Electrical Machines Rewinding and Maintenance

IPRC Musanze
Electrical and Electronics Engineering Department

Option: Electrical Technology
Year: Two
Semester: Two
Electrical Workshop Student’s Handout
Module Name: Electrical Machines Rewinding

&Maintenance
Student’s Handout
Prepared by: Leopold MUSENGIMANA, Instructor in electrical, email:

musengimanaleopold@yahoo.fr - Telephone: 0785212948
Revised: 2019
Contents
I. Course objectives........................................................................................................................4
1. Prerequisites...........................................................................................................................5
2. General Introduction...............................................................................................................5
3. Safety Practice ........................................................................................................................6
3.1. What is an Electric Shock .......................................................................................... 6
3.2. Safety Precautions ..................................................................................................... 7
3.3. Cautions when to Contact your Doctor ...................................................................... 7
3.4. First Aid for Electrical Burn Victims ......................................................................... 7
UNIT1: WINDING INSULATING MATERIALS ......................................................................................... 11
1.0. General Introduction......................................................................................................... 11
1.1. Electrical Properties .......................................................................................................... 11
1.2. Classification Of Insulating Materials ................................................................................. 11
1. Classification According to Substances and Materials ............................................. 12
2. Classification according to temperature................................................................... 12
1.3. Characteristics of a Good Insulating Material ..................................................................... 13
1.4. Applications of Insulating Materials................................................................................... 13
1.5. Insulating Materials Forms ................................................................................................ 13
1.6. Plastics Insulating Materials .............................................................................................. 14
1. Properties common to most of the plastics ............................................................... 14
2. Classification of plastic materials ............................................................................. 14
1.7. Insulating Varnishes .......................................................................................................... 15
1. Advantages of varnish coatings ................................................................................ 15
2. Classification ........................................................................................................... 15
3. Classification of Insulating varnish based on applications ...................................... 15
4. Special purpose varnishes Insulating varnish based on Curing method ................... 17
5. Method of applying varnish ..................................................................................... 17
6. Types of Insulating Varnishes for Various Applications .......................................... 17
2. Winding Wire........................................................................................................................ 18
1. General Introduction ............................................................................................... 18
2. Properties of Conductors ......................................................................................... 18
Prepared by: Leopold MUSENGIMANA, Instructor In Electrical.

3. Factors on which the Choice of a Conductor Material Depends on .......................... 19
4. Copper and Aluminium wires .................................................................................. 19
1. Copper wires............................................................................................................ 20
3. Enameled Wire ..................................................................................................................... 21
4. Grades of copper enamelled winding wires............................................................................ 23
5. Gauge Plate Reading ............................................................................................................. 24
UNIT 2: REWIND A THREE PHASE SQUIRREL CAGE INDUCTION MOTOR.............................................. 26
2.0. Terminologies used in Winding Diagrams................................................................................. 26
2.1. Details about the Winding Coil ............................................................................................... 27
2.2. Types and Shapes of Winding Wires ....................................................................................... 28
1. Round Wires............................................................................................................ 28
2. Rectangular straps ................................................................................................... 28
3. Stranded wires ......................................................................................................... 28
4. Applications ............................................................................................................. 29
2.3. Motor Rewinding Procedures/Repair Processes...................................................................... 29
2.3.1. Preliminary Inspection ............................................................................................ 30
2.3.2. Dismantling the Motor............................................................................................. 31
2.4. Motor Dismantling Procedures/steps................................................................................. 33
2.5. Removing the Old Windings and Cleaning the Core ............................................................ 35
1. Cutting and removing old burnt windings ............................................................... 35
2. Record and document all data taken........................................................................ 37
3. Winding calculation ................................................................................................. 37
4. Development of the diagram .................................................................................... 38
5. Cleaning the core and stator slots ............................................................................ 39
6. Inserting Insulation Papers in Slots ......................................................................... 40
2.6. Form the Coils ................................................................................................................... 41
1. Coil former preparation........................................................................................... 41
2. The Winding of Coils ............................................................................................... 42
2.7. Coil Insertion..................................................................................................................... 45
2.8. Coil configuration.............................................................................................................. 50
2.9. Coil insulation ................................................................................................................... 52
2.10. Binding the coils on the fan side ..................................................................................... 54

2.11. Binding the coils on the coupling side ............................................................................. 57
2.12. Insulation of the stator .................................................................................................. 61
2.13. Insulation measurement and testing .............................................................................. 62
2.14. Assembly of the housing ................................................................................................ 64
2.15. Testing the motor .......................................................................................................... 66
UNIT 3: VERNIER CALIPER MICROMETER READING ............................................................................ 68
3.1. Vernier Caliper .................................................................................................................. 68
3.1.1. Reading Vernier Calipers ........................................................................................ 69
3.1.2. Set-Up, Preparation and Measurements .................................................................. 71
3.1.3. How to use a Thread Pitch Gauge ............................................................................ 72
3.2. Micrometer Reading.......................................................................................................... 74
3.2.1. Main parts ............................................................................................................... 74
3.2.2. Micro-meter reading................................................................................................ 76
UNIT 4. THREE PHASE MOTOR WINDINGS DESIGN ............................................................................ 78
4.1. Motor Data Computation .................................................................................................. 78
UNIT 5. TESTING INDUCTION MOTORS ............................................................................................. 80
5.1. Testing a Three-Phase Induction Motor .................................................................................. 80
5.2. Electrical Tests to be conducted ............................................................................................. 81
5.2.1. Resistance Test .............................................................................................................. 81
5.2.2. Insulation Resistance Test ............................................................................................. 83
5.2.3. Activity.......................................................................................................................... 86
5.2.4. Test Report Sheet .......................................................................................................... 87
End ................................................................................................................................................. 87
I. Course objectives
After completing the course you should be able:
 To repair a burnt three phase induction motors

 To design a motor and then build one based on the computed data.
 Winding the stator coils
 Install and maintain the three phase induction motor.
 Identify materials needed for the given motor circuit installation and proper methods to
install them.
 Connecting up the coils
 Measuring the insulation resistance
 To read micro-meter and vernier caliper
 Winding design
 Computing the motor data.
 Identify possible electrical machine’s faults and methods to sort out.
1. Prerequisites
The prerequisites for working successfully through this course are:
 General knowledge of electrical engineering
2. General Introduction
You are employed in a company as an electrician or engineer responsible for a production line. Suddenly
the production line comes to a standstill. After a brief trouble-shooting phase it becomes clear that one of
the motors has failed.
You immediately disassemble the motor from the system and measure the insulation resistance of the
windings. The measurements show that there is a short-circuit between two windings in the motor. After
discussing the issue with the manufacturer you find out that delivery for this type of motor can take up to
three weeks due to the fact that the motor is not a standard type but a special model.
Your boss makes you responsible for solving this problem within the next four days because the company
cannot afford a more prolonged production loss period. Since there is no other alternative, you decide to
repair the machine yourself. By chance, you run across a manual which describes which materials you
need to build just such a machine.
Naturally, it also contains a description of the individual work steps needed to manufacture such a
machine. The tools and materials are quickly and easily obtained and within one day you can begin
winding the coils. You only have three more days left to complete the machine and re-assemble it in the
production line.... good luck!

3. Safety Practice
As quoted by the NIOSH states "Under dry conditions, the resistance offered by the human body
may be as high as 100,000 Ohms. Wet or broken skin may drop the body's resistance to 1,000
Ohms," adding that "high-voltage electrical energy quickly breaks down human skin, reducing
the human body's resistance to 500 Ohms.
3.1. What is an Electric Shock
An electric shock occurs when a person comes into contact with an electrical energy source.
Electrical energy flows through a portion of the body causing a shock. Exposure to electrical
energy may result in no injury at all or may result in devastating damage or death.
The danger from an electrical shock depends on the type of current, how high the voltage is, how
the current traveled through the body, the person's overall health and how quickly the person is
treated. An electrical shock may cause burns, or it may leave no visible mark on the skin. In
either case, an electrical current passing through the body can cause internal damage, cardiac
arrest or other injury. Under certain circumstances, even a small amount of electricity can be
fatal.
When a person is in contact with live wire, the followings can be resulted:
 Severe burns
 Confusion
 Difficulty breathing
 Heart rhythm problems (arrhythmias)
 Cardiac arrest
 Muscle pain and contractions
 Seizures
 Loss of consciousness

3.2. Safety Precautions
 Don’t touch supplied electrical cables with bare hands without purpose.
 Unplug the appliance or turn off the power at the control panel.
 If you can’t turn off the power, use a piece of wood, like a broom handle, dry rope or dry
clothing, to separate the victim from the power source.
 Do not try to move a victim touching a high voltage wire. Call for emergency help.
 Keep the victims lying down. Unconscious victims should be placed on their side to
allow drainage of fluids. Do not move the victim if there is a suspicion of neck or spine
injuries unless absolutely necessary.
 If the victim is not breathing, apply mouth-to-mouth resuscitation. If the victim has no
pulse, begin cardiopulmonary resuscitation (CPR). Then cover the victim with a blanket
to maintain body heat, keep the victim’s head low and get medical attention.
3.3. Cautions when to Contact your Doctor
A person who has been injured by contact with electricity should be seen by a doctor.
 Don't touch the injured person if he or she is still in contact with the electrical current.
 Call your local emergency number if the source of the burn is a high-voltage wire or
lightning. Don't get near high-voltage wires until the power is turned off. Overhead
power lines usually aren't insulated. Stay at least 20 feet (about 6 meters) away farther if
wires are jumping and sparking.
 Don't move a person with an electrical injury unless he or she is in immediate danger.
3.4. First Aid for Electrical Burn Victims
Electrical burns vary in severity depending upon:
How long the body is in contact with the electric current;
 The strength of the current;

 The type of current; and
 The direction the current takes through the body.

