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
FOR THE REPAIR OF ROTATINGELECTRICAL APPARATUS
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
FOR THE REPAIR OF ROTATINGELECTRICAL APPARATUS
EASA AR100-2006 Recommended Practice - Rev. May 2006
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]
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EASA AR100-2006 Recommended Practice - Rev. May 2006
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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
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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.
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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
EASA AR100-2006 Recommended Practice - Rev. May 2006
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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.
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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-
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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
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EASA AR100-2006 Recommended Practice - Rev. May 2006
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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
DIMENSIONS IN INCHES DIMENSIONS IN MILLIMETERS
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
Reference: NEMA Stds. MG 1, 4.9.1.Dimensions shown in millimeters are rounded off.
EASA AR100-2006 Recommended Practice - Rev. May 2006
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Section 2, Page 4
Table 2-5. SHAFT EXTENSION KEYSEAT WIDTH TOLERANCESNEMA FRAME SIZE MACHINES
DIMENSIONS IN INCHES DIMENSIONS IN MILLIMETERS
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
Reference: NEMA Stds. MG 1, 4.9.2.Dimensions shown in millimeters are rounded off.
Table 2-6. SHAFT EXTENSION KEYSEAT(KEYWAY) WIDTH TOLERANCES
IEC FRAME SIZE MACHINES
DIMENSIONS IN MILLIMETERS DIMENSIONS IN INCHES
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.
DIMENSIONS IN MILLIMETERS DIMENSIONS IN INCHES
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
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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
DIMENSIONS IN INCHES DIMENSIONS IN MILLIMETERS
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.
EASA AR100-2006 Recommended Practice - Rev. May 2006
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Table 2-9. MOUNTING SURFACE TOLERANCES,ECCENTRICITY AND FACE RUNOUT
NEMA TYPE P FLANGE-MOUNTING MOTORS
DIMENSIONS IN INCHES DIMENSIONS IN MILLIMETERS
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
DIMENSIONS IN MILLIMETERS DIMENSIONS IN INCHES
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.
EASA AR100-2006 Recommended Practice - Rev. May 2006
9
Table 2-11. MOUNTING SURFACE ECCENTRICITYAND FACE RUNOUT
IEC FLANGE-MOUNTED MACHINES
DIMENSIONS IN MILLIMETERS DIMENSIONS IN INCHES
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
DIMENSIONS IN MILLIMETERS DIMENSIONS IN INCHES
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.
EASA AR100-2006 Recommended Practice - Rev. May 2006
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
EASA AR100-2006 Recommended Practice - Rev. May 2006
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
EASA AR100-2006 Recommended Practice - Rev. May 2006
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
EASA AR100-2006 Recommended Practice - Rev. May 2006
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
EASA AR100-2006 Recommended Practice - Rev. May 2006
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).
EASA AR100-2006 Recommended Practice - Rev. May 2006
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
EASA AR100-2006 Recommended Practice - Rev. May 2006
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
EASA AR100-2006 Recommended Practice - Rev. May 2006
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
EASA AR100-2006 Recommended Practice - Rev. May 2006
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
EASA AR100-2006 Recommended Practice - Rev. May 2006
19
Section 4, Page 6
Table 4-1. HIGH-POTENTIAL TEST USING AC
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
EASA AR100-2006 Recommended Practice - Rev. May 2006
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
EASA AR100-2006 Recommended Practice - Rev. May 2006
21
Section 4, Page 8
Table 4-2. HIGH-POTENTIAL TEST USING DC
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.)
EASA AR100-2006 Recommended Practice - Rev. May 2006
22
Section 4, Page 9
Table 4-4. HIGH-POTENTIAL TEST USING DC
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.
Table 4-3. HIGH-POTENTIAL TEST USING AC
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).
EASA AR100-2006 Recommended Practice - Rev. May 2006
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.)
EASA AR100-2006 Recommended Practice - Rev. May 2006
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
EASA AR100-2006 Recommended Practice - Rev. May 2006
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.
EASA AR100-2006 Recommended Practice - Rev. May 2006
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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.
EASA AR100-2006 Recommended Practice - Rev. May 2006
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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.
EASA AR100-2006 Recommended Practice - Rev. May 2006
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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
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