Winding Resistance Testing of Motors - Megger

APPLICATION NOTE
Motor testing with MTO106

Winding resistance testing of motors
Megger MTO 106 Common AC Motor Construction
Winding resistance measurements are conducted for detecting various faults in transformers –
including shorted turns, loose connections, broken strands, and malfunctioning tap changer
mechanisms. Winding resistance test sets such as the MTO106 are also capable of testing
electric rotating machinery – motors and generators. Winding resistance measurements detect
problems in a motor that other tests may not find. These problems include partial or fully
shorted coils, poor crimps/connections, imbalance between phases (improper turns on a
phase), and incorrect coil (phasing) connections.
Studies conducted by IEEE and EPRI (Electric Power Research Institute) on electric rotating
machinery failures show that 48% of motor failures are due to electrical failures.
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Megger USA Megger Sweden AB ZR-BN01E • BN035607BE • 2019
Valley Forge Corporate Center Box 724
2621 Van Buren Avenue SE-182 17 Danderyd
Norristown, Pennsylvania, 19403, USA Sweden
T. 1-610 676 8500 T. +46 8 510 195 00
F. 1-610-676-8610 E. seinfo@megger.com
APPLICATION NOTE

Winding Resistance vs Insulation Resistance

As with transformers, a motor/generator is broken down into two main components – insulation
and mechanical.
When performing testing, the mechanical component relates to the winding and motor
construction. For mechanical tests, we use the winding resistance measurements (MTO106) to
validate the mechanical condition of the winding. Winding resistance testers apply a known DC
current through the windings, measure the resulting voltage drop across the winding, and then
calculate the resistance. You should not apply more than 10% of the winding current rating as
this will warm the winding and create a changing resistance value as the copper/aluminium
heats up.
Insulation Resistance Testing on a Motor
For the electrical insulation component, an insulation resistance (IR) instrument is used to
validate the condition of the winding relative to ground (outer case of the stator winding).
Insulation resistance testers apply a high DC voltage which causes a small current through the
insulation being tested. The tester then provides a resistance reading. Good insulation should
have a high resistance and typical values are in the mega-ohm or giga-ohm range. When
applying DC test voltage, you should not exceed the voltage rating of the motor winding being
tested. An exception to this are motors with winding rated voltages below 600 V (for example, a
380 V motor) which have a minimum test voltage of 500 V DC.
Winding Resistance Tester Requirements

For most common resistance measurements, you can use a regular multi-meter set to the ohms
scale. However, the windings in large motors have a low resistance and are very inductive –
therefore the tester must safely inject sufficient test current at a more significant test voltage to

T. 1-610 676 8500 T. +46 8 510 195 00
APPLICATION NOTE

measure the stator winding safely and in a timely manner. The higher test voltage overcomes
the inductance more quickly (up to 50 times faster versus a normal low resistance meter). This
is why a regular multi-meter is not capable of performing winding resistance measurements.
The MTO106 provides up to 6 amps of test current and 48 V of open circuit voltage.
In order to improve accuracy of a measurement, the MTO106 winding resistance tester uses a
four-wire measurement with a Kelvin lead set. This eliminates the resistance of the lead set
from the measurement providing the necessary accuracy.
An important consideration when testing winding resistance is safety. Motor/generator windings

can store a large amount of energy when DC current is injected into them during the test
(inductive charging). This energy must be safely dissipated from the winding after test current is
stopped. The MTO106 has circuits which automatically discharge this energy safely after a test
is terminated. The discharge function is passive which allows automatic discharge in the event
of an inadvertent (accidental) power loss or if the test leads are accidentally disconnected. The
MTO106 also features a visual and audible discharge indicator as a discharge condition occurs.
Why Perform Winding Resistance Tests

Detecting problems for vital motors or generators is important – and finding them before they
lead to catastrophic failure is critical. Predictive and preventative maintenance programs that
include regularly scheduled testing can help detect winding issues early. This reduces
catastrophic failure and the associated cost and down time.
Winding resistance tests provide information about the condition of the windings. As mentioned
previously, winding resistance tests can detect problems in a motor/generator that other tests
may not find. These problems include fully or partial shorted coils, poor crimp connections,
unbalance between phases, broken conductors, and incorrect coil connections.
Test Results Analysis

Winding resistance test readings can be used to check against factory or similar/sister motor
values. A common diagnostic technique is comparison to previous readings. Since winding
resistance is affected by temperature, it’s important to use temperature correction factors when
applicable.
Winding resistance test results are compared between the three phases (on a 3-phase motor).
The readings are used to compare balance between phases. There are a number of standards
(including IEEE) that provide maximum deviation percentages – typical limits are 1% to 3%
between the mean average for the three windings. Excessive differences in resistance readings
between phases may indicate a possible problem inside the motor.

T. 1-610 676 8500 T. +46 8 510 195 00
APPLICATION NOTE

Winding resistance is also used for measuring I2R losses in the winding (efficiency). Ideally, all
power supplied to a motor would make its way to the load with no losses. In reality there is
always some resistance, even if it is a small amount. This causes electrical losses that are
dissipated as heat.
The above information is related to testing the stator winding of a motor. The MTO106 is also
capable of testing the rotor portion of a motor. Typically, resistance tests on the rotor are done
with a low resistance ohmmeter. While a low resistance ohmmeter is able to test smaller stator
windings, it is generally limited to rotor testing. The MTO106 is capable of testing all stator and
rotor sizes (up to 500MVA) in a motor/generator.
Conclusion
Keeping motors running is critical in a vast number of industries. Knowing the condition of the
windings is one important part of ensuring the proper performance of motors. The ability to
detect issues in motor windings prior to failure is important - the MTO106 provides this ability.

T. 1-610 676 8500 T. +46 8 510 195 00

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APPLICATION NOTE

Motor testing with MTO106

Megger MTO 106 Common AC Motor Construction

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Motor testing with MTO106

Winding Resistance vs Insulation Resistance

Insulation Resistance Testing on a Motor

Winding Resistance Tester Requirements

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Motor testing with MTO106

An important consideration when testing winding resistance is safety. Motor/generator windings

Why Perform Winding Resistance Tests

Test Results Analysis

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Motor testing with MTO106

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