Often these burns are deep. There may be more than one area burned. One area may
be where the current entered the body and another may be where it left. Electrical
burn wounds may look minor on the outside, but could be severe on the inside.
If a person has received an electrical burn, check for shock and follow the steps outlined above
in safety precautions. If the person is conscious and there are no signs of shock (such as being
cold, clammy, pale and having a rapid pulse), begin treating the burned area.
Do not apply grease or oil to the burn. Cover the burn with a dry, sterile dressing, but do not cool
the burn. Keep the victim from getting chilled. Seek medical attention as soon as possible.
 If the casualty is unconscious but is breathing, loosen the closing about the neck, chest
and waist place casualty in the recovery position, then if he/she has wounds on his/her
back proceeds as shown in the figure below.

 Keep a constant check on the breathing and pulse rate; keep the casualty warm and
comfortable, so as to release the charged air.
 Gently apply a certain pressure on his chest/ or his back depending up on the wounds
location

 If the victim is not breathing (getting recoverd), apply the mouth to mouth method by
using a clean piece of cloth.
 If it is not easy to open victims mouth, then precede the mouth to nose method, with a
clean piece of cloth as stated above, or take the victim to hospital where they can use the
stored oxygen until the victim turns into the normal breathing.
 Figure below shows the equipment used to measure the human being breathing
(respiration) state.

UNIT1: WINDING INSULATING MATERIALS
1.0. General Introduction
The Electrical insulating materials are defined as materials which offer a very large resistance
to flow of current, and for that reason they are used to keep the current in its proper path
along the conductor. This is evident when we touch an electric machine when it is under
operation.
We don’t receive any electric shocks, because of the insulation. Breakdown of insulation results
in short circuiting of the coils, causing electric currents to flow in unintended paths . This may also
cause electric shocks to humans operating the machinery and also damage the machines.
Requirements of good insulating materials involve physical properties, reliability, cost,
availability, adaptability to machining operations etc.
Electrical insulation and dielectric materials includes various forms of materials that surround
and protect electrical conductors and prevent unwanted current flow, leakage. Electrical
specifications include electrical resistivity, dielectric strength, and dielectric constant.
1.1. Electrical Properties
 Electrical Resistivity: It is the electrical resistance (ohm-cm) to the flow of current

through it. Its value should be very high. Resistivity is the inverse of conductivity.
 Dielectric Strength: Dielectric strength is the maximum voltage gradient that the
material can withstand before electrical breakdown occurs. This value specified as
‘kV/mm’ should be very high even for very thin films.
1.2. Classification Of Insulating Materials

The insulating materials are classified in the following two ways:
 Classification according to substances and materials.

 Classification according to temperature.
1. Classification According to Substances and Materials
(i) Solid Insulating Materials [Inorganic and organic] Mica, wood, slate, glass, porcelain,
rubber, cotton, silk, rayon, terylene, paper and cellulose materials etc.
(ii) Liquid Insulating Materials [Oils and Varnishes] Refined hydrocarbon minerals oils,
Linseed oil, spirit and synthetic varnishes, etc.
(iii) Gaseous Insulating Materials Dry air, carbon dioxide, argon, nitrogen, etc.
2. Classification according to temperature
The insulating materials are classified mainly based on the thermal limit. The performance of the
insulation depends on its operating temperature. The higher the temperature, the higher will be
the rate of its chemical degrading, and hence the lower will be its useful life as shown in fig.1.1.
If a reasonably long life of insulation is expected, its operating temperature must be maintained
low. Therefore, it is necessary to determine the limits of temperature for the insulation, which
will ensure safe operation over its expected life.
This led IEC (International Electro technical Commission) to come up with the new categories:
 Class Y: 900 C: Paper, cotton, silk, natural rubber, polyvinyl chloride, etc. without
impregnation. (Formerly O)
 Class A: 1050 C: Same as class Y but impregnated, plus nylon.
 Class E: 1200 C: Polyethylene terephthalate (terylene fibre, melinex film), cellulose triacetate,
polyvinyl acetate enamel.
 Class B: 1300 C: Mica, fiberglass (alkali free alumino borosilicate), bituminized asbestos,
bakelite, polyester enamel.
 Class F: 1550 C: As class B but with alkyd and epoxy based resins, polyurethane.
 Class H: 1800 C: As class B with silicone resin binder, silicone rubber, aromatic polyamide
(nomex paper and fiber), polyamide film (enamel, varnish and film) and estermide enamel.
 Class C: Above 1800 C: As class B but with suitable non-organic binders; (Teflon, Mica,
Micanite, Glass, Ceramics, Polytetrafluoroethylene).

In the above classification Non-impregnated, moisture absorbing materials of Y- class are not
generally used for motor winding insulation purposes. Since they easily absorb moisture, their
quality quickly degrades. C-class materials are generally brittle, so they too are not suited for
motors. Insulation materials of A and B class are being used for a long time for winding
insulation purposes. In recent times F and H class are being increasingly used for winding
insulation.
1.3. Characteristics of a Good Insulating Material
A good insulating material should possess the following characteristics.
(i) Very high insulation resistance.

(ii) High dielectric strength.
(iii) Low thermal expansion.
(iv) Non-inflammable when exposed to arcing.
(v) Resistant to oils or liquids, gas fumes, acids and alkalies.
(vi) Should have no deteriorating effect on the material, in contact with it.
(vii) Good thermal conductivity.
(viii) High mechanical strength
(ix) High thermal strength.
(x) Should be resistant to thermal and chemical deterioration.
(xi) Should be resistant to moisture absorption.
1.4. Applications of Insulating Materials
They are:
 Between conductor /coils and earth (phase-to-earth),

 Between conductor /coils of different phases (phase-to-phase),
 Between turns in a coil (inter-turn) and
 Between the coils of the same phase (inter-coil).
1.5. Insulating Materials Forms

Insulating materials are available in different shapes and sizes. Insulating materials are available
as Tapes, rolls, sleeves, paper and cloth. Insulation Tapes and sleeves: Insulation tapes are used
cover the windings (coils) on the overhang side.
Shellac or varnish are applied over this covering to prevent it from absorbing moisture and
improve insulation strength. Tapes are sold as rolls in required lengths. Different types of
Insulation tapes available are: Cotton tape, PVC tape, Silk tape, Polyester tape, Asbestos tape,
Glass Fiber tape, Empire cloth tape, Mica tape.
1.6. Plastics Insulating Materials
A plastic in a broadest sense is defined as any non-metallic material that can be moulded to
shape. The most common definition for plastics is that they are natural or synthetic resins, or
their compounds which can be molded, extruded, cast or used as films or coatings.
Most of the plastics are of organic nature composed of hydrogen, oxygen, carbon and nitrogen.
1. Properties common to most of the plastics
 Light weight.
 Low thermal conductivity
 A wide range of colors
 Resistance to deterioration by moisture
 Low electrical conductivity Plastics,
2. Classification of plastic materials
 Thermoplastic and
 Thermosetting.
 Thermoplastic materials are those which soften on the application of heat, with or without
pressure but they require cooling to set them to shape.
Example: Polyethylene or Polythene, Polyvinyl chloride (PVC):

 Thermosetting materials are those plastics which require heat and pressure to mould them
into shape.
They are probably the most widely used and cheapest of thermosetting plastics. Strong, rigid and
dimensionally stable. Heat and solvent resistant.
Example: Used as Electrical appliance handles, TV and Radio cabinets
1.7. Insulating Varnishes
Varnish coating, also called Secondary Insulation, is an important component of the insulation
system of an electrical machine.
Varnishes, of different types are used in the insulation system of electrical machines for
impregnation and finishing applications.
1. Advantages of varnish coatings
 Increased mechanical bonding to the winding wires

 Improved dielectric properties
 Improved thermal conductivity
 Protection to the winding against moisture and chemically corrosive environment.
2. Classification
Varnishes are classified based on:
 Applications of varnish.
 Type of (varnish) curing method.
 Based on main raw material used in varnish.
3. Classification of Insulating varnish based on applications

 Impregnating varnish
 Finishing varnishes
 Core plate varnishes
 Bonding varnishes
1. Impregnating varnish:
The main function of impregnating varnish is not electrical insulation of current-carrying conductors. But
to fill the empty spaces in and around windings and to provide mechanical reinforcement of the loose
grouping of conductors, even at high temperatures.
The filling of empty spaces not only gives mechanical strength, but also hinders or prevents penetration of
unwanted substances from the environment. This gives the component improved resistance to chemical
attack, to moisture, thus extending its service life.
They are applied by dipping the component in the varnish, or less often by trickling process.
These type of varnishes needs to be cured (heated in a oven) at temperatures ranging from 100o c to
160oc for 2 to 12 hours time.
2. Finishing (coating) varnish:
Finishing varnishes are used not to strengthen the windings, but to protect the component from external
attack by environment conditions. They are applied purely as a surface coating, and are characterized by
outstanding film forming properties. Often applied by paint brush or sprayed, in repair shops after
rewinding works. They are mostly air drying type. It takes almost a day to completely cure.
3. Core plate varnish:
This varnish is applied to electrical laminations used in electrical machines. This acts as insulating layer
between successive laminations. It is baked at high temperatures, 350o -450o c for about 5 min.
4. Binder varnish:
This type of varnish is used as bonding agent between two insulating materials. Mechanically weak
materials when bonded show good rigidity. It is baked at temperatures of about 120o c to 450o c for
duration of 3min. to 60 min, depending on the grade of the varnish.

