EASA Standard AR100-2006 - MaintenanceEASA AR100-2006 Recommended Practice - Rev. May 2006 1 Section...

EASA Standard AR100-2006

R E C O M M E N D E DP R A C T I C E

FOR THE REPAIR OF ROTATINGELECTRICAL APPARATUS

EASA Standard AR100-2006

R E C O M M E N D E DP R A C T I C E


EA SAELE

CTRIC

AL APPARATUS

SERVICE ASSOCIAT

ION

Reliable SolutionsToday

Recognized as anAmerican NationalStandard (ANSI)

A N S I / E A S AAR100-2006

EASA AR100-2006 Recommended Practice - Rev. May 2006

1

EASA AR100-2006

RECOMMEN D EDP R A C T I C E



2

Copyright © 2006. All rights reserved.

Electrical Apparatus Service Association, Inc.1331 Baur Blvd. • St. Louis, MO 63132 USA

314-993-2220 • Fax: 314-993-1269www.easa.com • [email protected]

ii


3

TABLE OF CONTENTS

SECTION 1: GENERAL1.1 PURPOSE1.2 SCOPE1.3 IDENTIFICATION

1.3.1 Service Center Labeling1.3.2 Records1.3.3 Nameplate

1.4 CLEANING1.5 TERMINAL LEADS1.6 TERMINAL CONNECTORS1.7 TERMINAL BOXES1.8 COOLING SYSTEM1.9 EXTERIOR FINISH1.10 PACKAGING AND TRANSPORTATION

SECTION 2: MECHANICAL REPAIR2.1 SHAFTS

2.1.1 Shaft Extensions2.1.1.1 Diameter Tolerances2.1.1.2 Permissible Runout2.1.1.3 Keyseat (Keyway) Width

Tolerances2.2 BEARINGS

2.2.1 Ball or Roller Bearings2.2.2 Sleeve Bearings

2.2.2.1 Sleeve Bearing End-Thrust2.2.2.2 Oil Rings2.2.2.3 Seals

2.3 LUBRICATION2.3.1 Grease2.3.2 Oil

2.4 FRAME AND BEARING HOUSINGS2.4.1 General2.4.2 Mounting Surface Tolerances,

Eccentricity and Face Runout2.5 LAMINATIONS2.6 BALANCING2.7 SLIP RINGS2.8 COMMUTATORS

2.8.1 Machining2.8.2 Undercutting

2.9 BRUSHHOLDERS2.10 BRUSHES2.11 BRUSH SETTING FOR DC MACHINES2.12 AIR GAP MEASUREMENT OF DC

MACHINES2.13 ACCESSORIES

TABLES2-1 Shaft Extension Diameter Tolerances—

NEMA Frame Size Machines2-2 Shaft Extension Diameter Tolerances—IEC

Frame Size Machines2-3 Permissible Shaft Extension Runout—NEMA

Frame Size Machines2-4 Permissible Shaft Extension Runout—IEC

Frame Size Machines2-5 Shaft Extension Keyseat Width Tolerances—

NEMA Frame Size Machines2-6 Shaft Extension Keyseat (Keyway) Width

Tolerances—IEC Frame Size Machines2-7 Labyrinth Seal Diametral Clearance Guide2-8 Mounting Surface Tolerances, Eccentricity,

and Face Runout—NEMA Type C Face-Mounting Motors and Type D Flange-Mount-ing Motors

2-9 Mounting Surface Tolerances, Eccentricity,and Face Runout—NEMA Type P Flange-Mounting Motors

2-10 Mounting Rabbet (Spigot) Diameter Toler-ances—IEC Flange-Mounted Machines

2-11 Mounting Surface Eccentricity and FaceRunout—IEC Flange-Mounted Machines

2-12 Brush-to-Brushholder Clearance2-13 Radial Ball Bearing Fit Tolerances2-14 Cylindrical Roller Bearing Fit Tolerances

SECTION 3: REWINDING3.1 INSPECTION

3.1.1 Windings3.1.2 Core Laminations3.1.3 Thermal Protectors or Sensors

3.2 REWINDING SPECIFICATION3.3 STRIPPING OF WINDINGS3.4 INSULATION SYSTEM3.5 CONDUCTORS3.6 STATOR, ROTOR, AND ARMATURE

COILS3.6.1 Random-Wound Coils3.6.2 Form-Wound Coils

3.7 FIELD COILS3.7.1 Stationary Coils3.7.2 Rotating Coils

3.8 AMORTISSEUR AND SQUIRREL CAGEWINDINGS

3.9 THERMAL PROTECTORS OR SENSORS

Table of Contents, Page 1

iii


4

3.10 SHAPING AND LACING OF STATORWINDINGS

3.11 COIL CONNECTIONS3.11.1 Making Connections3.11.2 Insulating Connections

3.12 WEDGES3.13 BANDING OF ROTORS AND

ARMATURES3.14 IMPREGNATION OF WINDINGS

SECTION 4: TESTING4.1 SAFETY CONSIDERATIONS4.2 INSULATION CONDITION TESTS

4.2.1 Inspection4.2.2 Insulation Resistance Test4.2.3 Polarization Index (P-I) Test4.2.4 Insulation Power Factor Tests4.2.5 Step Voltage Test4.2.6 Turn-to-Turn Test4.2.7 Surge Comparison Testing4.2.8 Interlaminar Insulation Test4.2.9 Bearing Insulation Test

4.3 RECOMMENDED WINDING TESTS4.3.1 Stator and Wound-Rotor Windings4.3.2 Squirrel Cage Windings4.3.3 Armature Windings4.3.4 Shunt, Series, Interpole, Compen-

sating and Synchronous RotorWindings

4.3.5 Interconnection of Windings4.4 HIGH-POTENTIAL TESTS

4.4.1 Windings4.4.1.1 New Windings4.4.1.2 Reconditioned Windings4.4.1.3 Windings Not Recondi-

tioned4.4.2 Accessories

4.4.2.1 New Accessories4.4.2.2 Accessories of Machines

with ReconditionedWindings

4.4.2.3 Accessories of Machineswith Windings NotReconditioned

4.5 NO-LOAD TESTS4.5.1 Speed4.5.2 Current4.5.3 Cooling System4.5.4 Sound Level4.5.5 Bearing Temperature4.5.6 Vibration Tests

4.6 PERFORMANCE TESTS4.7 INSTRUMENT CALIBRATIONTABLES4-1 High-Potential Test Using AC—New

Windings4-2 High-Potential Test Using DC—New

Windings4-3 High-Potential Test Using AC—New

Accessories4-4 High-Potential Test Using DC—New

Accessories4-5 Unfiltered Vibration Limits—Resiliently

Mounted Machines

APPENDIX: ELECTRICAL TESTINGSAFETY CONSIDERATIONSA.1 PERSONAL SAFETY

A.1.1 TrainingA.1.2 ClothingA.1.3 SupervisionA.1.4 First Aid

A.2 TEST AREAA.2.1 EnclosureA.2.2 GatesA.2.3 SignsA.2.4 LightingA.2.5 Safety EquipmentA.2.6 Test Unit Clearance

A.3 UNIT UNDER TESTA.3.1 Suitability for TestA.3.2 Exclusive AttentionA.3.3 GroundingA.3.4 Base

A.4 TEST PANELSA.4.1 ConstructionA.4.2 VoltagesA.4.3 Warning LightsA.4.4 DisconnectA.4.5 Safety SwitchA.4.6 LeadsA.4.7 High-Potential Ground Test

BIBLIOGRAPHY

STANDARDS ORGANIZATIONS &OTHER RESOURCES

Note: Sections pertaining to the repair of liquid-filled anddry-type distribution transformers were withdrawn fromthis edition of EASA Recommended Practice for the Re-pair of Rotating Electrical Apparatus.

Table of Contents, Page 2

iv


1

Section 1General

of redesign shown. The original nameplate may bereversed (blank side out) to prevent misinterpreta-tion, but it should remain with the frame.

1.4 CLEANINGAll windings and parts should be cleaned. Dirt,

grit, grease, oil, and cleaning agents should be re-moved. Windings and parts should then be dried.

1.5 TERMINAL LEADSAll apparatus should be equipped with lead wire

of rated temperature and voltage insulation and ofsufficient current carrying capacity. The tempera-ture rating should be appropriate for the duty andany oven curing process, and allow for the effect ofheat transfer to the terminals.

All leads should be suitably marked or coloredwhere necessary to indicate correct connection. Leadmarkings should conform to original manufacturermarkings, NEMA Stds. MG 1 or IEC Stds. 60034-8,whichever is applicable.

Leads and markings should be of sufficient dura-bility to withstand the environment involved andbe of sufficient length for ease of connecting to powersupply at the terminal box or to terminal blocks.Leads on totally enclosed apparatus should be prop-erly sealed to meet environmental operatingconditions.

A print or plate should be furnished, where nec-essary, indicating correct connections.

1.6 TERMINAL CONNECTORSThe recommended method of attaching terminal

connectors (lugs) to lead wire is by crimping or pres-sure indenting the lug barrel, using a lug sized tosuit the particular cable stranding provided, in ac-cordance with recommendations of the lugmanufacturer.

Damaged or missing lugs should be repaired orreplaced.

1.7 TERMINAL BOXESTerminal boxes should accommodate the connec-

tions without crowding. Missing terminal boxesshould be replaced, and damaged terminal boxesshould be repaired or replaced. See NEMA Stds.MG 1, 4.19 for guidance on replacement terminalboxes. Gaskets and seals should be replaced wherenecessary.

1.8 COOLING SYSTEMThe fans and cooling ducts should be clean and

1.1 PURPOSEThe purpose of this document is to establish guide-

lines in each step of electrical apparatus rewindingand rebuilding.

1.2 SCOPEThis document describes record keeping, tests,

analysis, and general guidelines for the repair ofelectrical motors and generators. It is not intendedto take the place of the customer’s or the machinemanufacturer’s specific instructions or specifica-tions.

Excluded from the scope of this document are spe-cific requirements, certification, and inspectionrequired for listed explosion proof, dust-ignition-proof, and other listed machines for hazardouslocations; and specific or additional requirementsfor hermetic motors, hydrogen-cooled machines, sub-mersible motors, traction motors, or Class 1E nuclearservice motors.

1.3 IDENTIFICATION

1.3.1 Service Center LabelingMachines received for repair should have the re-

pair company’s name or identifying logo and shoporder number permanently embossed or inscribedadjacent to the nameplate on the frame for futurereference. This shop order number should be listedon the repair invoice.

