built-in foil strain gauges.

4.2 Locked-rotor characteristic at reduced voltage

For the type test, the results of the measurements made under 6. Are extended to 3 measuring
points to obtain a curve from which the values at rated voltage can be extrapolated.

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5 Run-up characteristic at reduced voltage

The run-up characteristic is obtained by differentiation of the speed curve over time. For this
purpose, a voltage signal, proportional to the speed, is recorded by means of a tachogenerator
during a no-load, quasy stationary, run-up at low voltage. From the rise of the speed (voltage
signal), the torque curve can be calculated. The parameters of the torque curve are obtained
from the stationary measurements under 7.

Current and torque curve

Ia
6 3

Mk
5 2,5

4 2
Ma
Torque
Current

Torque

3 1,5
Current
Ms
2 1

1 0,5

0 0
0 0,2 0,4 0,6 0,8 1
Speed
Ma = Starting torque (taken from short-circuit curve)
Ms = Pull-up torque
Mk = Breakdown torque
Ia = Starting current

6 Heat run test

6.1 Heat run test at UN, PN, fN

For determining the thermal behaviour of a machine, a sustained heat run test is carried out until
temperatures have reached steady-state condition. For this purpose, the machine is coupled to a
D.C. machine which can be operated both as a motor and as a generator. The braking power in
the motor mode and the electrical power in the generator mode are fed back into the system.
The test is continued until the thermal steady-state condition to EN is reached.
Loading times depend on motor size and cooling method and can be up to 10 hours with large
rib-cooled machines, unless suitable steps are taken to reduce this time.
During the heat run test, various temperatures e.g. bearing, frame and cooling air temperature,
are reached, the machine is disconnected and the cooling-down curve is plotted. From this curve
the winding temperature rise in accordance with EN 60034 is determined and converted to rated
output.

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 Test arrangement (schematic)

3-phase supply system

Motor or Articulated shafts Generator

Generator or Motor
Coupling

Machine under test D.C. machine

Cooling-down curve of stator (Example)

20
19
R / mOhm
18
Resistance (mOhm)

17 First reading
after shutdown
16
15
14
Extrapolation
13
point to
12
EN 60034 (e.g.90s)
11
10
0 50 100 150 200 250 300

t/s

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7 Load characteristics

7.1 Load characteristics at UN and fN

Load characteristics are established at loads between 0.25 and 1.25 rated output. Voltage,
output, currents and slips are measured and recorded. Measured values are computer-
processed and issued in the form of tables.

Load characteristic of an 1800 kW, 6 kV motor

P / Pn Volt. Frq. Current Pinp. Poutp. eta cos Slip

V Hz A kW kW % %
1.25 6000 50 250,1 2333 2250 96,45 0,898 0,837
1,00 6000 50 198,6 1859 1800 96,80 0,901 0,647
0,75 6000 50 151,7 1393 1350 96,95 0,883 0,468
0,50 6000 50 109,2 931,1 900,0 96,65 0,821 0,301
0,25 6000 50 70,79 474,2 450,0 94,90 0,645 0,146

8 Winding tests

8.1 Measurement of insulation resistance

To determine the winding insulation resistance between conductors and earth (frame), calibrated
instruments are used.
The following resistances are measured:

a) Windings against earth (frame)

b) Space heater against earth

This check is carried out before the machine is energised for the first time.

8.2 High-voltage test on windings and auxiliary equipment

The high-voltage test on the winding is carried out in accordance with EN 60034, usually with
2UN+1000 V. Second tests only with 80 % voltage to protect the winding.
The following tests are carried out:
Winding(s) against earth (frame)
(built-in thermal detectors are earthed)

8.3 High-voltage test on winding and auxiliary equipment, built-in winding

For built-in thermal detectors, a test voltage of 1500 V is specified.

Measurement is carried out against earth (frame)

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9 Measurement of shaft voltage

9.1 No-load measurement of shaft voltage at no load, UN

Shaft voltages can lead to bearing damage if currents are allowed to flow. Shaft voltages are
measured on all machines above frame size 355. This is done by means of sliding-contact wires
between the two ends of the rotor shaft, with the machine running at no load and rated voltage.

9.2 Inspection of bearing insulation, if available

To prevent currents from flowing through the bearings are insulated. Depending on the type
bearing insulation (sleeve bearing, antifriction bearing, on one or both sides), a test arrangement
in accordance with internal test regulations is used. In this test, the bearing insulation is checked
either directly or indirectly. Results are recorded.

10 Accessories

Built-in space heaters

Built-in thermal detectors, e.g. for bearings
External fans
Brakes
SPM-adapters

10.1 Inspection of accessories

For space heaters a high-voltage test is carried out with 2 x UN (rated voltage of space heater)
+ 1000 V against earth
For built-in thermal detectors, e.g. for bearings, an insulation resistance test is carried out.
For all accessories a functional test is carried out and the conformity with connection-drawings
are examined.

10.2 Measurement of SPM-values

If built-in SPM-adapters are available, the bearing run is tested. Results are recorded.

10.3 Temperature measurements on machines with sleeve bearings

For a functional check of the sleeve bearings, a 2-hour no-load heat run test is carried out, during
which D-end and N-end bearing temperatures, and the temperature of the cooling medium are
measured (Pt 100) and recorded. The machine is released only if the temperature curves are
within specified limits.

11 Vibration measurement

Vibration measurements serve to verify the running smoothness of a machine. In accordance

with EN 60034, vibration velocity is measured at 6 points, i.e. at each bearing in horizontal,
vertical and axial direction. Permissible limit values for all speed ranges and frame sizes are also
stated in the above standard.

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12 Noise measurement

Test conditions, limit values, etc. for noise measurements are stated in EN 60034, Part 9. The
actual measurement and the location of measuring points are described in EN 21680, Part 2
and/or Part 3. Measurements are usually carried out to Accuracy Class 3, EN 21680, Part 2, with
the machine running at no load.
Measurements to Accuracy Class 2, EN 21680, Part 1, have to be agreed upon between
purchaser and manufacturer.

Established Inspected / Released

(Schmauck) (Wessel / Head of Testing Machines)

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