4. Special purpose varnishes Insulating varnish based on Curing method
a. Air drying type

b. Oven baking type
5. Method of applying varnish
 Applying a coating with a paint brush

 Dipping the specimen into varnish
 Vacuum pressure method
 Conveyorised dip method.
6. Types of Insulating Varnishes for Various Applications
 Clear baking varnish: Armatures, field coils and instruments.

 Black baking varnishes: Armatures, field coils and transformers when higher
electric strength and resistance to moisture, acids, and alkalies are wanted. They
have less resistance than those of clear.
 Sticking varnish: Cementing cloth, paper, mica etc.
 Core-plate varnish [air drying, baking and flashing]: Insulating armature and
transformer laminations. The air drying is not suitable for oil-immersed operation.
 Epoxy resin varnish [baking]: All coil impregnation, internal curing, where
superior durability and chemical and moisture resistance are required.
 Silicone resin varnish [air drying and baking]: Motor stators and rotors,
transformers, coils, for high temperatures and high-humidity service.
 Polyester resin varnishes [baking]: Motor stators and rotors, transformers, coils,
for high temperature service not so severe as to require silicones.
 Phenolic varnishes [baking]: Hermetic motor coils and bonding of form wound
coils.

2. Winding Wire
1. General Introduction
Winding wire is solid wire, which, to allow closer winding when making electromagnetic coils,
is insulated only with varnish, rather than the thicker plastic or other insulation commonly used
on electrical wire. It is used for the winding of electric motors, transformers, inductors,
generators, speaker coils, etc. A wire is a single, usually cylindrical or rectangular cross-section,
length of metal. Wires are used to carry electricity and telecommunications signals. Wire is
generally formed by drawing the metal through a hole in a die or draw plate. Standard sizes are
determined by various wire gauges.
The term wire is also used more loosely to refer to a bundle of such strands, as in ‘multi-stranded
wire’, which is more correctly termed a wire rope in mechanics, or a cable in electricity. The
metals must in the first place be ductile and strong in tension, the quality on which the utility of
wire principally depends. The metals suitable for wire, possessing almost equal ductility, are
platinum, silver, iron, copper, aluminium and gold; and it is only from these and certain of their
alloys with other metals, principally brass and bronze, that wire is prepared.
By careful treatment extremely thin wire can be produced. Copper wires could be plated with
other metals, such as tin, nickel, and silver to handle different temperatures, provide lubrication,
and provide easier stripping of rubber from copper.
Wire used to carry electricity is made up of materials having very low resistivity such as pure
copper or aluminium.
2. Properties of Conductors
Electrical Properties:
 The conductivity must be good.

 Electrical energy dissipated in the form of heat must be low.
 Resistivity must be low
 Temperature resistance ratio must be low.
Mechanical Properties:
 Good Ductility: It is that property of a material which allows it to be drawn into a wire.
 Solder-ability: The joint should have minimum contact resistance.
 Resistance to corrosion: Should not get rusted when used outdoors.
 Withstand stress and strain.
 Easy to fabricate.
Economical Factors:
 Low cost
 Easily available
 Easy to manufacture Characteristics of a Good Conductor Material: The conductor
materials should have low resistivity so that any amount of power can be transmitted
without much loss in the conductor.
3. Factors on which the Choice of a Conductor Material Depends on

 Resistivity of the materials
 Temperature coefficient of resistance
 Resistance against corrosion
 Oxidation characteristics
 Ease of soldering and welding
 Ductility.
 Mechanical strength
 Flexibility and abundance
 Durability and low cost
 Resistance to chemicals and weather Commonly Used Conductor Materials
4. Copper and Aluminium wires

1. Copper wires
a. Pure copper is one of the best conductors of electricity and its conductivity is
highly 16 sensitive to impurities.
b. It is reddish-brown in color.
c. It is malleable and ductile.
d. It can be welded at red heat.
e. It is highly resistant to corrosion.
f. Melting point is 10840 C
g. Specific gravity of copper is 8.9.
h. Electrical resistivity is 1.682 micro ohm cm.
i. Its tensile strength varies from 3 to 4.7 tones/cm2 .
j. It forms important alloys like bronze and gun-metal. Copper is very widely used
in wires, cables, windings of generators and transformers, overhead conductors,
bus-bars.
It is obtained by drawing cold copper bars into conductor length. It is used for overhead line
conductors and bus-bars. Annealed copper (Soft Copper) conductor is mechanically weak having
a tensile strength of 20 kg/mm2.
It can be easily shaped into any form. Low-resistivity Hard Copper is used in power cables,
windings, and coils as an insulated conductor. It has high flexibility and high conductivity.
2. Aluminium:
 Pure aluminium has silvery colour and polish. It offers high resistance to
corrosion.
 Its electrical conductivity is next only to that of copper.
 It is ductile and malleable.
 Its electrical resistivity is 2.669 µΩ- cm (micro ohm- cm) at 200 C
 It is good conductor of heat and electricity.
 Its specific gravity is 2.7.
 Its melting point is 6580 C.
 It forms useful alloys with iron, copper, zinc and other metals.

 It cannot be soldered or welded easily.
Aluminium is most often used as overhead transmission conductors, bus-bars, and ACRS
conductors. Well suited for cold climate.
Comparison of Copper and Aluminium as conductors for Power Transmission Lines
3. Enameled Wire
Enameled wire is a wire coated with a very thin insulating layer. The core material (‘wire’) is
copper or aluminum, coated with a thin layer of a polyurethane, polyamide, or polyester resin -
called as “enamel”.
The thin layer of insulation coated on Enameled wire, prevents the wire surfaces from being in a
short circuit when wound into coils. It is used mainly in the construction of motors,
electromagnets, transformers and inductors.
For ease of manufacturing inductive components like transformers and inductors, most new
enameled wire has enamel that acts as a flux when burnt during soldering.

This means that the electrical connections at the ends can be made without stripping off the
insulation first. Older enameled copper wires normally require sandpapering or scraping to
remove the insulation before soldering.
Enameled wires are classified by their diameter (as SWG number) or area (square millimeters),
temperature class and insulation class.
Enameled wires are manufactured in both round and rectangular shapes.
 Rectangular wire is used in larger machine windings to make the most efficient use of
available winding space.
 Breakdown voltage depends on the thickness of the covering, which can be of 3 types:
Grade 1, Grade 2 and Grade 3.
 Higher grades have thicker insulation and thus higher breakdown voltages. The
temperature class indicates the temperature of the wire at which it can have a 20,000 hour
service life.
 At lower temperatures the service life of the wire is longer (about a factor 2 for every 10
°C lower temperature). Common temperature classes are 120, 155 and 180 °C.

Table: Standard wire gauge and equivalent sizes in mm and inch.
4. Grades of copper enamelled winding wires
a. Solderable Polyurethane Enamelled Round Copper Wire, Class 130, with a

Bonding Layer
b. Solderable polyurethane enamelled round copper wire. It has thermal capacity of
120°C, 130°C and 155°C. The diameter ranges from 0.08 mm to 1.00 mm and can
be used in Transformers, Meters, Electronic and Communication Devices.
c. Polymide- imide enamelled round copper wire, Class 200
d. Paper Covered Rectangular Copper Wire

e. Polyesterimide enamelled rectangular copper wire. It has Thermal Capacity of
180°C. These types of enamel wire are used in High Power Motors.
f. Polyester or Polyesterimide over-coated with Polyamide-imide Enamelled Copper
Wire. With thermal capacity of 200°C and diameter range from 0.1mm to 1.6mm,
they are used in Microwave oven, Transformer and Air-conditioning Motors.
g. Polyester Enamelled Round Copper Wire, Class 155. Polyester Enamel wire can
be used in Motors for Household Application and Appliances. 8. Glass-fibre
Wound, Polyester or Polyesterimide Varnish-treated, Bare or enamelled
rectangular copper wire, temperature index 180
h. Glass-fiber wound, polyester or polyesterimide varnish-treated, bare or enamelled
rectangular copper wire, temperature index 155
i. Glass-fiber wound, silicone varnish treated bare or enamelled rectangular copper
wire, temperature index 200
j. Polyester Enamelled Round Copper Wire, class 130 L
k. Glass-fiber braided, polyester or polyesterimide varnish-treated, bare or
enamelled rectangular copper wire, temperature index 180
l. Aromatic polymide tape wrapped round copper wires, Class 240
m. Aromatic polyimide tape wrapped rectangular Copper wire, Class 240
5. Gauge Plate Reading
The sizes of wire are estimated by a device, called gauges, which consist of plates of circular or
oblong form having notches of different widths around their edges.
Each notch is stamped with a number, and the wire which just fits a given notch, is stated to be
of, say, No. 10, 11, 12, etc., of the wire gauge.
The circular forms of wire gauge measurement devices are the most popular, and are generally 3
3/4 inch. (95 mm) in diameter, with thirty-six notches; may have the decimal equivalents of the
sizes stamped on the back. Oblong plates are similarly notched.
Many gauges are made with a wedge-like slot into which the wire is thrust; one edge being
graduated, the point at which the movement of the wire is arrested gives its size.