1.3.2 RecordsA record of each machine received for repair should

be established at the time of receipt and kept on filefor at least 3 years. The record should include thenameplate data, electrical test data (both before andafter repair), mechanical measurements (both be-fore and after repair), original winding data, finalwinding data, and details of replaced parts. Thisrecord should be made available to the customer forreview if requested. The primary cause of failureshould be determined, if possible, and should be re-corded on the apparatus repair record.

1.3.3 NameplateAn electrical machine should have a permanent

nameplate containing the principal informationneeded to put the machine into service. The originalnameplate is preferred. If a machine is redesigned,the original nameplate should remain on the unitand a new nameplate mounted adjacent to it withthe word “redesigned” and the new rating and date

Section 1, Page 1


2

operational. Cover plates and air baffles should bein place. Damaged or missing parts of the coolingsystem should be repaired or replaced.

1.9 EXTERIOR FINISHApparatus should be externally cleaned and

painted. Shaft extensions should be treated to pre-vent corrosion.

1.10 PACKAGING ANDTRANSPORTATION

After completion of the repair and testing, themachine should be packed in a manner suitable for

the form of transport to be used. Packing and trans-port should be as arranged with the customer.Blocking of the shaft is recommended, dependingon the type of machine, mode of transport and thedistance to be traveled. Where blocking is used, itshould be clearly identified. Oil-lubricated machinesshould be shipped without oil, and the need for lu-bricant clearly identified.

Section 1, Page 2


3

Section 2Mechanical Repair

ers, when provided, should be inspected and replacedif necessary.

2.2.2.3 SealsSeal clearance should be set to original equipment

manufacturer’s specifications if available. Otherwise,the values in Table 2-7 are provided as a guide.Measure the final seal dimensions.

2.3 LUBRICATION

2.3.1 GreaseGrease passages and pipes should be clean. Grease

inlets should be equipped with fittings. Greaseshould be compatible with the customer’s lubricant.Open bearings should be filled with grease duringassembly.

In the absence of the machine manufacturer’s lu-brication instructions, the grease reservoir shouldbe filled to approximately 1/3 capacity.2.3.2 Oil

Oil should be compatible with the customer’s lu-bricant. There should be a means to determine oillevel, such as an oil sight gauge.

2.4 FRAME AND BEARINGHOUSINGS

2.4.1 GeneralFrame and bearing housings should be examined

for defects. Cracks and breaks should be repairedand fits restored to manufacturer’s specifications.2.4.2 Mounting Surface Tolerances,

Eccentricity and Face Runout• NEMA Type C face-mounting motors and Type

D flange-mounting motors: See Table 2-8.• NEMA Type P flange-mounting motors: See

Table 2-9.• IEC flange-mounted machines: See Table 2-10

and Table 2-11.

2.5 LAMINATIONSThe rotor laminations should be of proper fit on

the shaft, sleeve or spider on which the laminationstack is assembled. The fit should be restored if it isfound to be loose. The outer diameter of the rotorlaminations should be true and concentric with thebearing journals.

The stator laminations should not be loose in theframe. The bore of the stator laminations should betrue and concentric with the rabbet (spigot) diam-eter of the frame.

2.1 SHAFTSShafts should be checked for wear, cracks, scoring

and straightness.2.1.1 Shaft Extensions

Shaft extensions should be smooth, polished andconcentric with the shaft center. Shaft extensiondimensions should be checked.2.1.1.1 Diameter Tolerances

• NEMA frame size machines: See Table 2-1.• IEC frame size machines: See Table 2-2.

2.1.1.2 Permissible Runout• NEMA frame size machines: See Table 2-3.• IEC frame size machines: See Table 2-4.

2.1.1.3 Keyseat (Keyway) WidthTolerances

• NEMA frame size machines: See Table 2-5.• IEC frame size machines: See Table 2-6.Keyseats should be true and accommodate keys

to a tap fit.

2.2 BEARINGS

2.2.1 Ball or Roller BearingsBearing housing and shaft bearing fits should be

measured and compared to manufacturer’s specifi-cations (Reference: ANSI/ABMA Stds. 7 as a guide).Any fits that are not within tolerance should berestored. See Tables 2-13 and 2-14.2.2.2 Sleeve Bearings

When sleeve bearings are remanufactured orreplaced by new bearings, the fit in the housing andthe diametral clearance should be set to originalequipment manufacturer’s specifications if available.See Section 9 of the EASA Technical Manual forguidance on diametral clearances for oil-lubricatedhorizontally-mounted sleeve bearings. Measure thenew bearing dimensions.

Sleeve bearings should be uniform in diameter, ofproper fit in the housing, smooth internally, andsuitably grooved for adequate distribution oflubricant. Note: Not all sleeve bearing bores are cy-lindrical.

2.2.2.1 Sleeve Bearing End-ThrustBearings of horizontal machines should be posi-

tioned on the shaft to eliminate end-thrust againsteither bearing.2.2.2.2 Oil Rings

Oil rings should be true and rotate freely. Retain-

Section 2, Page 1


4

2.6 BALANCINGDynamic balancing should be to the level speci-

fied by the customer. In the absence of a requestedlevel, dynamic balancing to balance quality gradeG2.5 (ISO 1940/1) should enable the machine to meetfinal vibration limits as defined in Paragraph 4.5.6.

Note: Locate balance weights so that they do notinterfere with other components.

2.7 SLIP RINGSThe slip rings should be turned to concentricity

with the shaft bearing seats.The surface of the finished rings should be smooth

and polished.Slip rings should have sufficient stock to ensure

proper brush performance. Manufacturer’s limitsshould apply.

2.8 COMMUTATORS

2.8.1 MachiningThe commutator should be turned to concentric-

ity with the shaft bearing seats.The surface of the machined commutator should

be smooth and burnished. No flat spots or high, lowor loose segments should exist.

Commutators should have sufficient stock to en-sure proper brush performance. Manufacturer’slimits should apply.

2.8.2 UndercuttingThe mica should be undercut, or left flush, as re-

quired by the application. When undercut, the micashould be removed along the sides of the bar for atleast the complete length up to the riser or dustgroove and to a depth of approximately the width ofthe slot. Undercut areas should be free of foreignmaterial and high mica.

Beveling may be required for those commutatorsthat have rough segment edges resulting from work-hardening of the copper during the undercuttingprocess.

2.9 BRUSHHOLDERSBrushholders should be clean and free of any grit,

oil, or dirt. Movable brushholder parts should be freeworking. The brush fit in the brushholder box shouldbe inspected for excessive clearance, and worn brush-holders should be replaced. Clearances should be asspecified in Table 2-12.

Brush stud insulation should be free of cracks andshould not be charred or have pieces missing.

In the final assembly of the machine, brushhold-ers should be adjusted for clearance to thecommutator or slip rings of 0.060 inch (1.5 mm) to0.125 inch (3mm), depending on the size of the unit.

Manufacturer’s specifications should apply.For commutator machines, it should be verified

that the brushholders align the brushes with thecommutator bars and maintain equal radial spac-ing between brushes.

Spring pressure should be measured and adjustedto a range recommended by the original equipmentmanufacturer or the brush manufacturer for thespecific application and brush type. For commuta-tor machines, brush springs should provide therequired brush pressure for successful commutation.

Brushholders and jumpers should be high-poten-tial tested to the machine frame at the test voltagespecified for the corresponding winding circuit (seeSubsection 4.4).

2.10 BRUSHESBrush shunts should be tight in the brush and

connections to the holder should be clean and tightand clear of other items.

The face of the brush should be seated, or con-toured, to make full contact with the commutatorsurface or slip rings. The brush fit in the brushholderbox should be inspected for side clearance (see Table2-12) and for excessively worn brushes. Brushesworn beyond useful length should be replaced.

Brushes in the same circuit of a machine shouldbe of the same grade unless otherwise specified bythe original equipment manufacturer. For DC ma-chines, brushes should be the size and grade to givesuccessful commutation in normal service.

2.11 BRUSH SETTING FOR DCMACHINES

In the final assembly, the brush rigging should bepositioned so that the brushes are set for brush neu-tral, with brush position clearly marked. Acceptedmethods of determining this position vary widely,and no single standard procedure applies.

Note: In an assembled DC machine, each brushmust contact at least two commutator bars at a time.Then, the brush short-circuits the armature coil con-nected to these bars. The brushes are considered tobe set for brush neutral when the armature coilsshorted by the brushes are midway between mainpoles.

2.12 AIR GAP MEASUREMENT OFDC MACHINES

In a DC machine, the radial length of all mainand interpole air gaps should be uniform and to origi-nal manufacturer specification.

2.13 ACCESSORIESCapacitors should be tested for rated capacitance

and subjected to a high-potential test (see Paragraph

Section 2, Page 2


5

4.4). Capacitors should be replaced if damaged.Short circuit devices, centrifugal mechanisms,

switches, and starting relays should be verified forelectrical and mechanical operation at correct speedand voltage. These items should be replaced ifdamaged.

Terminal boards should be replaced if damaged.

Space heaters should be tested for rated currentor power and subjected to a high-potential test (seeParagraph 4.4). They should be replaced if damaged.

Bearing temperature sensors or protectors shouldbe identical with or equivalent to the original de-vices in electrical and thermal characteristics.

Section 2, Page 3

Table 2-3. PERMISSIBLE SHAFT EXTENSION RUNOUT

NEMA FRAME SIZE MACHINES

DIMENSIONS IN INCHES DIMENSIONS IN MILLIMETERS

Shaft Diameter Shaft Runout* Shaft Diameter Shaft Runout*0.1875 to 1.625 incl. 0.002 4.76 to 41.3, incl. 0.051Over 1.625 to 6.500, incl. 0.003 Over 41.3 to 165.1, incl. 0.076

*Maximum permissible change in indicator reading when measured at the end of the shaft extension.Note: The permissible shaft runout tolerance has not been established where the shaft extensionlength exceeds the NEMA standard. However, runouts for shafts longer than standard are usuallygreater than those indicated above.

Reference: NEMA Stds. MG 1, 4.9.7.Dimensions shown in millimeters are rounded off.

