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Motor Winding PR'N

The document outlines common issues in motor windings, including short circuits, open circuits, and insulation breakdown, along with their symptoms and repair techniques. It details steps for visual inspection, electrical testing, and repair options such as spot repairs and rewinding. Additionally, it emphasizes safety protocols, the use of personal protective equipment, and best practices for winding operations to prevent accidents and ensure effective repairs.

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Hillary Omondi
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5 views16 pages

Motor Winding PR'N

The document outlines common issues in motor windings, including short circuits, open circuits, and insulation breakdown, along with their symptoms and repair techniques. It details steps for visual inspection, electrical testing, and repair options such as spot repairs and rewinding. Additionally, it emphasizes safety protocols, the use of personal protective equipment, and best practices for winding operations to prevent accidents and ensure effective repairs.

Uploaded by

Hillary Omondi
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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MOTOR WINDING

COMMON ISSUES IN MOTOR WINDINGS


 Electric motors are subject to a variety of operational stresses, which may
lead to failure over time.
Typical Winding Issues:

Fault Type Description

Short Circuits Adjacent coils or wires in contact, causing abnormal


current paths.

Open Circuits Broken coil wire, often due to overheating or mechanical


strain.

Ground Faults Coil insulation breaks down, allowing current to flow to


motor body/frame.

Unbalanced Windings Uneven coil resistance or incorrect phase windings leading


to poor performance.

Overheating Damage Caused by prolonged overloading, poor ventilation, or


incorrect winding specs.

Insulation Breakdown Degradation of insulation due to aging, moisture,


chemicals, or abrasion.
 Symptoms of Winding Faults:
 Motor fails to start or runs with difficulty.
 High current draw or tripped protection devices.
 Unusual noise or vibration.
 Uneven motor temperature.
 Reduced torque or speed fluctuations.
 Burnt smell or visible coil discoloration
Repair Techniques

Before starting any repair, always disconnect power, follow lockout/tagout procedures, and
ensure safety measures are in place.

1. Visual Inspection

 Look for burnt wires, discolored coils, broken insulation, and signs of overheating.
 Inspect mechanical parts (bearings, shaft) for wear that may affect the winding.

2. Electrical Testing

 Use a multimeter to check continuity and resistance of windings.

 Apply a megger (insulation tester) to verify insulation integrity.

 Conduct a growler test for shorts in armature windings (mostly in DC motors).

 Perform impedance balancing on 3-phase motors to detect winding imbalances.


Repair Options:

A. Minor Faults – Spot Repair

 Re-insulate exposed or damaged winding portions using varnish and fiberglass tape.

 Secure loose windings with tie cords or spot welds.

 Replace damaged leads or terminals.


B. Major Faults – Rewinding

If damage is extensive, rewinding becomes necessary.

Steps for Rewinding:

1. Strip and Clean:

o Remove all old windings and insulation.

o Clean the core slots using a wire brush and compressed air.

2. Inspect and Measure:

o Measure slot size, core length, and winding configuration (turns per coil, wire
gauge).

o Compare with nameplate data or manufacturer specs.


1. Winding Process:

o Wind new coils with correct number of turns and wire size.

o Use insulation between layers and apply uniform tension.

o Insert coils into stator/rotor slots and secure them.

2. Insulation and Varnishing:

o Apply insulation tape between coil ends.

o Immerse in varnish and cure using heat treatment.

3. Final Testing:

o Test resistance and insulation.

o Perform a no-load run before final commissioning.


Rewinding Procedures

A structured approach to rewinding improves accuracy and motor reliability.

Step-by-Step Rewinding Procedure:

1. Motor Identification:

o Note voltage, frequency, horsepower, and configuration (star/delta).

2. Core and Coil Removal:

o Cut old windings carefully to preserve slot integrity.

o Use core burners (if available) for large motors.

3. Measurement and Coil Forming:

o Use winding jig to create coil shapes.

o Verify all dimensions before winding full coil sets.


1. Slot Insertion and Insulation:

o Insert coil into slots using insertion sticks.

o Use slot wedges to lock coils in place.

2. Lead Connection:

o Solder or crimp connections to motor terminals.

o Double-check phase sequence.

3. Varnishing and Baking:

o Use dip or trickle varnishing methods.

o Bake stator in an oven to harden insulation.

4. Testing and Final Assembly:

o Test winding resistance, insulation, and run under no-load.

o Assemble motor parts and check bearing alignment.


Practical Troubleshooting Scenarios

Scenario 1: Motor Tripping Breaker Immediately After Start

 Cause: Ground fault or short circuit.

 Fix: Test insulation resistance. Rewind if insulation is damaged.

Scenario 2: Motor Runs but is Noisy and Vibrates

 Cause: Unbalanced winding or defective bearings.

 Fix: Balance coils, inspect for shorts. Replace faulty bearings.

Scenario 3: Motor Speed is Inconsistent

 Cause: Phase loss or turn-to-turn short.


Fix: Use a multimeter to compare phase resistance. Rewind if needed
Safety Protocols

Why Safety Matters

Motor winding involves tools, machines, and electrical components that can pose serious risks
if not handled properly. Safety protocols are crucial to prevent accidents, ensure smooth
operations, and protect life and property.

Common Hazards in Motor Winding

 Electrical Shock: Occurs when live wires or terminals are touched unknowingly.

 Burn Injuries: May result from heated motor components or short circuits.

 Mechanical Injuries: Caused by sharp tools, flying debris, or motor spinning


unexpectedly.
 Eye Injuries: Result from wire recoiling or pieces of insulation flying off.

 Repetitive Strain Injuries: From poor posture and continuous winding motions.

Basic Safety Guidelines


 Always disconnect power sources before beginning any work on motors.
 Clearly label machines that are under maintenance.
 Ensure the workplace is clean, well-lit, and ventilated.
 Follow manufacturer’s instructions for all tools and equipment.
 Report defective equipment immediately.
 Keep fire extinguishers and first aid kits nearby.
Use of Personal Protective Equipment (PPE)
PPE is the first line of defense against injuries and exposure to workplace
hazards.

PPE Item Function


Protect eyes from debris, dust, and
Safety Glasses
wire particles
Protect hands from electric shock
Insulated Gloves
and sharp wire ends
Shields the body from varnish spills
Protective Apron
and wire strikes
Prevent slips and protect from heavy
Safety Boots
tool drops
Required when working with noisy
Ear Protection
winding machines
Best Practices in Winding Operations
Before Starting
•Read and understand the motor’s datasheet and wiring diagram.
•Clean the stator/rotor slots.
•Inspect for old insulation and remove it safely.
During Winding
•Use calibrated tools (turn counter, tensioner).
•Wind coils neatly and evenly to avoid imbalances.
•Apply insulation materials properly between layers.
•Keep a log of turns, wire gauge, and resistance readings.
After Winding
•Perform insulation and resistance tests.
•Allow enough time for varnish to cure.
•Secure all terminations and connections.
Workplace Conduct
•Stay focused—avoid distractions.
•Avoid horseplay or misuse of tools.
•Keep personal phones away during practical work.
Case Study Analysis
Case Study 1: Motor Overheating After Rewinding
•Scenario: A 3-phase motor was rewound by a technician. It overheated during testing.
•Findings:
• Turn count was incorrect.
• Wire insulation was damaged during winding.
•Corrective Action:
• Rewind with correct specifications.
• Ensure proper insulation between coil layers.
•Lesson Learned: Always double-check wire gauge and turn count before starting.

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