The graduations are those of standard wire, or in thousandths of an inch. In some cases both
edges are graduated differently to serve for comparison between two systems of measurement. A
few gauges are made with holes into which the wire has to be thrust. All gauges are hardened
and ground to dimensions.
In some applications wire sizes are specified as the cross sectional area of the wire, usually in
mm². Advantages of this system include the ability to readily calculate the physical dimensions
or weight of wire, ability to take account of non-circular wire, and ease of calculation of
electrical properties.
This determines the amount of electric current a wire can safely carry, as well as its electrical
resistance and weight per unit of length. Wire gauge is applicable to both electrical and non-
electrical wires, mostly used in electrical wiring.
The basis being the mil. No. 7/0, the largest size, is 0.50 in. (500 mils or 12.7 mm) in diameter,
and the smallest, No. 50, is 0.001 in. (1 mil or about 25 µm) in diameter. Between these, the
diameter, or thickness, decreases by 10.557%, and the weight reduces by 20%.
The ‘mil’ denotes one thousandth part of an inch (more commonly denoted as ‘thou’). The
circular mil is the equivalent area of a circle whose diameter is 0.001" (10-3) inch.
This can also be expressed as the diameter in thousandths of an inch raised to the power 2 and
may or may not be rounded to the nearest ten. The circular mil is an old unit of cross sectional
area, used for denoting the cross-sectional size of an electrical conductor or cable.

UNIT 2: REWIND A THREE PHASE SQUIRREL CAGE INDUCTION MOTOR
2.0. Terminologies used in Winding Diagrams
 Conductor: An individual piece of wire placed in the slots in the machine in the
magnetic field.
 Turn: Two conductors connected in series and separated from each other by a pole pitch
so that the emf induced will be additive.
 Coil: When one or more turns are connected in series and placed in almost similar
magnetic positions. Coils may be single turn or multi turn coils.
Figure: 3 turns coil
 Winding: Number of coils arranged in coil group is said to be a winding.

 Pole Pitch: Distance between the poles in terms of slots is called pole pitch.

2.1. Details about the Winding Coil
A length of wire lying in the magnetic field and in which an emf is induced is called a coil. The
coils used in windings are shown in Fig. below
Fig. - Winding Coil representation
Active side of a coil: It is the part of a coil which lies in the slots under a magnetic pole and emf
is induced in this part only. In Fig. above, coil sides AB and CD are called as active sides. For a
double layer winding, one half portion of the coil drawn with solid line corresponds to the coil
side lying on the top of a slot, and the dotted line corresponds to the coil side lying in the bottom
layer of another slot. This type of representation is used for double layer winding. For a single
layer winding, the complete coil is represented by a solid line.
Inactive side of a coil: The inactive side of a coil consists of two portions, namely the front end
side and the back end side. The portion of the conductor which joins the two active sides and
placed around the core is called the back end side of the coil. The portions which are used to
connect other coils are called front end side.
Coil Groups: One or more coils connected in series are called coil groups. The number of coil
groups is equal to the number of poles.

In Fig. above there are four coil groups, which are equal to four numbers of poles. For AC
winding, the total number of coil groups depends upon the number of poles and the number of
phases.
 The total number of Coil groups = mP
 Also, total number of coil groups/phase = 3
 Where m = number of phases P = number of poles.
2.2. Types and Shapes of Winding Wires
The winding wires used in electrical motors are classified as follows.
 Round wires
 Rectangular straps
 Stranded wires
1. Round Wires
It has thin and thick conductors and is used in semi-closed slot type motors and mush winding
rotors. It is wounded in reels and available in Kilograms.
2. Rectangular straps
It is used in open type slot motors. These conductors are available as long straps in meters.
3. Stranded wires
Stranded wire is composed of a bundle of small-gauge wires to make a larger conductor.

Stranded wire is more flexible than solid wire of the same total cross-sectional area. Stranded
wire is used whenever ease of bending or repeated bending are required.

Such situations include connections between circuit boards in printed-circuit-board devices,
where the rigidity of solid wire would produce too much stress as a result of movement during
assembly or servicing; A.C. line cords for appliances; musical instrument cables; computer
mouse cables; welding electrode cables; control cables connecting moving machine parts;
mining machine cables; trailing machine cables; and numerous others.
a. Cotton covered insulating wire

b. Silk covered insulating wire
c. Paper insulated wire
d. Varnish coated glass paper covered wire
e. Enamel coated round shaped wire.
Note: Usage of alternate sizes 1. If rewinding is done, use the existing winding wire gauge
number for the new winding. Sometimes if same gauge winding wire is not available then we
can use the 2 runs of wire each having half of the area of cross section of the original one.
4. Applications
They are used in the following places.
 Low voltage motor windings.

 Used as conductor in high current motor.
 Series field motor winding coils.
2.3. Motor Rewinding Procedures/Repair Processes
Most repair processes, if done improperly can reduce motor efficiency. Conversely doing them
well will maintain and may improve the motor efficiency. It is always to keep clear, concise
written records throughout the repair process. Therefore this inspection can yield much useful
information.
The main motor rewinding processes include:
 Preliminary inspection (motor tests).

 Dismantling the motor.
 Documenting (recording) and removing the old windings and cleaning the core.
 Rewinding the motor.
 Mechanical repairs.
 Reassembling the motor and testing the motor to the 3 phase supply.
2.3.1. Preliminary Inspection
The preliminary inspection forms an important part of the complete motor repair record and may yield
vital clues about the cause of failure. It is important to include all data sources on a data card. In
particular record the following information:
1. Record all data on the name plate
Power: ……… kilowatts Frame number: ………….

Voltage: …… Volts Manufacturers name: ……………………..
Connection: Star/ delta Ambient temperature: ……………..
Rated current: Amperes Motor weight: …… kilograms
Frequency: Hz Motor type: …….. Example: 3phase motor
Insulation class: Example: F Power factor: Example: 0.9
Motor speed in: Rpm Duty cycle: ……….
Remark:
 Record all the data on the name plate, some codes, numbers or letters which seem
meaningless may be very important.
 If it is necessary to contact the manufacturers for information, please do it.
 The motor can have more than one nameplate in case repairers have added another
nameplate to indicate that the motor was rewound.
 Check whether the motor is for use in hazardous environment.
2. Results from external inspection
Look for and record:
 General condition old/new, dirty/clean, etc.

 Cooling air ducts clear/ obstructed may have caused overheating.
 Shaft dis-colorated (brown/blue) – sign of rotor overheating or bearings seizure.

 Parts missing damage or previously replaced/repaired (example: covers, seals, terminal box, fan
cover, etc).
3. Customer input
Technicians /re-winders should ask information from the customer so as to identify the cause
root of the motor failure:
Customers may be able to provide:
 Operating environment temperature

 Type of driven equipment
 How many hours/ days do the motor run?
 Approximate motor load.
 Type of starter and how often it is it is started.
 Power supply and starting methods.
 Unusual events eg: power outage, lightening strike, problem with driven equipment.
2.3.2. Dismantling the Motor
It is essential to dismantle the motor carefully and keep adequate records to ensure that if the
motor is repaired it can be reassembled correctly.
1. Terminal box layout and connections.
 Record marking on both winding leads/end terminals.

 Record position of any links between terminals and make a sketch/motor windings end
connections.
 Check that the insulations on winding leads immediately adjacent to terminals do not
show any signs of overheating.
 Record size and type of lead wire.
 Confirm that all terminals are firmly crimped or blazed to winding leads.
2. Orientation of end bracket and bearing caps.

 End bracket and stator frame are rabbet fits are not always perfectly circular, end
brackets and bearings should be installed in exactly the same position as originally fitted.
Therefore indelibly mark all end brackets and stator frame at both ends of the motor.
Example: by marking the center punch.
3. Bearing size, type and clearances.
Most motors have a ball bearing at each end. Some may have a roller bearing at the drive end to
increase the radial load capacity or thrust bearing for high axial loads. Always fit new bearings
of the same type as those removed, unless there were misapplied.
The following items are critically important in bearing selection:
 Bearing enclosure
 Fit and tolerance
 Precision class
 Internal clearance
 Load application
 Type of lubricant
4. Orientation of shaft with respect to the main terminal box.
Document the mounting position of the shaft in relation to the leads, some repairers describe this
as lead left facing shaft or shaft right facing leads.
5. Axial position of rotor relative to stator.
The rotor should be centered axially within the stator core, if it is displaced axially, centering
forces will exert pressure on the bearings.
6. Mechanical damage to components or signs of misuse.
Mechanical damage may affect motor performance, and then look for:
 Damage to fan or fan cover.