Table 2-2. SHAFT EXTENSION DIAMETER TOLERANCES

IEC FRAME SIZE MACHINES

DIMENSIONS IN MILLIMETERS DIMENSIONS IN INCHES

NominalTolerance Shaft Diameter Tolerance Shaft Diameter Tolerance

Designation Over Up To Over Up To

j6* 6 10 +0.007 -0.002 0.236 0.394 +0.0003 -0.0001j6* 10 18 +0.008 -0.003 0.394 0.709 +0.0003 -0.0001j6* 18 30 +0.009 -0.004 0.709 1.181 +0.0004 -0.0002k6 30 50 +0.018 +0.002 1.181 1.969 +0.0007 +0.0001m6 50 80 +0.030 +0.011 1.969 3.150 +0.0012 +0.0004m6 80 120 +0.035 +0.013 3.150 4.724 +0.0014 +0.0005m6 120 180 +0.040 +0.015 4.724 7.087 +0.0016 +0.0006m6 180 250 +0.046 +0.017 7.087 9.843 +0.0018 +0.0007m6 250 315 +0.052 +0.020 9.843 12.402 +0.0020 +0.0008m6 315 400 +0.057 +0.021 12.402 15.748 +0.0022 +0.0008m6 400 500 +0.063 +0.023 15.748 19.685 +0.0025 +0.0009m6 500 630 +0.070 +0.026 19.685 24.803 +0.0028 +0.0010

*In some countries the k6 tolerance is used instead of j6.Reference: IEC Stds. 60072-1, C.1.4.Dimensions shown in inches are rounded off.

Table 2-1. SHAFT EXTENSION DIAMETER TOLERANCES

NEMA FRAME SIZE MACHINES


Shaft Diameter Tolerance Shaft Diameter Tolerance0.1875 to 1.5000, incl. +0.000 -0.0005 4.76 to 38.1, incl. +0.000 -0.013Over 1.5000 to 6.500, incl. +0.000 -0.001 Over 38.1 to 165.1, incl. +0.000 -0.025



6

Section 2, Page 4

Table 2-5. SHAFT EXTENSION KEYSEAT WIDTH TOLERANCESNEMA FRAME SIZE MACHINES


Width of Keyseat Tolerance Width of Keyseat Tolerance0.188 to 0.750, incl. +0.002 -0.000 4.78 to 19.1, incl. +0.051 -0.000Over 0.750 to 1.500, incl. +0.003 -0.000 Over 19.1 to 38.1, incl. +0.076 -0.000


Table 2-6. SHAFT EXTENSION KEYSEAT(KEYWAY) WIDTH TOLERANCES

IEC FRAME SIZE MACHINES


Nominal Width of Width ofKeyseat (Keyway) Tolerance* Keyseat (Keyway) Tolerance*Over Up To Over Up To2 up to 3 -0.004 -0.029 0.078 0.118 -0.0002 -0.0011

3 6 0 -0.030 0.118 0.236 0 -0.00126 10 0 -0.036 0.236 0.394 0 -0.0014

10 18 0 -0.043 0.394 0.709 0 -0.001718 30 0 -0.052 0.709 1.181 0 -0.002030 50 0 -0.062 1.181 1.969 0 -0.002450 80 0 -0.074 1.969 3.150 0 -0.002980 100 0 -0.087 3.150 3.937 0 -0.0034

*Normal keys, Tolerance N9.

Reference: IEC Stds. 60072-1, C.1.5.Dimensions shown in inches are rounded off.


Nominal Shaft ShaftShaft Diameter Runout* Shaft Diameter Runout*Over Up To Over Up To

6 10 0.030 0.236 0.394 0.00110 18 0.035 0.394 0.709 0.00118 30 0.040 0.709 1.181 0.00230 50 0.050 1.181 1.969 0.00250 80 0.060 1.969 3.150 0.00280 120 0.070 3.150 4.724 0.003

120 180 0.080 4.724 7.087 0.003180 250 0.090 7.087 9.843 0.004250 315 0.100 9.843 12.402 0.004315 400 0.110 12.402 15.748 0.004400 500 0.125 15.748 19.685 0.005500 630 0.140 19.685 24.803 0.006

This table applies to rigid foot-mounted and flange-mountedmachines.*Maximum permissible change in indicator reading when mea-sured midway along the shaft extension length.

Reference: IEC Stds. 60072-1, C.1.6.Dimensions shown in inches are rounded off.

Table 2-4. PERMISSIBLE SHAFT EXTENSION RUNOUTIEC FRAME SIZE MACHINES


7

Section 2, Page 5

Table 2-8. MOUNTING SURFACE TOLERANCES,ECCENTRICITY AND FACE RUNOUT

NEMA TYPE C FACE-MOUNTING MOTORS ANDTYPE D FLANGE-MOUNTING MOTORS


Rabbet Tolerance on Eccentricity & Rabbet Tolerance on Eccentricity &Diameter Diameter Face Runout* Diameter Diameter Face Runout*

Less than 12 +0.000 -0.003 0.004 Less than 304.8 +0.000 -0.076 0.10212 to 24 +0.000 -0.005 0.007 304.8 to 609.6 +0.000 -0.127 0.178Over 24 to 40 +0.000 -0.007 0.009 Over 609.6 to 1016 +0.000 -0.178 0.229

*Maximum permissible change in indicator reading.Reference: NEMA Stds. MG 1, 4.12, Table 4-5.Dimensions shown in millimeters are rounded off.

Table 2-7. LABYRINTH SEALDIAMETRAL CLEARANCE GUIDE

DIMENSIONS IN INCHES

Shaft Diameter Diametral Shaft Diameter Diametral3000 to 3600 rpm Clearance 1800 rpm or lower ClearanceFrom Up To (+.002”/-.000”) From Up To (+.002”/-.000”)3.000 3.500 0.009 3.000 3.500 0.0123.500 4.000 0.010 3.500 4.000 0.0144.000 4.500 0.012 4.000 4.500 0.0164.500 5.000 0.014 4.500 5.000 0.0185.000 5.500 0.015 5.000 5.500 0.0205.500 6.000 0.017 5.500 6.000 0.0226.000 6.500 0.018 6.000 6.500 0.0246.500 7.000 0.020 6.500 7.000 0.0267.000 7.500 0.021 7.000 7.500 0.028

DIMENSIONS IN MILLIMETERS

Shaft Diameter Diametral Shaft Diameter Diametral3000 to 3600 rpm Clearance 1800 rpm or lower ClearanceFrom Up To (+.050mm/-.000mm) From Up To (+.050mm/-.000mm)

76 89 .230 76 89 .30589 102 .255 89 102 .355

102 114 .305 102 114 .405114 127 .355 114 127 .455127 140 .380 127 140 .510140 152 .430 140 152 .560152 165 .455 152 165 .610165 178 .510 165 178 .660178 191 .535 178 191 .710

Speeds given are synchronous speeds corresponding to the applicable line frequencyand winding poles. Dimensions shown in millimeters are rounded off. The above table isto be used for horizontal machines with bronze/brass labyrinth seals, absent specificclearance recommendations from the manufacturer. Galling materials, such as cast-iron,may require greater clearance. Vertical machines may require less clearance. Labyrinthseal clearance must always be greater than the bearing clearance. A general rule ofthumb suggests labyrinth seal clearance should be 0.002” - 0.004” (.050 - .100 mm)greater than the sleeve bearing clearance.*The shaft diameter is the diameter at the seal fit; and “up to” means “up to but not including.”**The diametral clearance is the clearance for the applicable range of shaft diameter.


8

Table 2-9. MOUNTING SURFACE TOLERANCES,ECCENTRICITY AND FACE RUNOUT

NEMA TYPE P FLANGE-MOUNTING MOTORS


Rabbet Tolerance on Eccentricity & Rabbet Tolerance on Eccentricity &Diameter Diameter Face Runout* Diameter Diameter Face Runout*

Less than 12 +0.003 -0.000 0.004 Less than 304.8 +0.076 -0.000 0.10212 to 24 +0.005 -0.000 0.007 304.8 to 609.6 +0.127 -0.000 0.178Over 24 to 40 +0.007 -0.000 0.009 Over 609.6 to 1016 +0.178 -0.000 0.229Over 40 to 60 +0.010 -0.000 0.012 Over 1016 to 1524 +0.254 -0.000 0.305

*Maximum permissible change in indicator reading.Reference: NEMA Stds. MG 1, 4.13, Table 4-6.Dimensions shown in millimeters are rounded off.

Section 2, Page 6

Table 2-10. MOUNTING RABBET (SPIGOT)DIAMETER TOLERANCES

IEC FLANGE-MOUNTED MACHINES


NominalTolerance Rabbet (Spigot) Rabbet (Spigot)

Designation Diameter Tolerance Diameter ToleranceOver Up To Over Up To

j6 30 50 +0.011 -0.005 1.181 1.969 +0.0004 -0.0002j6 50 80 +0.012 -0.007 1.969 3.150 +0.0005 -0.0003j6 80 120 +0.013 -0.009 3.150 4.724 +0.0005 -0.0004j6 120 180 +0.014 -0.011 4.724 7.087 +0.0006 -0.0004j6 180 250 +0.016 -0.013 7.087 9.843 +0.0006 -0.0005h6 250 315 0 -0.032 9.843 12.402 0 -0.0013h6 315 400 0 -0.036 12.402 15.748 0 -0.0014h6 400 500 0 -0.040 15.748 19.685 0 -0.0016h6 500 630 0 -0.044 19.685 24.803 0 -0.0017h6 630 800 0 -0.050 24.803 31.496 0 -0.0020h6 800 1000 0 -0.056 31.496 39.370 0 -0.0022h6 1000 1250 0 -0.066 39.370 49.213 0 -0.0026h6 1250 1600 0 -0.078 49.231 62.992 0 -0.0031h6 1600 2000 0 -0.092 62.992 78.740 0 -0.0036h6 2000 2200 0 -0.110 78.740 86.614 0 -0.0043

Note: This table applies to machines with FF, FT and FI mounting flanges.Reference: IEC Stds. 60072-1, C.1.7.Dimensions shown in inches are rounded off.


9

Table 2-11. MOUNTING SURFACE ECCENTRICITYAND FACE RUNOUT

IEC FLANGE-MOUNTED MACHINES


Nominal RabbetEccentricity &

Rabbet (Spigot)Eccentricity &(Spigot) Diameter

Face Runout*Diameter

Face Runout*Over Up To Over Up To

40 up to 100 0.080 1.575 3.937 0.003100 230 0.100 3.937 9.055 0.004230 450 0.125 9.055 17.717 0.005450 800 0.160 17.717 31.496 0.006800 1250 0.200 31.496 49.213 0.008

1250 2000 0.250 49.213 78.740 0.0102000 2240 0.315 78.740 88.189 0.012

Note: This table applies to machines with FF, FT and FI mounting flanges.*Maximum permissible change in indicator reading.Reference: IEC Stds. 60072-1, C.7.Dimensions shown in inches are rounded off.