 Damaged or blocked cooling ducts/ channels.
 Shaft discoloration adjacent to either bearing (overload or misalignment)

2.4. Motor Dismantling Procedures/steps.
Step 1: Remove the shaft key or grub screw holding the pulley
Step 2: Remove the pulley by using a suitable pulley puller
To avoid confusion make a single punch mark on one side and a dual punch mark on the
other end of the motor.
Step3: Remove the grease cup screw; make a centre punch alignment mark on the stator and the
end shield cover.
Step 4: Loosen the bolts gradually, switching from side to until they can be removed.

Step 5: Keep the cold chisel tip between the stator and con and gently tap the chisel with a
hammer and separate the stator and the end shield cover
Step 6: Pull off the end shield cover and rotor together parallel to the motor shaft
Step 7: Hold the shaft in one hand, rotate the end cover and tap it lightly with a nylon mallet to
remove it from the rotor.
Step 8: Remove the end shield cover also by gently priming it out, inspect the rotor for any
defect and the bearings for its condition.

Step 9: If the bearing is worn out replace it with a new one. All fastening devices should be kept
in a separate tray, and then the dismantled parts are shown below.
2.5. Removing the Old Windings and Cleaning the Core
While doing rewinding, you should remove the old burnt windings from the stator frame by
using the winding cut off machine or the traditional method of using the chisel. Then after
cutting windings on one side use the controlled temperature burnout oven as shown in figures
below, thereafter clean the stator core.
1. Cutting and removing old burnt windings
Step 1: Cut all coils to one side of the machine by using a chisel or windings cutt off machine

Figure: windings cutt off machine
Step 2: With a long flat ended nail and the nylon mallet, gently tap the coils in each slot of the
machine or use the tempetature controlled burnout oven, then with your hands pull out the coils.

Figure: Controlled temperature burnout oven.
2. Record and document all data taken
 Record all data on the name plate

 Old winding details that includes the following:
 Existing coil diameter with and without insulation by means of the vernier caliper or by
using the micro-meter,
 The overhang( back end sides of the coil) length on both sides
 Slot length
 Slot lower and upper width
 Number of slots of the machine
 Number of parallel wire
 Number of turns/coils
3. Winding calculation
In order to repair/rewind the motor as the original existing coils the following motor data must be
computed:
1. Given data:

After checking the motor faults and record all necessary information, the following data
allows you to make your calculations;
 Motor type: single phase or three phase types

 Windings configuration: single layer or double layer
 Winding distribution details: balanced distributed (equal size) or unbalanced distributed
(unequal size).
 Number of slots
 Number of poles
2. Calculations to be done
𝑇𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑙𝑜𝑡𝑠

a) Number of slots per phase = 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝ℎ𝑎𝑠𝑒𝑠
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑙𝑜𝑡𝑠 𝑝𝑒𝑟 𝑝ℎ𝑎𝑠𝑒

b) Number of slots per pole =𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑚𝑎𝑐ℎ𝑖𝑛𝑒𝑠 𝑝𝑜𝑙𝑒𝑠
c) Number of coils per pole =Number of slots per pole
d) 360 Mechanical degrees = 360 Electrical degrees = Total number of motor slots
e) Always the alternating current changes direction after 180 electrical degrees, therefore
this formula can be used to calculate the slot after which it will change direction:
𝑇𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑙𝑜𝑡𝑠 ∗180

360 ∗𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑎𝑖𝑟 𝑜𝑓 𝑝𝑜𝑙𝑒𝑠
f) The winding 1 (phase1) always starts at slot number one taken according to the
technician’s wish.
g) The winding 2 (phase2) starts after 120 electrical degrees hence it will starts after;
360 ∗𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑎𝑖𝑟 𝑜𝑓 𝑝𝑜𝑙𝑒𝑠
h) The winding 3 (phase3) starts after 240 electrical degrees hence it will starts after;

360 ∗𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑎𝑖𝑟 𝑜𝑓 𝑝𝑜𝑙𝑒𝑠
4. Development of the diagram

Example of diagrams
5. Cleaning the core and stator slots
The following methods have been approved to be used while removing and cleaning stator slots
burnout insulations for preparing new coils:

 Careful scraping: using a sharp knife to separate the remaining pieces of slot liner
materials from the stator cores.
 High pressure washing: using a domestic high pressure washer.
 Abrasive blasting: using mildly abrasive material such as walnut hulls, crushed
corncobs or plastic beads. Blasting with more abrasive materials like sand, crushed flint,
ceramic pellets or even glass beads may cause surface shorting of the laminations which
increase core and stray losses.
 Wire brush: using a medium soft wire brush. Avoid using files or grinders to remove
slot insulation. These can smear the laminations together and increase eddy current near
the air gap surfaces of the core.
6. Inserting Insulation Papers in Slots
Steps 1: Cut insulation papers according to the motor slots, In order to prevent the coils that are
subsequently inserted into the groove slots from making contact to the stator you must first slide insulator
slot paper into the grooves.
Step 2: Slide these slot insulators into all of the slotted grooves.

Step 3: Further preparations include cutting two pieces of wire corresponding to the previously computed
lengths and bending them into two loops. Place these into the grooves to check whether the calculated
lengths are correct. Leave a gap of 6 unoccupied groove slots on the outer coil and four slots free on the
inner coil. On both sides of the stator the winding loops should appear protruding out as shown in the
picture.
2.6. Form the Coils
1. Coil former preparation
Step 1: Take this gauge or reference winding out of the stator and place it around the winding template.
Step 2: The outer and inner coils should also be insulated where they connect so their connection line is
insulated. The insulating hose (0.5 mm) is used as an insulator for this and has to be correctly measured.
To do this cut a section of approx. 5 cm from the roll. Place this section into the stator and check whether
this piece of hose is 5 groove slots long.

Step 3: The connection line between the inner and outer coils has a length of 5 groove slots (see image).
Take two pieces of tape and attach them in front and behind the winding roller so that the roller can only
move above the reference length for the inner coil. If the winding roller is not fixed in this fashion during
the reeling of the winding it is possible that the roller drifts too far to the right or left thus yielding the
wrong coil gauge.
2. The Winding of Coils
Step 1: Pull the insulation over the wire and attach this to the arm so that the wire is positioned directly
above the gauge length for the outer coil (marked by the strip of tape on the winding template). Attach the
starting end of the wire to the winding machine.

Step 2: Hold the wire tightly between the fingers of your right hand and crank with your left hand. Make
sure that you don't squeeze your fingers too tightly together as this might distort or stretch the wire
adversely affecting the cross-section and thus altering the conductor resistance. Any stretching of the
conductor causes tapering and the same current which might flow through a larger cross-section has to
"squeeze" through a smaller cross-section. This might lead to excessive heat buildup in the wire causing
the insulation to melt with the result that a short-circuit could arise.
Step 3: Wind the coil until the number of winding turns initially calculated is reached on the counter
(280). Then detach the insulation hose from the arm and slide it down to the winding template. Then take
the wire and place it over the winding roller wheel to wind the inner coil. Briefly press the red counter
reset button to set the counter to 0. Make sure that the insulation hose does not protrude too far over into
the channel for the inner coil as this can prevent the coil from being wound cleanly. Now wind the inner
coil and make sure again the wire is not being held too tightly or too loosely in your fingers.

Step 3: Keep turning the coil winding until the counter indicates 280 turns.
Step 4: Before you can remove the winding template with the coil, you have to tie the coils using wires so
that they do not fall apart and come un-raveled. Use wire to tie your coils on both sides.
Step 5: Cut the two ends of the wire with a length of 10-15 cm. These two ends are used to connect the
coils to the terminal board and connect the coils to each other.

Step 6: Remove the winding templates from the winding machine and carefully take the coils out of the
templates. The first coils are finished and can be inserted into the stator.
2.7. Coil Insertion
Step 1: When the coils are inserted into the stator always start with the inner coil. Use your hands to bend
the coil into an oval shape so that you can insert the coil into the stator without touching the grooves. The
wires used to attach the coils are slide to the outer sides of the coil (see image).
Step 2: Make sure that when you insert the coils into the stator you orient them so that the end of the coil
(need for connection of the terminal board) peeks out onto the side where the duct to the terminal board
is. First place two folded open slot insulators into a given groove. The insulators are supposed to ensure
that the wire is not damaged when inserted into the groove. Furthermore it also guarantees that none of
the winding turns accidentally slip past the slot insulation and thus come into direct contact with the
stator. An additional benefit is that thanks to these insulators it is easier fit the coil into the groove slot.

Step 3: First the winding that is connected to the terminal board is inserted into the groove. The
connections for both the terminal board and for the coil connections should always be located at the outer
periphery of the stator to avoid complications later on during connection wiring.
Now insert one side of the coil into the groove slot. Make sure here that you do not twist it too much as
otherwise it becomes more difficult to insert.
Once one side of the coil is inserted into a groove you can remove the insulators you used to assist in the
coils insertion. Afterwards slide a slot liner into the slot over the inserted coil side. Make sure here that all
of the windings are located between the slot liner and slot insulation.