Section 2, Page 7

Table 2-12. BRUSH-TO-BRUSHHOLDER CLEARANCE


Nominal Brush Nominal BrushDimensions Clearance Dimensions ClearanceWidth and Width andThickness Max. Min. Thickness Max. Min.

1.6 0.144 0.044 1/16 0.0056 0.0017522.53.2 0.158 0.050 1/8 0.0062 0.00204 0.178 0.050 3/16 0.0070 0.002056.3 0.193 0.055 1/4 0.0076 0.00228 5/16

10 3/812.5 0.232 0.072 7/16 0.0091 0.002816 1/2

5/820 0.254 0.080 3/4 0.0100 0.003225 7/8

132 0.300 0.100 1-1/4 0.0118 0.003940 1-1/25064 0.330 0.110 1-3/4 0.0130 0.004380 2

Reference: IEC Stds. 60136, Table I.

To avoid confusion between dimensions in millimeters and in inches, brushes andbrushholders may have markings as follows: metric dimensions ❒; inchdimensions ∆.

NOTE: Replacement of a brush made to inch dimensions with a brush madeto millimeter dimensions (or vice versa) might cause problems because of animproper fit in the brushholder.


10

Tab

le 2

-13. R

AD

IAL

BA

LL

BE

AR

ING

FIT

TO

LE

RA

NC

ES

*

SH

AF

T F

ITS

(j5

an

d k

5)H

OU

SIN

G F

ITS

(H

6)

BEA

RIN

GSH

AFT

DIA

MET

ER (i

nche

s)B

EAR

ING

200

SER

IES

BEA

RIN

G30

0 SE

RIE

SBA

SIC

TOLE

RANC

EBO

REO

DHO

USIN

G B

ORE

(inc

hes)

OD

HOUS

ING

BO

RE (i

nche

s)N

UM

BE

RC

LAS

Sm

mM

AX

IMU

MM

INIM

UM

mm

MIN

IMU

MM

AX

IMU

Mm

mM

INIM

UM

MA

XIM

UM

00j5

100.

3939

0.39

3630

1.18

111.

1816

351.

3780

1.37

8601

j512

0.47

260.

4723

321.

2598

1.26

0437

1.45

671.

4573

02j5

150.

5908

0.59

0535

1.37

801.

3786

421.

6535

1.65

4103

j517

0.66

950.

6692

401.

5748

1.57

5447

1.85

041.

8510

04k5

200.

7878

0.78

7547

1.85

041.

8510

522.

0472

2.04

7905

k525

0.98

470.

9844

522.

0472

2.04

7962

2.44

092.

4416

06k5

301.

1815

1.18

1262

2.44

092.

4416

722.

8346

2.83

5307

k535

1.37

851.

3781

722.

8346

2.83

5380

3.14

963.

1503

08k5

401.

5753

1.57

4980

3.14

963.

1503

903.

5433

3.54

4209

k545

1.77

221.

7718

853.

3465

3.34

7410

03.

9370

3.93

7910

k550

1.96

901.

9686

903.

5433

3.54

4211

04.

3307

4.33

1611

k555

2.16

602.

1655

100

3.93

703.

9379

120

4.72

444.

7253

12k5

602.

3628

2.36

2311

04.

3307

4.33

1613

05.

1181

5.11

9113

k565

2.55

972.

5592

120

4.72

444.

7253

140

5.51

185.

5128

14k5

702.

7565

2.75

6012

54.

9213

4.92

2315

05.

9055

5.90

6515

k575

2.95

342.

9529

130

5.11

815.

1191

160

6.29

926.

3002

16k5

803.

1502

3.14

9714

05.

5118

5.51

2817

06.

6929

6.69

3917

k585

3.34

723.

3466

150

5.90

555.

9065

180

7.08

667.

0876

18k5

903.

5440

3.54

3416

06.

2992

6.30

0219

07.

4803

7.48

1419

k595

3.74

093.

7403

170

6.69

296.

6939

200

7.87

407.

8751

20k5

100

3.93

773.

9371

180

7.08

667.

0876

215

8.46

468.

4657

21m

510

54.

1350

4.13

4419

07.

4803

7.48

1422

58.

8583

8.85

9422

m5

110

4.33

184.

3312

200

7.87

407.

8751

240

9.44

889.

4499

24m

512

04.

7257

4.72

5021

58.

4646

8.46

5726

010

.236

210

.237

5

26m

513

05.

1194

5.11

8723

09.

0551

9.05

6228

011

.023

611

.024

928

m5

140

5.51

315.

5124

250

9.84

259.

8436

300

11.8

110

11.8

123

30m

515

05.

9068

5.90

6127

010

.629

910

.631

232

012

.598

412

.599

832

m5

160

6.30

056.

2998

290

11.4

173

11.4

186

340

13.3

858

13.3

872

34m

617

06.

6945

6.69

3531

012

.204

712

.206

036

014

.173

214

.174

636

m6

180

7.08

827.

0872

320

12.5

984

12.5

998

380

14.9

606

14.9

620

38m

619

07.

4821

7.48

1034

013

.385

813

.387

240

015

.748

015

.749

440

m6

200

7.87

587.

8747

360

14.1

732

14.1

746

420

16.5

354

16.5

370

*Sha

ft R

otat

es—

Out

er R

ing

Sta

tiona

ry.

Ada

pted

from

AB

MA

Sta

ndar

d 7,

Tab

les

1, 2

, 3 a

nd 4

.T

he a

bove

Sha

ft (in

terf

eren

ce)

Fits

and

Hou

sing

(cl

eara

nce)

Fits

are

pra

ctic

al fo

r m

ost s

tand

ard

elec

tric

mot

or a

pplic

atio

ns. W

here

wid

er to

lera

nces

(ho

usin

g fit

s) a

re p

erm

issi

ble,

use

tole

ranc

e cl

ass

H7

inst

ead

of H

6.

Section 2, Page 8


11

Tab

le 2

-14. C

YL

IND

RIC

AL

RO

LL

ER

BE

AR

ING

FIT

TO

LE

RA

NC

ES

*

SH

AF

T F

ITS

(k5

, m5,

m6

and

n6)

HO

US

ING

FIT

S (

H6)

BEA

RIN

GSH

AFT

DIA

MET

ER (i

nche

s)B

EAR

ING

200

SER

IES

BEA

RIN

G30

0 SE

RIE

SB

AS

ICT

OL

ER

AN

CE

BO

RE

OD

HO

US

ING

BO

RE

(in

ches

)O

DH

OU

SIN

G B

OR

E (

inch

es)

NUM

BER

CLAS

Sm

mM

AXIM

UMM

INIM

UMm

mM

INIM

UMM

AXIM

UMm

mM

INIM

UMM

AXIM

UM

00m

510

0.39

420.

3939

301.

1811

1.18

1635

1.37

801.

3786

01m

512

0.47

300.

4727

321.

2598

1.26

0437

1.45

671.

4573

02m

515

0.59

120.

5909

351.

3780

1.37

8642

1.65

351.

6541

03m

517

0.66

990.

6696

401.

5748

1.57

5447

1.85

041.

8510

04m

520

0.78

810.

7877

471.

8504

1.85

1052

2.04

722.

0479

05m

525

0.98

500.

9846

522.

0472

2.04

7962

2.44

092.

4416

06m

530

1.18

181.

1814

622.

4409

2.44

1672

2.83

462.

8353

07m

535

1.37

881.

3784

722.

8346

2.83

5380

3.14

963.

1503

08m

540

1.57

561.

5752

803.

1496

3.15

0390

3.54

333.

5442

09m

645

1.77

271.

7721

853.

3465

3.34

7410

03.

9370

3.93

7910

m6

501.

9695

1.96

8990

3.54

333.

5442

110

4.33

074.

3316

11m

655

2.16

662.

1658

100

3.93

703.

9379

120

4.72

444.

7253

12m

660

2.36

342.

3626

110

4.33

074.

3316

130

5.11

815.

1191

13m

665

2.56

032.

5595

120

4.72

444.

7253

140

5.51

185.

5128

14n6

702.

7574

2.75

6712

54.

9213

4.92

2315

05.

9055

5.90

6515

n675

2.95

432.

9536

130

5.11

815.

1191

160

6.29

926.

3002

16n6

803.

1511

3.15

0414

05.

5118

5.51

2817

06.

6929

6.69

3917

n685

3.34

833.

3474

150

5.90

555.

9065

180

7.08

667.

0876

18n6

903.

5451

3.54

4216

06.

2992

6.30

0219

07.

4803

7.48

1419

n695

3.74

203.

7411

170

6.69

296.

6939

200

7.87

407.

8751

20n6

100

3.93

883.

9379

180

7.08

667.

0876

215

8.46

468.

4657

21n6

105

4.13

574.

1348

190

7.48

037.

4814

225

8.85

838.

8594

22n6

110

4.33

254.

3316

200

7.87

407.

8751

240

9.44

889.

4499

24n6

120

4.72

624.

7253

215

8.46

468.

4657

260

10.2

362

10.2

375

26n6

130

5.12

015.

1192

230

9.05

519.

0562

280

11.0

236

11.0

249

28n6

140

5.51

385.

5129

250

9.84

259.

8436

300

11.8

110

11.8

123

30p6

150

5.90

825.

9072

270

10.6

299

10.6

312

320

12.5

984

12.5

998

32p6

160

6.30

196.

3009

290

11.4

173

11.4

186

340

13.3

858

13.3

872

34p6

170

6.69

566.

6946

310

12.2

047

12.2

060

360

14.1

732

14.1

746

36p6

180

7.08

937.

0883

320

12.5

984

12.5

998

380

14.9

606

14.9

620

38p6

190

7.48

347.

4823

340

13.3

858

13.3

872

400

15.7

480

15.7

494

40p6

200

7.87

717.

8760

360

14.1

732

14.1

746

420

16.5

354

16.5

370

*Sha

ft R

otat

es—

Out

er R

ing

Sta

tiona

ry.

Ada

pted

from

AB

MA

Sta

ndar

d 7,

Tab

les

1, 2

, 3 a

nd 4

.T

he a

bove

Sha

ft (in

terf

eren

ce)

Fits

and

Hou

sing

(cl

eara

nce)

Fits

are

pra

ctic

al fo

r m

ost s

tand

ard

elec

tric

mot

or a

pplic

atio

ns. W

here

wid

er to

lera

nces

(ho

usin

g fit

s) a

re p

erm

issi

ble,

use

tole

ranc

e cl

ass

H7

inst

ead

of H

6.