Step 4: To hold the coil in place and prevent it from slipping out of the groove at a later date slide a
wooden slot closure in to seal off the groove.
Step 5: You have now finished inserting the one side of one inner coil. Now lets take the the circuit
diagram into consideration. You have laid the side of the coil into the groove slot at which the end of the
wire used for connection sticks out. Now you can see from the circuit diagram that now this can be one of
the slots 3, 7, 11, 15, 19 or 23. Precisely which one this is can now be selected as desired. Let's just
simply decide to call this groove slot the number 11 slot. The other side of the inner coil must be inserter
accordingly into slot 6.
Step 6: Proceed in precisely the same manner as with the first side when inserting the opposite coil side.

Step 7: Use your fingers to bend the coil so that the corners are bent at an angle. The front side should
almost be straight.
Step 8: Bend the other side of the coil in the same way. Finally press the side protruding out as far down
as possible. This is necessary to preserve as much space as possible for the subsequent coils.
Step 9: Proceed in precisely the same fashion with the outer coil. Again refer to the circuit diagram and
carefully consider how the outer coil has to be integrated. Again make sure that the end of the coil is
sticking out on the correct side of the stator. Again bend the outer coil at the protruding sides as
previously almost straight and then bend this downwards as far as possible to save space.

Step 10: The insulation of the connection wire for both coils is found on the other side.
Step 11: Push about 7 cm of 0.55 insulation hose onto the ends of the coils and label these wires. To do
this refers to the following circuit diagram for assistance. Print the winding scheme out (available on the
CD in PDF format) and place it as close as possible to where you are working. This will help to prevent
faulty circuitry.
Step 12: If we have designated the first coil as v1, this automatically means that the end of the outer coil
becomes the connection terminal v1. The end of the inner coil automatically becomes v12 (see circuit
diagram).

You have now finished inserting the first two coils into the stator.
2.8. Coil configuration
Step 1: Once you have completed winding the next coils we must now ensure that the coils are inserted
at the right location. To do these refer once again to your circuit diagram. As previously the inner coil has
to be inserted first. Start again with the side of the coil where the end of the coil is located. Now begin
counting from the first inner coil (groove slot 11) four slots to the left (slot 7). Insert the first side of the
coil into this groove slot. You can see from the circuit diagram that u12 is located in slot 7. The other
second side of the inner coil is placed in slot 2. The outer coil is correspondingly placed in groove slots 1
and 8. Use a needle to pull the ends of the coils out through under the coil so the terminal connections are
always completely outside and accessible.
Step 2: Now again bend the coil ends protruding outwards straight and then downwards as much as
possible. Also label these ends of the coils too.

Step 3: From the other side of the stator.
Step 4: Carry on winding the remaining coils and insert them into the stator as specified in the circuit
diagram. Press the coils outward to the extent that later the rotor can be inserted without any obstacle.

Step 5: Put an insulation hose piece on each connection end and label each of the connections
immediately after having inserted the coils. The coils must initially be tied from the side on which there
are no coil ends. In order to avoid damaging the connection terminals when working on the motor right
side up you should fold the wires inward as shown in the image below.
Proceed with the next work step which entails having to permanently tie the coils together.
2.9. Coil insulation
Step 1: First of all the individual coils have to be mutually insulated from each other. No connection
whatsoever may exist between any two different coil pairs. Consider your circuit diagram. To express this
graphically the colours must all be separate from each other, only coils of like colour may be in contact
with each other. First cut a piece of insulation material and place it between two coils. Trace a line on the
sheet along the corresponding coils.

Step 2: Cut away approx. 0.5 - 1 cm above this mark.
Step3: Take this cut out and place it again between the coils to check whether this completely separates
the coils from each other. Take this cut out now use it as a template and cut 5 additional pieces of the
same size and form from the insulation material.
Step 4: Now place all six insulation sheets between the coil pairs. Make sure that not a single coil pair
comes in contact with another pair. Also check to see whether any individual winding is not bent past the
insulation and thus coming into contact with another coil.

2.10. Binding the coils on the fan side
Step 1: The coils have to be bound with strips of insulation tape so that they can no longer come loose.
The strip of tape must be pulled through the insulation paper between each groove slot. You have several
possibilities - you can first mark the spots on the insulation sheets where you wish to make holes and pull
through the tie strips and then remove the insulation sheets and make the holes and then return them or
make the holes directly in the insulation material by carefully poking holes in the sheet using the tip of a
scissors or knife.
Step 2: Once you have made the first hole pull the tie strip through it. Pull it through so far that the ends
on both sides are approx. 80 - 100 cm long. Tie these ends together above the coil. To do this you have to
fold the insulation paper outwards first.

Step 3: Use a needle to help tie the coils into a spiral shape between each groove slot.
Step 4: Pull on the strip until it is pulled down tight over the coil. When tying it down make sure that the
insulation paper does not slip too far upwards causing a connection to be made between two coil pairs.

Step 5: With the one side of the strip you tie down the coils in one direction until you have completed
half of them. Proceed with the other side of the strip using the same method to tie the coils in the other
direction until all of coils are bound.
Step 6: Once all of the coils are tied down you can tie the two ends of the strip together in a knot.

2.11. Binding the coils on the coupling side
Step 1: Take two coil ends that belong together and connect them. You can find out which ones have to
be connected together by looking at the circuit diagram. Here we shall begin by connecting U12 and U21.
Shorten the connections and the insulation to the extent that afterwards, when connected up, the
connection can be flattened down on the coil without any problems. Before twisting the coil ends together
you still have to slide a section of insulation hose of 5 mm over the wire insulation. This is done to ensure
that the connection is not left exposed. Once you have twisted the two ends together the connection must
still be soldered to ensure that the contact between the coils is guaranteed.
Step 2: Straighten this segment of the connection and then pull the insulation over it.

Step 3: Proceed in precisely the same manner with the other two coil connections V12- V21 and W12-
W21.
Step 4: Cut 3 pieces of approx. 20 cm long green and yellow cable sections. Slide approx. 5-10 cm
insulation hosing onto the cables and then push these through the motor feedthrough channel between the
terminal board and the coils.
Step 5: Insulate the ends on the terminal board side and tin coat the ends with tin lead solder. Bend
lugs onto the ends which match precisely to the screws on the terminal board. When cutting the ends
leave a little extra since there might be some length missing on the other side for the connection of the
coil ends. Pull the cable out so far on the coil side so that there are matching lengths (refer to the
pictures).

Step 6: Place plain washers above and below the lugs. A lock washer is then placed over this and then
screw on and tightens the nut. Tighten the nut sufficiently so that it cannot come off. During subsequent
connection of the terminal board lines to the coil ends make sure that the appropriate and corresponding
lines are connected together. Both the coil ends as well as the terminal lines have been labelled with U1,
U2, V1, V2, W1 and W2 designations. The coil ends have merely been prolonged to the terminal board.
The only components still missing now are the temperature sensors. These are connected in series
between the terminal board and the coils. The sensors have contacts which open to prevent any
overheating of the motor.
Step 7: Take the two ends of the temperature sensor and cut one end off at approx. 5 cm, cut a section
of approx. 10 cm off the other end. Insulate the ends and and then slide a piece of insulation hose over
the short end.

Step 8: Slide a piece of 5 mm insulation hose over the coil terminal connections (U1, V1, W1, U2, V2,
and W2). Twist and solder the short end of the temperature sensor to the connection side of the coils.
Step 9: Bend the connection down flat and then first slide the thinner insulation hose over the insulation
free section.
Step 10: Pull the second insulation hose over the connected segment of the two thinner hoses.

Step 11: Connect the longer ends of the temperature sensor to the corresponding line on the terminal
board. Make sure that the correct lines are connected to each other. Connect the U1 coil to the U1
terminal board connection etc.,.... Twist and solder the two ends to each other. Bend the connection
down flat.
Step 12: Slide the insulation hose over the soldered connection point.
Step 13: Proceed in precisely the same way with the other two contacts (V1, W1).
2.12. Insulation of the stator
Step 1: The coil windings could still come into contact with the housing on the motor's coupling and fan
side.

Step 2: For that reason cut out a strip of insulation paper approx. 35 cm long. Place it between the coil
and the casing in the motor and slide it as far down as it goes. Now the fan side of the motor is
completely insulated.
Step 3: Now proceed to cut another strip of insulation paper of about 35 cm in length for the coupling
side. But here you cut a notch out for the feed through channel to the terminal board.
2.13. Insulation measurement and testing
Step 1: Prior to measuring the coil winding resistances and insulation, calculate the resistance values you
expect to find. You need to refer to the chapter on "Computing motor data" to find the computed values
for wSp, lw1, lw2 and qL. The conductivity of copper at 20°C is κ = 56 * 103 S/mm.
After the motor has been completely assembled the motor's coil winding resistance must be checked by
measurement. Prior to measuring this compute the resistance values you expect to find. Between u1 and
u2, v1 and v2 and w1 and w2 we expect the following: R20 = (1 / κ) * (2 * wSp * (lw1 + lw2) / qL) R20
= 74,8 Ω Correct!

Step 2: Now measure the coil winding resistances. Compare the measured values to the calculated
ones. If the values happen to be in the same range, you have correctly wound the windings.
Step 3: Now test the insulation of the windings with respect to each other and the insulation between
the coil windings and the casing. The motor may only be put into operation if all of these tests are
passed. If an insulation test fails then the potential cause has to be search for. If the cause cannto be
found and thus cannot be rectified, then you have to remove the coils from the motor and proceed to
rewind them anew. Adjust the insulation measuring instrument to the 1KV setting. This is the test
voltage used to measure insulation between the coils and the housing. The measured resistance value is
indicated on the display. To perform the test keep the yellow test button pressed down. The display
scale gradually fills up. If the resistance value between the coil and the housing is ∞, then OL is indicated
on the display. There is no proper termination.
Measurement w1 – housing

Measurement v1 – housing
Measurement u1 – housing
2.14. Assembly of the housing
Step 1: First slide the rotor with fan wheel into the stator.

Step 2: Lay the locking ring into the end shield and mount it by sliding the shaft through it.
Step 3: Fasten the end shield and fan wheel onto the housing using screws. Make sure that the four
screws on each side are tightened bit by bit alternating in gradual succession. Never tighten down a
screw on its own while the others are still loose. This could result in having the end shield unevenly
secured to the housing. Carry out the insulation tests one more time to ensure that the coil windings
have not been damaged during assembly.
Step 4: The last step involves sliding the coupling onto the shaft. Make sure that the screw to the
coupling is located right above the shank in the shaft. Once you have mounted the coupling onto the
shaft (with the aid of the rubber mallet), you can secure the coupling with a screw.

Step 5: Motor assembly is now complete.
2.15. Testing the motor
Step 1: Assemble the experiment setup:
You must first put the motor into no-load operation in order to be able to measure current
consumption.

To measure the current flowing through the phase windings, connect the meter between the
power supply and the machine (see figure above). Switch on the power supply. The current
should be in the 0.6 A range. Carry out this measurement for all three phase windings.
What current level do you measure in the individual phases?
Phase 1 Phase 2 Phase 3

0.6 Amps 0.6 Amps 0.6 Amps
Correct!!!!!!!
Step 2: Now assemble the experiment setup without the meter and switch the power voltage on.
The motor should now begin rotating. Check the rotation direction of the motor. To do this have
a look at the coupling from the front. If it rotates in the clockwise direction, then the motor shaft
is rotating to the right, in the positive direction.
This means the coil windings have been arranged in the correct configuration. If the motor is
rotating in the other direction, you need to interchange two of the phase windings (e.g. L1 and
L2).

The motor operates properly. You will have no problem re-installing the motor into the
production line.
UNIT 3: VERNIER CALIPER MICROMETER READING
3.1. Vernier Caliper
The vernier caliper is a measuring instrument that incorporates a main scale, a vernier scale and a
fixed and sliding jaw. Other types of caliper may employ other types of readout such as, a dial
for least count readout or an electronic digital readout.
Three types of measurement can be made with a typical caliper, that is to say, outside, inside
and depth.
Calipers are available in various sizes, with measuring ranges from 100 mm to 3000 mm (4 in. to
120 in. for inch calipers). Generally, calipers that have a measuring range of 300 mm (12 in.) or
less are classified as small calipers and ones with larger ranges are classified as large calipers.
Typical measurement resolutions are 0.05 mm for a vernier caliper, 0.02 mm for dial calipers and
0.01 mm for digital calipers. ]

3.1.1. Reading Vernier Calipers
The following example explains how a reading is taken using a metric vernier calliper. Figure
below illustrates the case where the zero graduation on the vernier scale aligns perfectly with a
graduation on the main scale.
Figure: An integer reading
In this case, the zero on the vernier scale and the 35 mm graduation on the main scale align. The
correct caliper reading is therefore 35.00 mm.
Figure: A non-integer reading on the main scale.
In this case the procedure for finding the correct reading is as follows:

Look along the main scale and determine the smaller of the two graduation numbers that most
closely line up with the zero on the vernier scale. In the example above the zero on the vernier
scale lies between 20 and 21 on the main scale. The correct main scale reading to use is therefore
20.
Now look along the vernier or sliding scale and see which graduation lines up with a main scale
division. In figure 14 this is 64 on the vernier scale.
The correct reading in the above example is therefore 20 mm + 0.64 mm = 20.64 mm Figures
below show further examples for callipers with 0.05 mm and 0.02 mm discrimination.
Exercise no1
Exercise no2:

3.1.2. Set-Up, Preparation and Measurements
Now we know how to read the callipers it's now time to make a measurement. It is good practice
to observe the following list of steps and precautions when making external measurements with
callipers. British standard BS 887:2008 Precision vernier callipers – Requirements and test
methods Appendix C contains notes on the use of precision callipers. ISO 13385-1 contains
further information in its Annex B.
 Set-up and preparation
a) Select the calliper that bests suits the application by ensuring that the type, measuring
range, graduation and other specifications of the calliper are appropriate for the
measurement to be made.
b) Check that the calliper calibration has not expired. If the calibration has expired, use
another calliper whose calibration is valid.
c) Inspect the calliper measurement faces for signs of damage. Do not use damaged
callipers.
d) Before taking a measurement, remove cutting chips, dust, burrs, etc. from the workpiece.
Make sure that the workpiece is at room temperature.
e) Wipe off any dust and oil from the calliper before use. Thoroughly wipe the sliding
surfaces and measuring faces, using only clean lint free paper or cloth.
f) When measuring, slowly move the slider while lightly pressing the finger hold against the
main scale. The slider should not feel loose or have any play. If any problems are found
they should be corrected by adjusting the pressing screw and setscrew on the slider (if
fitted). Tighten the pressing screw and setscrew, then loosen them in a counter clockwise
direction about 1/8 of a turn (45°). Check the sliding action again. Repeat the procedure
while adjusting the angular position of the screws until an appropriate sliding smoothness
is obtained.
g) Check the zero reading.

 Measurements
The procedure to make measurements is as follows:

a) Close the jaws and set the calliper zero.
b) Open the callipers to a length larger than the size of the object to be measured.
c) Placed the fixed jaw in contact with the workpiece. The workpiece should be as close as
possible to the main scale.
d) Align the beam of the calliper to be parallel with dimension to be measured and bring the
sliding jaw into contact with the workpiece ensuring that the measuring faces are in even
contact. Do not use excessive force to avoid distorting either the work piece or instrument
frame. If a clamping screw is fitted, use this to reduce angularity error. Do not regard the
clamping screw as a memory device.
e) Record the calliper reading.
f) Recheck the zero reading. If the zero is incorrect, this may be a sign that a piece of dirt
has transferred from the work piece to the calliper faces. Clean the faces and work piece,
and repeat the measurements from step 1. Consistency of measurement may be gained by
first using the calliper on a standard length bar assembly. This is particularly useful when
the operator is required to ‘feel’ the jaws in contact with the item to be measured. Taking
several measurements on any one dimension and recording the mean can give extra
confidence in measurements and is necessary for estimating the uncertainty of
measurement.
3.1.3. How to use a Thread Pitch Gauge
a) Read the value of the main (stationary) bar scale which is just to the left and
above the '0' zero reading on the vernier (moveable) scale. values will be in mm.
b) Then add the value on the vernier (moveable) scale which exactly coincides with
a line on the main (stationary) bar scale. values will be in 0.1 or 0.15 mm.

Practice no 3
c) Select the individual thread gage from the set which exactly matches the pitch or
number of threads per inch on the item to be measured.
d) Note the marking on the individual gage. it may be in metric pitch (p) or in
threads per inch (tpi).
Procedures:
 Read the values from the vernier caliper, and the data from the Thread pitch gage.

 Then determine the size and identity of the thread (metric, usa, or british) from the thread
identification chart data.
Note: If you are measuring an internal (female) thread; then this yields the minor diameter of the
item. The necessary (external male) major diameter (OD) value will have to be calculated.
Example:
Take Fig. for example. Pincers A and B grip an object and the 0th tick of G falls between 16 and
17 mm of the main ruler, we then have to find out the tick on G which matches (or being the
closest) to one of the tick on F. As shown in the Fig., 1.5 (3rd tick) on G perfectly matches a tic
on F, then the length is measured as (16 + 3×0.05) ± 0.025 =16.15± 0.025 mm.
3.2. Micrometer Reading

Screw micrometer can get a more accurate measurement of the thickness of an object
3.2.1. Main parts

Figure: Sectioned view of a micrometer
The main components are described below:
 The inner sleeve, which has the guide threads of the feed mechanism, is fixed to one end
of the frame. The anvil, which serves as a fixed measuring face, is attached to the
opposite end of the frame.
 The spindle has a measuring face at one end and an external thread at the other. It is
fitted to the inner sleeve, which ensures the linearity of the spindle motion in the axial
direction. The spindle’s external thread engages with the internal thread of the inner
sleeve.
 The measuring face of the spindle serves as a contact point for measuring the workpiece.
Measurement is performed by feeding the spindle so that both the anvil measuring face
and the spindle measuring face touch the workpiece.
 The outer sleeve has graduations that correspond to the spindle’s thread pitch and an
index line to aid reading of the graduations on the thimble.