Section 2, Page 9


12

Section 3Rewinding

3.1 INSPECTION

3.1.1 WindingsThe condition of the windings and the extent of

repairs should be determined by inspection and, asnecessary, by tests (see Section 4).

Bars and end rings for amortisseur and squirrelcage windings should be examined for evidence ofdefects. Testing may be needed (see Paragraph 4.3.2).

Winding data should be reviewed for accuracy.3.1.2 Core Laminations

Cores should be examined for evidence of short-ing or lamination hot spots. Testing may be needed(see Paragraph 4.2.8).3.1.3 Thermal Protectors or Sensors

Thermostats, resistance temperature detectors(RTDs), thermocouples and thermistors should bechecked for electrical and physical defects.

3.2 REWIND SPECIFICATIONThe winding should maintain the same electrical

characteristics as the original.

3.3 STRIPPING OF WINDINGSDefective windings should be removed from the

core in a manner that will not damage the lamina-tions or other components. Oven temperature shouldbe controlled to avoid degradation of the inter-laminar insulation and distortion of any parts. Coreslots should be clean and free of sharp edges or par-ticles.

3.4 INSULATION SYSTEMThe entire insulation system, materials, and meth-

ods of application should be equal to or better thanthat used by the original machine manufacturer. Allcomponents of the insulation system must be com-patible with each other with respect to electrical,mechanical, and thermal characteristics. The insu-lation system should withstand the high-potentialtests described in Subsection 4.4 and the normaloperation of the machine.

3.5 CONDUCTORSThe current-carrying capacity, insulation, and

mechanical qualities of the conductors should besuitable for the environment in which the machineis to operate. The temperature rating of the coil con-ductor insulation should be equal to or higher thanthat of the insulation system. If the conductor ma-terial is changed, it should be equal to or better than

the original material in all aspects of performanceand application.

3.6 STATOR, ROTOR, ANDARMATURE COILS

Coil extensions should not be longer than theoriginals.

3.6.1 Random-Wound CoilsCoils should be wound and inserted in the core

slots with a minimum of crossed conductors. Careshould be taken not to damage the insulation or con-ductors. Coils should be wedged with full-length topsticks to hold them securely in the slots. Inter-phaseinsulation should be used (where applicable).

3.6.2 Form-Wound CoilsThe fabricating of coil loops and the forming of

these loops into the coil shape should be accom-plished without damage to the conductor insulation.Each layer of coil insulation should be uniformly andtightly applied to minimize stress points and airvoids.

Coils should be placed in the core slots withoutdamaging the coil insulation. Coils should tightlyfit slots. Coils should be wedged to hold them se-curely in the slots. Surge rings or similar supportsshould be secured to the coils and the coils laced toone another as necessary to minimize coil distor-tion.

3.7 FIELD COILSWhere high rigidity and a complete bonding of all

the components is required, a high bond strengthvarnish or a thixotropic resin should be applied tothe ground insulation and to each layer of the coilduring winding of the coil; otherwise, vacuum pres-sure impregnation may be utilized when a completebond between insulation and conductors can beensured.

3.7.1 Stationary CoilsVarnish treatment of shunt, series and interpole

coils is acceptable for coils originally manufacturedby this method.

The insulation of the outer coil layer should besufficient to withstand surges or inductive voltagespikes.

3.7.2 Rotating CoilsCoils and pole pieces should be securely wedged

and braced when installed.

Section 3, Page 1


13

3.8 AMORTISSEUR AND SQUIR-REL CAGE WINDINGS

Bars for amortisseur and squirrel cage windingsshould fit tightly in the core slots. End rings shouldbe secured to the bars by welding or brazing, as ap-propriate for materials used. The winding shouldmaintain the same electrical characteristics as theoriginal unless redesigned by agreement with, or atthe instruction of, the customer.

The winding should withstand thermal and me-chanical forces that occur during normal operationof the machine.

For balancing, see Subsection 2.6.

3.9 THERMAL PROTECTORS ORSENSORS

Thermostats, resistance temperature detectors(RTDs), thermocouples and thermistors should beidentical with or equivalent to the original devicesin electrical and thermal characteristics and placedat the same locations in the winding. Thermal pro-tectors or sensors should be removed or omitted onlywith customer consent.

3.10 SHAPING AND LACING OFSTATOR WINDINGS

End windings should be shaped and laced asneeded to provide the necessary clearance to therotor, stator, frame, bearing housings, air deflectorsand frame hardware. End windings should be ableto endure starting currents. On larger machineswhere surge rings (coil supports) are used, the ringsshould be suitably insulated, accurately fitted andlaced to the coils to insure adequate support for thewinding. Blocking between coils on end windings offormed coils should equal or exceed the original instrength against end winding movement.

Restrictions to air flow should be avoided.

3.11 COIL CONNECTIONS

3.11.1Making ConnectionsConnections which are made by crimping, solder-

ing, brazing, or welding should use materials thathave adequate conductivity and are mechanicallystrong enough to withstand the normal operatingconditions. Materials such as solder paste, fluxes,inhibitors and compounds, where employed, shouldbe neutralized after using. These materials shouldbe suitable for the intended use and of a type thatwill not adversely affect the conductors. Solderedjoints should not be used in place of brazed or weldedjoints.

Connections and splices should be so constructedas to have conductivity equal to or greater than theconductors of the winding.

3.11.2 Insulating ConnectionsConnections should be adequately insulated to

withstand the temperature and voltage ratings ofthe machine and be mechanically adequate to with-stand normal operation. Connections and leadsshould be laced, tied, or otherwise securely fastenedto prevent movement.

The insulation should be applied so as to allowthe varnish/resin to penetrate.

3.12 WEDGESWedges for stators, armatures and rotors should

have adequate mechanical strength and thermalrating to withstand normal operation of the machine.

Wedges should fit tightly in the slots.

3.13 BANDING OF ROTORS ANDARMATURES

Bandings should be secured, tied, or laced and bemechanically strong enough to withstand the cen-trifugal force, current surges, and vibrations ofnormal operation of the machine, includingoverspeed (where applicable).

Resin-filled glass banding tape may be applieddirectly to the winding. It should be applied at themanufacturer’s recommended tension and methodof curing. The banding should be of sufficient thick-ness and width to restrain the coils.

When wire banding is used, it should be appliedto the winding over banding insulation. The band-ing should match the original in location, material(magnetic or non-magnetic), wire size and numberof turns. The wire should be applied with sufficienttension to hold the coils in place without distortingthem.

Caution: Replacing wire banding with resin-filledglass banding may change the magnetic circuit con-figuration, affecting commutation and thermalrating of the winding. Similar effects may result fromreplacing glass banding with wire banding.

3.14 IMPREGNATION OF WINDINGSWindings of rewound machines should be pre-

heated, varnish/resin treated and cured using amethod of application and a material of sufficientthermal rating to withstand the normal operationof the machine. The treatment should be compat-ible with the entire insulation system and suitablefor the environment in which the machine is tooperate.

Section 3, Page 2


14

Section 4Testing

4.2.3 Polarization Index (P-I) TestThe polarization index test should be performed

at the same voltage as the test in Paragraph 4.2.2for ten minutes. The recommended minimum valueof polarization index for windings rated Class B andhigher is 2.0 (References: IEEE Stds. 43, Sec. 9.2;and IEEE Stds. 432, App. A2).

If the one minute insulation resistance is above5000 megohms, the calculated polarization index(P.I.) may not be meaningful. In such cases, the P.I.may be disregarded as a measure of winding condi-tion (Reference: IEEE 43, Sec. 5.4 and 12.2).4.2.4 Insulation Power Factor Tests

Insulation power factor, dissipation factor, and tip-up tests may be performed on large machines.Interpretation of results is by comparison with re-sults of tests on similar machines. No standardinterpretation of results has been established (Ref-erence: IEEE Stds. 432, Sec. 8.1).

4.1 SAFETY CONSIDERATIONSSee Appendix for safety considerations.

4.2 INSULATION CONDITIONTESTS

Tests should be performed to indicate the suitabil-ity of the insulation for continued operation.Inspection and insulation resistance tests should beperformed with acceptable results before the high-potential tests. Other tests, indicated below, may alsobe applied. All test results should be retained. Trendsin results are often better condition indicators thanthe absolute values (Reference: IEEE Stds. 95).

4.2.1 InspectionInsulation should be examined for evidence of deg-

radation or damage, such as:(1) Puffiness, cracking, separation or discolora-

tion as indication of thermal aging.(2) Contamination of coil and connection

surfaces.(3) Abrasion or other mechanical stresses.(4) Evidence of partial discharges (corona).(5) Loose wedges, fillers, ties, banding, or surge

rings.(6) Fretting at supports, bracing or crossings (an

indication of looseness or movement).(Reference: IEEE Stds. 432, Sec. 5.)

4.2.2 Insulation Resistance Test

Section 4, Page 1

GUIDELINES FOR DCVOLTAGES TO BE APPLIED DURING

INSULATION RESISTANCE TEST

detaRgnidniW)V(egatloV a

tseTecnatsiseRnoitalusnI)V(egatloVtceriD

0001< 005

0052-0001 0001-005

0005-1052 0052-0001

000,21-1005 0005-0052

000,21> 000,01-0005

a Rated line-to-line voltage for three-phase AC machines, line-to-ground for single-phase machines, and rated direct voltagefor DC machines or field windings.

Reference: IEEE Stds. 43, Table 1.

RECOMMENDED MINIMUM INSULATIONRESISTANCE VALUES AT 40° C

(All Values in MΩΩΩΩΩ)

noitalusnImuminiMecnatsiseR nemicepStseT

RI nim1 1+Vk=

edamsgnidniwtsomroFdleiflla,0791tuobaerofeb

tonsrehtodna,sgnidniw.wolebdebircsed

RI nim1 001=dnaerutamraCDtsomroF

tuobaretfatliubsgnidniwCA.)sliocdnuow-mrof(0791

RI nim1 5=

htiwsenihcamtsomroFsliocrotatsdnuow-modnardetarsliocdnuow-mrofdna

.Vk1woleb

Notes:1 IR1min is the recommended insulation resistance, in meg-

ohms, at 40° C of the entire machine winding.2 kV is the rated machine terminal-to-terminal voltage, in rms

kV.

Reference: IEEE Stds. 43, Table 3.

Test voltage should be applied for one minute. (Ref-erence: IEEE Stds. 43, Sec. 5.4 and 12.2).


15

4.2.5 Step Voltage TestStep voltage tests are useful if performed at regu-

lar maintenance intervals. Changes in results mayindicate insulation degradation (Reference: IEEEStds. 95).4.2.6 Turn-To-Turn Test

Accepted methods of testing turn-to-turn insula-tion vary widely. No single standard procedureapplies, although several standards touch on thesubject (IEEE Stds. 432, 522, and 792; and NEMAStds. MG 1, 12.5).4.2.7 Surge Comparison Testing

The surge comparison test is most often appliedto winding circuits using a test voltage of twice thecircuit rating plus 1000 volts.4.2.8 Interlaminar Insulation Test

Defects in laminated cores can be detected by loopor core tests (Reference: IEEE Stds. 432, Sec. 9.1,App. A4).4.2.9 Bearing Insulation Test

Bearing insulation should be tested with a 500Vmegohmmeter. Insulation resistance should be 1megohm or greater.

4.3 RECOMMENDED WINDINGTESTS

Windings should be tested to ensure that thereare no grounds, short circuits, open circuits, incor-rect connections or high resistance connections.

4.3.1 Stator and Wound-RotorWindings

One or more of the following tests should be per-formed:

(1) Insulation resistance test.(2) Winding resistance test.(3) Growler test.(4) Phase-balance test.(5) Surge comparison test.(6) Polarity test.(7) Ball rotation test (low voltage energization).

4.3.2 Squirrel Cage WindingsOne or both of these tests should be performed:(1) Growler test.(2) Single-phase test.

4.3.3 Armature WindingsOne or more of the following tests should be

performed:(1) Insulation resistance test.(2) Growler test.(3) Surge comparison test.(4) Bar-to-bar resistance or voltage drop test.

4.3.4 Shunt, Series, Interpole, Compen-sating and Synchronous RotorWindings

One or more of the following tests should beperformed:

(1) Insulation resistance test.(2) Winding resistance test.(3) Surge comparison test.(4) Voltage drop test (DC or AC voltage), coils in

series.The variation in DC voltage drops shouldnot be greater than 5% between coils ofsame field circuit.10% variation in AC test results is accept-able if the DC test is within limit.

4.3.5 Interconnection of WindingsShunt, series, interpole, compensating, and syn-

chronous rotor windings should be tested to ensurethat the polarities and connections are correct. Ter-minal and lead markings should comply withSubsection 1.5.

4.4 HIGH-POTENTIAL TESTSHigh-potential tests should be performed on wind-

ings and some accessories of electrical machines ata specified voltage. To avoid excessive stressing ofthe insulation, repeated application of the high-po-tential test voltage is not recommended.

Machines to be tested must be clean and dry. In-spection and insulation resistance tests withacceptable results should be performed before thehigh-potential tests. Insulation resistance testsshould be repeated at the completion of the high-potential tests.

When a high-potential test is conducted on an as-sembled brushless exciter and synchronous machinefield winding, the brushless circuit components (di-odes, thyristors, etc.) should be short-circuited (notgrounded) during the test.

High-potential tests should be successively appliedbetween each winding or electric circuit under testand the frame (or core) of the machine. All otherwindings or electric circuits not under test shouldbe connected to the frame (or core).

Capacitors of capacitor-type motors must be leftconnected to the winding in the normal manner formachine operation (running or starting).

Electrical machines may be tested using AC or DChigh-potential test equipment. A DC instead of anAC voltage may be used for high-potential tests. Insuch cases, the DC test voltage should be 1.7 timesthe specified AC voltage. A failure under test can beless damaging to the winding if a DC voltage is used.

Section 4, Page 2


16

Multiply the AC test voltage by 1.7 to obtain theequivalent DC test voltage.

AC high-potential testing should be performed byapplying specified voltage at 50-60 Hz continuouslyfor one minute.

DC high-potential testing should be performed byapplying specified voltage for a duration of oneminute after test voltage is reached. The DC poten-tial should be increased gradually to the desired testvoltage in order to limit the charging current.

Caution: After completion of a DC high-potentialtest, the winding must be grounded to the frame (orcore) until the charge has decayed to zero. (Refer-ences: IEEE Stds. 4 and 95; and NEMA Stds. MG 1,3.1.1.)

4.4.1 Windings

4.4.1.1 New WindingsHigh-potential tests should be applied as speci-

fied in Table 4-1 for AC voltage and Table 4-2 for DCvoltage. To avoid excessive stressing of the insula-tion, repeated application of the high-potential testvoltage is not recommended. Immediately after re-wind, when equipment is installed or assembled anda high-potential test of the entire assembly is re-quired, it is recommended that the test voltage notexceed 85 percent of the original test voltage. Thetests should be applied once only at the specifiedvoltage. (Reference: NEMA Stds. MG 1, 12.3).4.4.1.2 Reconditioned Windings

High-potential tests for reconditioned windingsshould be performed at 65% of the new winding testvalue.4.4.1.3 Windings Not Reconditioned

Machines with windings not reconditioned shouldhave an insulation resistance test instead of a high-potential test.4.4.2 Accessories

4.4.2.1 New AccessoriesAccessories such as surge capacitors, lightning

arresters, current transformers, etc., which haveleads connected to the machine terminals should bedisconnected during the test, with the leads con-nected together and to the frame or core. Theseaccessories should have been subjected to the high-potential test applicable to the class of machine attheir point of manufacture. Capacitors of capacitor-type motors must be left connected to the windingin the normal manner for machine operation (run-ning or starting).

Component devices and their circuits, such asspace heaters and temperature sensing devices in

contact with the winding (thermostats, thermo-couples, thermistors, resistance temperaturedetectors, etc.), connected other than in the line cir-cuit, should be connected to the frame or core duringmachine winding high-potential tests. Each of thesecomponent device circuits, with leads connected to-gether, should then be tested by applying a voltagebetween the circuit and the frame or core. The high-potential tests should be applied as specified in Table4-3 for AC voltage and Table 4-4 for DC voltage.During each device circuit test, all other machinewindings and components should be connected to-gether and to the frame or core. (Reference: NEMAStds. MG 1, 3.1.8).

4.4.2.2 Accessories of Machines withReconditioned Windings

The high-potential test for accessory circuits of re-conditioned machines should be performed at 65%of the new device test value.

4.4.2.3 Accessories of Machines withWindings Not Reconditioned

Accessory circuits of machines which have not hadtheir windings reconditioned should have an insu-lation resistance test instead of a high-potential test.

4.5 NO-LOAD TESTS

4.5.1 SpeedFor AC motors, no-load running tests should be

made at rated voltage and rated frequency. Thespeed should be measured and compared with name-plate speed.

Shunt-wound and compound-wound DC motorsshould be run with rated voltage applied to the ar-mature, and rated current applied to the shunt field.The speed should be measured and compared withnameplate speed.

Series-wound motors should be separately excitedwhen tested due to danger of run-away.

DC generators should be driven at rated speedwith rated current applied to the shunt field. Theoutput voltage should be measured and comparedwith rated voltage.

4.5.2 CurrentNo-load current should be compared with full-load

current.

4.5.3 Cooling SystemThe cooling system should be verified as being

operational.

4.5.4 Sound LevelTests may be made for sound level as an indica-

tion of fault or as an irritation to those in the

Section 4, Page 3


17

machine ambient (Reference: NEMA Stds. MG 1, 9,12.81 and 20.50).

4.5.5 Bearing TemperatureAmbient and bearing housing temperatures may

be measured periodically until temperatures are sta-bilized.4.5.6 Vibration Tests

The vibration tests should be in accordance withNEMA Stds. MG 1, 7 for standard machines, as ar-ranged with the customer, or as necessary to checkthe operating characteristics of the machine. Whenthere are special requirements, i.e., lower than stan-dard levels of vibration for a machine, NEMA Stds.MG 1, 7 for special machines is recommended.

The unfiltered vibration limits for resilientlymounted standard machines (having no special vi-bration requirements), based on rotational speed,are shown in Table 4-5. Vibration levels for speedsabove 1200 rpm are based on the peak velocity of0.15 inch per second (3.8 mm/s). Vibration levels forspeeds below about 1200 rpm are based on the peakvelocity equivalent of 0.0025 inch (0.0635 mm) peak-to-peak displacement. For machines with rigidmounting, multiply the limiting values by 0.8.

Note: International standards specify vibrationvelocity as rms in mm/s. To obtain an approximatemetric rms equivalent, multiply the peak vibrationin in/s by 18 (Reference: NEMA Stds. MG 1, 7.8).

4.6 PERFORMANCE TESTSFull-load tests may be made as arranged with the

customer or as necessary to check the operating char-acteristics of the machine (References: IEEE Stds.112 and 115 and NEMA Stds. MG-1).

4.7 INSTRUMENT CALIBRATIONEach instrument required for test results should

be calibrated at least annually against standardstraceable to the National Institute of Standards andTechnology (NIST) or equivalent standards labora-tories (References: ANSI/NCSL Z540-1-1994 andISO 10012).

Each instrument should bear record of recent cali-bration and, if extreme importance is attached tothe test results, the instrument should be calibratedimmediately before and after the completion of thetest procedure.

Section 4, Page 4


18

AC INDUCTION MACHINES AND NONEXCITEDSYNCHRONOUS MACHINES STATOR WINDING ROTOR WINDING

Motors rated 0.5 hp and less, generators rated 373 watts(or equivalent) and less, and for operation on circuits:

a) 250 volts or less 1000 volts

b) Above 250 volts 1000 volts + 2 times the

secondary voltage

Motors rated greater than 0.5 hp, generators rated 1000 volts + 2 times thegreater than 373 watts (or equivalent), and for: rated voltage of the machine

a) Non-reversing duty

b) Reversing duty 1000 volts + 4 times thesecondary voltage

AC SYNCHRONOUS MACHINES WITH SLIP RINGS STATOR WINDING FIELD WINDING

MOTORS 1000 volts + 2 times the Starting Method 1*rated voltage of the motor 10 times the rated excitation

voltage but not less than 2500volts nor more than 5000volts

Starting Method 2*2 times the IR drop acrossthe resistor but not less than2500 volts

GENERATORS

a) With stator (armature) or field windings rated 500 volts35 volts or less

b) With output less than 250 watts and rated voltage 1000 volts250 volts or less

c) With rated excitation voltage 500 volts DC or less 10 times the rated excitationvoltage but not less than 1500

1000 volts + 2 times the volts

d) With rated excitation voltage above 500 volts DC rated voltage of the generator 4000 volts + 2 times the ratedexcitation voltage

* Starting Method 1: For a motor to be started with its field short-circuited or closed through an exciting armature.