 The thimble is fixed to the spindle so that both components turn together and is knurled
for ease of turning.
 The ratchet stop applies constant pressure to the workpiece being measured and consists
of a leaf spring and a ratchet mechanism.
 The clamp, fixed to the spindle guide section of the frame, locks the spindle against the
inner sleeve.
A standard micrometer has a screw thread of 0.5 mm pitch with a thimble graduated in fifty
equal divisions around its circumference. Micrometers are manufactured in size ranges of 0 mm
to 25 mm, 25 mm to 50 mm, …, 575 mm to 600 mm etc. As an example, you would measure a
dimension of 19.45 mm with a 0 mm to 25 mm micrometer and a dimension of 580.25 mm with
a 575 mm to 600 mm micrometer.
3.2.2. Micro-meter reading

Exercise no1:
Reading to the sleeve: 7mm
Reading to the thimble: 0.375mm
Total: 7.375mm
Exercise no2:

Exercise no3:
Exercise no4:

UNIT 4. THREE PHASE MOTOR WINDINGS DESIGN
4.1. Motor Data Computation
 The following data can be read from the rating plate of the defective motor:
 Compute the apparent power in star and delta circuit configuration;
 To find out how many winding the coils have to have, count the number of windings in the coils
from the old machine. You obtain a winding number of w = 280. Use your vernier caliper to
measure the wire diameter and the cross-section of the grooves. The wire diameter is d = 0.335
mm. The cross-section of the groves is F = 73 mm2.
 In your manual you read that there is a so-called fullness factor for a groove slot which
determines by what % of the groove's cross-section may be filled. Factor specifications range
from 34% up to a maximum of 37%. The higher the fullness factor, the harder it is to insert the
coils into the groove slots. Now compute whether the number of counted wire windings
exceeds the groove's fullness factor.

The number of required winding turns per coil has been counted and mathematically tested. What is still
of interest is the winding length of the coils.

The winding lengths can be computed according to the following equation. This equation is based on the
motor's geometry. In the previous drawing you have an illustration of the groove or slot pitch for the
internal and external coil. The length of iron amounts to lFe = 65mm.
Now you know all of the variables that you need to build a motor. You can start building the motor now...
UNIT 5. TESTING INDUCTION MOTORS
5.1. Testing a Three-Phase Induction Motor

5.2. Electrical Tests to be conducted
5.2.1. Resistance Test

This test is carried out on an isolated motor, to check the resistance of the stator windings. It is necessary
to make an accurate measurement, so a low reading ohmmeter or a high-resolution digital multi-meter
should be used.
Step 1: Isolate the motor electrically, and if necessary, mechanically.

Step 2: Identify the way the motor terminal block is connected.
 Star connected: Make a careful note of how the three supply cables are connected so as to avoid
errors when re-connecting. Two links connect U2-V2-W2. Remove the links and the supply
cables before carrying out the test. Disconnecting the supply cables ensures that there are no
parallel paths via any control equipment, which would lead to false readings being obtained.
 Delta connected: Make a careful note of how the three supply cables are connected so as to avoid
errors when re-connecting. Three links connect U1 to W2, V1 to U2, and W1 to V2; Remove the
links and the supply cables before carrying out the test. Disconnecting the cables ensures that
there are no parallel paths via any control equipment, which would lead to false readings being
obtained.
 Star-Delta conne cted: Make a careful note of how the six supply cables are connected so as to
avoid errors when re-connecting. It is required that all conductors be disconnected from the
terminal block during the test. Disconnecting the supply cables ensures that there are no parallel
paths via any control equipment, which would lead to false readings being obtained.
Step 3: Identify the 3 stator windings - usually labelled U1-U2, V1-V2, and W1-W2.
Step 4: Measure and record the resistance of each winding.
If there is any appreciable difference between one winding and the other two, this indicates a fault
condition. If one winding resistance is higher than the other two, this indicates that a high resistance fault
is developing possibly due to a poor quality solder joint. An infinite resistance indicates an open circuit
(or break) in the winding.

If the resistance of one winding is lower than the other two, this indicates that the winding is becoming
short-circuited. This is possibly due to an inter-turns short circuit on that winding. It is usually the result
of the winding overheating, which damages the insulation (shellac / varnish), or because of mechanical
damage. Both faults may necessitate having the motor rewound.
The following Figures illustrate how to complete the winding resistance test.

5.2.2. Insulation Resistance Test
This is a test carried out to determine the quality of the insulation between:
 The windings and the motor frame

 Between the individual windings
 Insulation Resistance Tests Between Windings and Frame
Step 1: Isolate the motor electrically, and if necessary, mechanically.

Step 2: Make a careful note of how the supply cables are connected so as to avoid errors when
re-connecting. Disconnect the supply cables from the motor terminal block to ensure that there
are no parallel paths via the control equipment, which would lead to false low readings being
obtained. Such disconnection of cables will also ensure that any electronic equipment in the
circuit will be isolated before the test commences, as it may be damaged, by the Insulation
Resistance Test, voltage.
Step 3: Measure the insulation resistance between the U winding and frame. Some however
amotor manufactures recommend a reading of not less than 10 M is generally accepted.
Reading of not less than 2 M

Step 4: Measure the insulation resistance between the V winding and frame.
Step 5: Measure the insulation resistance between the W winding and frame.

 Insulation Resistance Tests Between Windings
Step 1: Insulation Resistance Test between windings U and V.
Step 2: Insulation resistance test between windings U and W.
Step3: Insulation Resistance Test between Windings V and W

If the motor becomes damp it may need drying out to obtain the minimum acceptable insulation
resistance value. (2 M)
5.2.3. Activity
Each apprentice to perform the following electrical tests and observations on an isolated 3- phase
induction motor and complete the attached test report sheet.
 Makers Name.
 Number of internal connections.
 Motor rated voltage. ( Include any star or delta symbols
 Motor full load current. as they appear on motor nameplate )
 Determine from manufacturer’s nameplate the rotor speed.
 Motor rated power in watts & HP (1 Horse Power (HP) = 746 watts).
 Motor rated frequency.
 Motor IP rating.
 Should the motor be connected in star or delta?
 Sketch the motor terminal box and show the three stator windings connected to their
respective terminals.
 Identify stator winding markings and insert on the report.
 Carry out resistance tests of stator windings and record.

 Carry out insulation resistance tests and record.
5.2.4. Test Report Sheet
End

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IPRC Musanze

Electrical and Electronics Engineering Department

Module Name: Electrical Machines Rewinding

Prepared by: Leopold MUSENGIMANA, Instructor in electrical, email:

Prepared by: Leopold MUSENGIMANA, Instructor In Electrical.

Prepared by: Leopold MUSENGIMANA, Instructor In Electrical.

After completing the course you should be able:

 To repair a burnt three phase induction motors

Prepared by: Leopold MUSENGIMANA, Instructor In Electrical.

The prerequisites for working successfully through this course are:

 General knowledge of electrical engineering

Prepared by: Leopold MUSENGIMANA, Instructor In Electrical.

3.1. What is an Electric Shock

Prepared by: Leopold MUSENGIMANA, Instructor In Electrical.

3.3. Cautions when to Contact your Doctor

3.4. First Aid for Electrical Burn Victims

Electrical burns vary in severity depending upon:

How long the body is in contact with the electric current;

 The strength of the current;

Prepared by: Leopold MUSENGIMANA, Instructor In Electrical.

Prepared by: Leopold MUSENGIMANA, Instructor In Electrical.

Prepared by: Leopold MUSENGIMANA, Instructor In Electrical.

Prepared by: Leopold MUSENGIMANA, Instructor In Electrical.

1.0. General Introduction

1.1. Electrical Properties

 Electrical Resistivity: It is the electrical resistance (ohm-cm) to the flow of current

1.2. Classification Of Insulating Materials

Prepared by: Leopold MUSENGIMANA, Instructor In Electrical.

 Classification according to substances and materials.

2. Classification according to temperature

Prepared by: Leopold MUSENGIMANA, Instructor In Electrical.

1.3. Characteristics of a Good Insulating Material

A good insulating material should possess the following characteristics.

(i) Very high insulation resistance.

1.4. Applications of Insulating Materials

 Between conductor /coils and earth (phase-to-earth),

1.5. Insulating Materials Forms

Prepared by: Leopold MUSENGIMANA, Instructor In Electrical.

1.6. Plastics Insulating Materials

1. Properties common to most of the plastics

2. Classification of plastic materials

Example: Polyethylene or Polythene, Polyvinyl chloride (PVC):

Prepared by: Leopold MUSENGIMANA, Instructor In Electrical.

Example: Used as Electrical appliance handles, TV and Radio cabinets

1.7. Insulating Varnishes

1. Advantages of varnish coatings

 Increased mechanical bonding to the winding wires

Varnishes are classified based on:

3. Classification of Insulating varnish based on applications

Prepared by: Leopold MUSENGIMANA, Instructor In Electrical.

2. Finishing (coating) varnish:

3. Core plate varnish:

Prepared by: Leopold MUSENGIMANA, Instructor In Electrical.

a. Air drying type

5. Method of applying varnish

 Applying a coating with a paint brush

6. Types of Insulating Varnishes for Various Applications

 Clear baking varnish: Armatures, field coils and instruments.

Prepared by: Leopold MUSENGIMANA, Instructor In Electrical.

 The conductivity must be good.