Starting Method 2: For a motor to be started with a resistor in series with the field winding. The IR drop is taken as the product ofthe resistance and the current that would circulate in the field winding if short-circuited on itself at the specified starting voltage(Reference: NEMA Stds. MG 1, 21.22.3).

Section 4, Page 5

DESCRIPTION OF MACHINE EFFECTIVE AC HIGH-POTENTIAL TEST VOLTAGE

Table 4-1. HIGH-POTENTIAL TEST USING AC

NEW WINDINGS


19

Section 4, Page 6


NEW WINDINGS—continued

AC BRUSHLESS SYNCHRONOUS MACHINES MAIN STATOR MAIN FIELD WINDING ANDAND EXCITERS WINDING EXCITER ARMATURE

Armature (stator) or field windings rated 35 volts or less 500 volts

With rated output less than 250 watts and 250 volts or less 1000 volts

With rated main excitation voltage 350 volts DC or less10 times the rated excitation

1000 volts + 2 times the voltage but not less than 1500 volts*

With rated main excitation voltage greater than 350 volts DCrated voltage of the machine 2800 volts + 2 times the rated

excitation voltage*

BRUSHLESS EXCITERS EXCITER STATOR (FIELDS)

a) With exciter field excitation voltage not greater than 10 times the rated excitation Alternatively, the brushless exciter350 volts DC voltage but not less than 1500 volts rotor (armature) shall be permitted

b) With exciter field excitation voltage greater than 2800 volts + 2 times the to be tested at 1000 volts plus 2

350 volts DC rated excitation voltage times the rated nonrectified alter-

c) With AC-excited stators (fields) 1000 volts + 2 times thenating current voltage but in no

AC-rated voltage of the statorcase less than 1500 volts.*

DC MOTORS AND GENERATORS FIELD WINDING ARMATURE WINDING

With armature or field windings rated 35 volts or less 500 volts

Motors rated 0.5 hp and less, generators rated lessthan 250 watts, and for operation on circuits:a) 240 volts or less 1000 volts

b) Above 240 volts1000 volts + 2 times the

Motors rated greater than 0.5 hp and generators rated voltage of the machinerated 250 watts and larger

UNIVERSAL MOTORS RATED 250 VOLTS OR LESS FIELD WINDING ARMATURE WINDING

Rated 0.5 hp and less, except motors marked 1000 voltsfor portable tools

Rated greater than 0.5 hp, and all motors marked for 1000 volts + 2 times theportable tools rated voltage of the motor

* The brushless circuit components (diodes, thyristors, etc.) should be short-circuited (not grounded) during the test.

References: NEMA Stds. MG 1, 12.3, 15.48, 20.17, 21.22.4, 21.22.5, 23.20 and 24.49.

DESCRIPTION OF MACHINE EFFECTIVE AC HIGH-POTENTIAL TEST VOLTAGE


20

Section 4, Page 7

AC INDUCTION MACHINES AND NONEXCITEDSYNCHRONOUS MACHINES STATOR WINDING ROTOR WINDING

Motors rated 0.5 hp and less, generators rated 373 watts(or equivalent) and less, and for operation on circuits:

a) 250 volts or less 1700 volts

b) Above 250 volts 1700 volts + 3.4 times thesecondary voltage

Motors rated greater than 0.5 hp, generators ratedgreater than 373 watts (or equivalent), and for: 1700 volts + 3.4 times the

a) Non-reversing duty rated voltage of the machine

b) Reversing duty 1700 volts + 6.8 times thesecondary voltage

AC SYNCHRONOUS MACHINES WITH SLIP RINGS STATOR WINDING FIELD WINDING

Starting Method 1*MOTORS 17 times the rated excitation1700 volts + 3.4 times the

voltage but not less than 4250rated voltage of the motorvolts nor more than 8500 volts

Starting Method 2*3.4 times the IR drop acrossthe resistor but not less than4250 volts

GENERATORS

a) With stator (armature) or field windings rated 850 volts35 volts or less

b) With output less than 250 watts and rated voltage 1700 volts250 volts or less

c) With rated excitation voltage 500 volts DC or less 17 times the rated excitationvoltage but not less than 2550

1700 volts + 3.4 times the volts

d) With rated excitation voltage above 500 volts DC rated voltage of the generator 6800 volts + 3.4 times therated excitation voltage

* Starting Method 1: For a motor to be started with its field short-circuited or closed through an exciting armature.

Starting Method 2: For a motor to be started with a resistor in series with the field winding. The IR drop is taken as the product ofthe resistance and the current that would circulate in the field winding if short-circuited on itself at the specified starting voltage(Reference: NEMA Stds. MG 1, 21.22.3).

Caution: After completion of a DC high-potential test, the winding must be grounded to the frame (or core) until the charge hasdecayed to zero. (References: IEEE Stds. 4 and 95; and NEMA Stds. MG 1, 3.1.)

DESCRIPTION OF MACHINE DC HIGH-POTENTIAL TEST VOLTAGE

Table 4-2. HIGH-POTENTIAL TEST USING DC

NEW WINDINGS


21

Section 4, Page 8


NEW WINDINGS—continued

DESCRIPTION OF MACHINE DC HIGH-POTENTIAL TEST VOLTAGE

AC BRUSHLESS SYNCHRONOUS MACHINES MAIN STATOR MAIN FIELD WINDING ANDAND EXCITERS WINDING EXCITER ARMATURE

Armature (stator) or field windings rated 35 volts or less 850 volts

With rated output less than 250 watts and 250 volts or less 1700 volts

With rated main excitation voltage 350 volts DC or less17 times the rated excitation

1700 volts + 3.4 times the voltage but not less than 2550 volts*

With rated main excitation voltage greater than 350 volts DCrated voltage of the machine 4750 volts + 3.4 times the rated

excitation voltage*

BRUSHLESS EXCITERS EXCITER STATOR (FIELDS)

a) With exciter field excitation voltage not greater than 17 times the rated excitation Alternatively, the brushless exciter350 volts DC voltage but not less than 2550 volts rotor (armature) shall be permitted

b) With exciter field excitation voltage greater than 4750 volts + 3.4 times the to be tested at 1700 volts plus 3.4

350 volts DC rated excitation voltage times the rated nonrectified alter-

c) With AC-excited stators (fields) 1700 volts + 3.4 times thenating current voltage but in no

AC-rated voltage of the statorcase less than 2550 volts.*

DC MOTORS AND GENERATORS FIELD WINDING ARMATURE WINDING

With armature or field windings rated 35 volts or less 850 volts

Motors rated 0.5 hp and less, generators rated lessthan 250 watts, and for operation on circuits:a) 240 volts or less 1700 volts

b) Above 240 volts1700 volts + 3.4 times the

Motors rated greater than 0.5 hp and generators rated rated voltage of the machine250 watts and larger

UNIVERSAL MOTORS RATED 250 VOLTS OR LESS FIELD WINDING ARMATURE WINDING

Rated 0.5 hp and less, except motors marked 1700 voltsfor portable tools

Rated greater than 0.5 hp, and all motors marked for 1700 volts + 3.4 times theportable tools rated voltage of the motor

* The brushless circuit components (diodes, thyristors, etc.) should be short-circuited (not grounded) during the test.References: NEMA Stds. MG 1, 12.3, 15.48, 20.17, 21.22.4, 21.22.5, 23.20 and 24.49.

Caution: After completion of a DC high-potential test, the winding must be grounded to the frame (or core) until the charge hasdecayed to zero. (References: IEEE Stds. 4 and 95; and NEMA Stds. MG 1, 3.1.)


22

Section 4, Page 9


NEW ACCESSORIES

Accessory* Rated DC High-PotentialVoltage** Test Voltage

Thermostats 600 volts 1700 volts + 3.4 times the

Thermocouples rated voltage of the accessory

Thermistors 50 volts or equal to the high-potential

Resistance temperature test voltage of the machine,

dectectors (RTDs) whichever is lower.

Space heaters All

* Accessories not connected in the line circuit.** Unless otherwise stated.

Reference: NEMA Stds. MG 1, 3.1.8.


NEW ACCESSORIES

Accessory* Rated Effective AC High-PotentialVoltage** Test Voltage

Thermostats 600 volts 1000 volts + 2 times the

Thermocouples rated voltage of the accessory

Thermistors 50 volts or equal to the high-potential

Resistance temperature test voltage of the machine,

dectectors (RTDs) whichever is lower.

Space heaters All

* Accessories not connected in the line circuit.** Unless otherwise stated.

Reference: NEMA Stds. MG 1, 3.1.8.

RPM @ Velocity Velocity RPM @ Velocity Velocity60 Hz in/s peak mm/s 50 Hz in/s peak mm/s

3600 0.15 3.8 3000 0.15 3.8

1800 0.15 3.8 1500 0.15 3.8

1200 0.15 3.8 1000 0.13 3.3

900 0.12 3.0 750 0.10 2.5

720 0.09 2.3 600 0.08 2.0

600 0.08 2.0 500 0.07 1.7

Table 4-5. UNFILTEREDVIBRATION LIMITS

RESILIENTLY MOUNTED MACHINES

Note: For machines with rigid mounting, multiply the limiting val-ues by 0.8

(Reference: NEMA Stds. MG 1, 7.8.2, Table 7-1).


23

AppendixElectrical Testing Safety Considerations

an insulated mat.A.2.6 Test Unit Clearance

Clearance should be provided between the testunit and test area boundaries to allow ease of move-ment for personnel. Lead length should allow aminimum of ten feet (3 meters) between test centeroperator and test unit. Exposed shafts and couplings/sheaves should be guarded.

A.3 UNIT UNDER TEST

A.3.1 Suitability For TestTest personnel should verify that the unit is me-

chanically and electrically suitable to undergo theproposed test procedures.A.3.2 Exclusive Attention

Only the unit under test should be in the test area.A.3.3 Grounding

An equipment ground should be installed on allapparatus under test.A.3.4 Base

Units under test should be secured to prevent roll-ing or tipping during testing.

A.4 TEST PANELS

A.4.1 ConstructionConstruction should be of the “dead front” type.

Instantaneous over-current trips or fuses shouldlimit fault currents in the main power supply to thepanel capacity.

A.4.2 VoltagesOutput voltages should be clearly marked. Volt-

ages above 600V should require special selectionprocedures to prevent inadvertent application.

A.4.3 Warning LightsA warning light should indicate when the panel is

energized. An additional warning light should indi-cate when power leads to a unit under test areenergized.A.4.4 Disconnect

A means for disconnecting the lines to the panelshould be located within sight from the test panel.A.4.5 Safety Switch

An emergency hand or foot operated switch orpush button to de-energize the power source shouldbe located in the test area. A remote emergency

A.1 PERSONAL SAFETY

A.1.1 TrainingEmployees should be trained in safe operation of

all electrical equipment within their responsibility.Training should be provided by use of relevant equip-ment operational manuals, hands-on training and/or training video tapes. Employees should be in-formed of the relevant safety rules, and employersshould enforce compliance.

A.1.2 ClothingClothing should be suitable for the work to be per-

formed. Flame-retardant material is recommended.The wearing of exposed jewelry should be avoided.Safety glasses should be worn at all times.

A.1.3 SupervisionEmployees should work under the direction of an

experienced and qualified person within the testarea. At least two persons should be within the testarea at all times.

A.1.4 First AidPersonnel should be trained in the procedure for

securing emergency medical aid.

A.2 TEST AREA

A.2.1 EnclosureTest area should be enclosed with a fence or col-

ored rope—preferably yellow. Red or yellow strobelights may be placed at test corner areas for addi-tional warning.

A.2.2 GatesWhen a metallic fence or cage is used, it should be

grounded. Gates provided for entry of equipment andpersonnel should be equipped with interlocks sopower to test area is interrupted if gate is opened.

A.2.3 SignsSigns should be posted concerning the electrical

hazards, warning unauthorized personnel to stay outof the test area.

A.2.4 LightingTest areas should be well illuminated.

A.2.5 Safety EquipmentFire extinguishers and first aid equipment should

be readily available and personnel should be trainedin their use. Operating personnel should stand on

Appendix, Page 1

(This Appendix is not a part of EASA AR100-2006, Recommended Practice for the Repair of Rotating Electrical Apparatus.)


24

safety switch adjacent to the test area also isrecommended.

A.4.6 LeadsTest leads and insulated clips should be of ad-

equate ampacity and voltage class for the machinebeing tested.

A.4.7 High-Potential Ground TestAC or DC high-potential testing current should

be limited by impedance or instantaneous trips tolimit damage when breakdown occurs.

Appendix, Page 2


25

BibliographyAll references are to the revision dates listed below.

Bibliography, Page 1

ANSI/ABMA Standard 7-1995: Shaft and HousingFits for Metric Radial Ball and Roller Bearings(Except Tapered Roller Bearings) Conforming toBasic Boundary Plans.American Bearing Manu-facturers Association, Inc. and American NationalStandards Institute. New York, NY, 1995.

ANSI S2.41-1985: Mechanical Vibration of LargeRotating Machines With Speed Ranges From 10to 200 RPS. Measurement And Evaluation ofVibration Severity In Situ. American NationalStandards Institute. New York, NY, 1985; reaf-firmed 1997. (Note: Published originally byInternational Organization for Standardization;Geneva, Switzerland, 1985; withdrawn by ISO in1995 but retained by ANSI.)

ANSI/NCSL Z540-1-1994: Calibration—CalibrationLaboratories and Measuring and Test Equip-ment—General Requirements. American NationalStandards Institute. New York, NY, 1994.

IEC Standard Publication 60034-8: Rotating Elec-trical Machines, Part 8: Terminal Markings andDirection of Rotation of Rotating Machines. In-ternational Electrotechnical Commission.Geneva, Switzerland, 1972; second impression,1990.

IEC Standard Publication 60072-1: Part 1—FrameNumbers 56 to 400 and Flange Numbers 55 to1080. International Electrotechnical Commission.Geneva, Switzerland; seventh edition, 2000.

IEC Standard Publication 60136: Dimensions ofBrushes and Brush-holders for Electric Machin-ery. International Electrotechnical Commission.Geneva, Switzerland; second edition, 1986.

IEEE Standard 4-1995: Standard Techniques forHigh-Voltage Testing. Institute of Electrical andElectronics Engineers, Inc. New York, NY, 1995.

IEEE Standard 43-2000: IEEE Recommended Prac-tice for Testing Insulation Resistance of RotatingMachinery. Institute of Electrical and Electron-ics Engineers, Inc. New York, NY, 2000.

IEEE Standard 95-1977: IEEE Recommended Prac-tice for Insulation Testing of Large AC RotatingMachinery with High Direct Voltage. Institute ofElectrical and Electronics Engineers, Inc. NewYork, NY, 1977; reaffirmed 1991.

IEEE Standard 112-1996: IEEE Standard Test Pro-cedure for Polyphase Induction Motors andGenerators. Institute of Electrical and Electron-ics Engineers, Inc. New York, NY, 1997.

IEEE Standard 115-1995: IEEE Guide: Test Proce-dures for Synchronous Machines. Institute ofElectrical and Electronics Engineers, Inc. NewYork, NY, 1996.

IEEE Standard 432-1992: IEEE Guide for Insula-tion Maintenance for Rotating Electric Machinery(5 hp to less than 10 000 hp). Institute of Electri-cal and Electronics Engineers, Inc. New York,NY, 1992.

IEEE Standard 522-1992: IEEE Guide for TestingTurn-To-Turn Insulation on Form-Wound StatorCoils for Alternating-Current Rotating ElectricMachines. Institute of Electrical and ElectronicsEngineers, Inc. New York, NY, 1992.

IEEE Standard 792-1995: IEEE Recommended Prac-tice for the Evaluation of the Impulse VoltageCapability of Insulation Systems for AC ElectricMachinery Employing Form-Wound Stator Coils.Institute of Electrical and Electronics Engineers,Inc. New York, NY, 1995.

IEEE Standard 1068-1996: IEEE RecommendedPractice for the Repair and Rewinding of Motorsfor the Petroleum and Chemical Industry. Insti-tute of Electrical and Electronics Engineers, Inc.New York, NY, 1997.

ISO 10012-1: Quality assurance requirements formeasuring equipment. International Organiza-tion for Standardization. Geneva, Switzerland,1992.

ISO 1940-1: Mechanical Vibration - Balance QualityRequirements of Rigid Rotors. International Or-ganization for Standardization. Geneva,Switzerland, 1986.

ISO 1940-2: Determination of Permissible ResidualUnbalance. International Organization for Stan-dardization. Geneva, Switzerland, 1997.

ISO 10816-1: Mechanical Vibration - Evaluation ofMachine Vibration by Measurements on Non-Rotating Parts - Part 1: General Requirements.International Organization for Standardization.Geneva, Switzerland, 1995.


26

Bibliography, Page 2

NEMA Standards MG 1-2003: Motors and Genera-tors. National Electrical ManufacturersAssociation. Rosslyn, VA; 2003.

NFPA Standard 70E-2000: Standard for ElectricalSafety Requirements for Employee Workplaces.National Fire Protection Association, Quincy,MA; 1998.

29CFR1910.331 - .335 OSHA: Electrical Safety-Re-lated Work Practices. Occupational Safety AndHealth Administration. Washington, DC; revised1994.


27

Standards Organizations & Other Resources

The following organizations produce documentsand standards, some of which are referenced inthe EASA Recommended Practice for the Repair ofRotating Electrical Apparatus.

ABMA—American BearingManufacturers Association2025 M St., NW, Ste. 800Washington, DC 20036202-367-1155Fax: 202-367-2155Web Site: www.abma-dc.orgE-mail: [email protected]

ANSI—American NationalStandards Institute25 West 43rd St., 4th FloorNew York, NY 10036212-642-4900Fax: 212-398-0023Web Site: www.ansi.orgE-mail: [email protected]

CSA–Canadian Standards Association178 Rexdale Blvd.Rexdale, ON M9W 1R3Canada416-747-4044Fax: 416-747-2475Web Site: www.csa-international.orgE-mail: [email protected]

IEC—InternationalElectrotechnical Commission *3, rue de VarembéP. O. Box 131CH-1211 Geneva 20Switzerland41-22-919-02 11Fax: 41-22-919-03-00Web Site: www.iec.chE-mail: [email protected]

IEEE—Institute of Electrical and ElectronicsEngineers, Inc.3 Park Ave., 17th FloorNew York, NY 10016-5997212-419-7900Fax: 212-752-4929Web Site: www.ieee.org

PublicationsIEEE Operations Center445 Hoes LanePiscataway, NJ 08854-1331732-981-0060Fax: 732-981-1721

ISO—International Organizationof Standardization *1, rue de Varembé, Case postale 56CH-1211 Geneva 20Switzerland41-22-749-01-11Fax: 41-22-733-34-30Web Site: www.iso.orgE-mail: [email protected]

MIL-STD—United States GovernmentPrinting Office710 North Capitol St.Washington, DC 20420202-512-1800Fax: 202-512-2250Web Site: www.gpo.govOrdersSuperintendent of DocumentsP. O. Box 371954Pittsburgh, PA 15250Web Site: Bookstore.gpo.gov (Do not put

“www.” in front of this address)

NEMA—National ElectricalManufacturers Association1300 North 17th St., Ste. 1847Rosslyn, VA 22209703-841-3200Fax: 703-841-5900Web Site: www.nema.orgE-mail: [email protected]: 703-841-3300

Standards Organizations, Page 1

* IEC and ISO standards are available through ANSI, whichis the American representative to all international stan-dards groups.


28

NFPA—National FireProtection Association1 Batterymarch ParkP. O. Box 9101Quincy, MA 02269-9101617-770-300095-800-844-6058 (Mexico-toll free)Fax: 617-770-0700Web Site: www.nfpa.orgPublications800-344-3555, Option 1617-770-3000, Option 1Fax: 800-593-6372Fax: 508-895-8301

NIST—National Institute ofStandards and Technology100 Bureau Dr.Stop 3460Gaithersburg, MD 20899-3460301-975-6478Fax: 301-975-8295Web Site: www.nist.govE-mail: [email protected]

UL—Underwriters’ Laboratories, Inc.333 Pfingsten Rd.Northbrook, IL 60062847-272-8800Web Site: www.ul.comPublicationsComm 20001414 Brook Dr.Downers Grove, IL 60515888-853-3503Fax: 888-853-3512Web Site: www.comm-2000.comE-mail: [email protected]

Standards Organizations, Page 2

AR100-2006 coverTitle PageCopyright NoticeTable of ContentsSection 1: GeneralSection 2: Mechanical RepairSection 3: RewindingSection 4: TestingAppendix: Electrical Testing Safety ConsiderationsBibliographyStandards Organizations & Other Resources

EASA Standard AR100-2006 - MaintenanceEASA AR100-2006 Recommended Practice - Rev. May 2006 1 Section...

Documents

Transcript of EASA Standard AR100-2006 - MaintenanceEASA AR100-2006 Recommended Practice - Rev. May 2006 1 Section...