Open Stator Impedance Testing November 8, 2022
Open Stator Impedance Testing
Mike Howell – Technical Support Specialist
Electrical Apparatus Service Association, Inc.
+1 314 993 2220 |
[email protected] Learning objectives
• After the webinar, attendees should have a
general understanding of:
– the principles of the test
– performing the test safely and consistently
– increasing the test value with thermography
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Open Stator Impedance Testing November 8, 2022
Magnetic field in solenoid
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Magnetic field in solenoid with iron core
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Open Stator Impedance Testing November 8, 2022
Magnetic circuit properties
• Permeability – how
much flux can we get
per amp?
• Air gap dominates
ampere-turns required
in electric machines
• Air gap is minimized
within reason
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Magnetic field with rotor
• 40 hp (30 kW) 4 pole
• Current = 52 A
• Back iron flux density of
100k lines/in2 (1.6 T)
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Open Stator Impedance Testing November 8, 2022
Magnetic field with rotor
• 40 hp (30 kW) 4 pole
• Current = 52 A
• Back iron flux density of
100k lines/in2 (1.6 T)
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Magnetic field without rotor – open stator test
• 40 hp (30 kW) 4 pole
• Current = 52 A
• Back iron flux density of
12k lines/in2 (0.2 T)
• Low flux per amp when
doing this test – not a
core test
• Low impedance too –
low volts per amp
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Open Stator Impedance Testing November 8, 2022
Open stator test
• Apply 3 phase balanced voltage
• Nameplate current at roughly
12 to 20% of rated volts (V/Hz)
• 460 V 60 Hz (7.7 V/Hz)
– FLA at 55-90 V 60 Hz
• 460 V 200 Hz (2.3 V/Hz)
– 2.3 V/Hz * 60 Hz = 138 V
– FLA at 17-28 V 60 Hz
• Typical current balance within
10% of average acceptable
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Example – 20 hp 4 pole 460 V 60 Hz 24 A
VOLTS 60 Hz AMPS
62 63 62 24 22 23
62 + 63 + 62 187 24 + 22 + 23 69
= = 62.3 = = 23.0
3 3 3 3
63.0 − 62.3 0.7 24 − 23 1
= = 1.1% = = 4.3%
62.3 62.3 23 23
62.3
= 13.5%
460 < 10%
OK
≈12 to 20%
OK
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Open Stator Impedance Testing November 8, 2022
Example – 37 kW 6 pole 400 V 80 Hz 68 A
VOLTS 60 Hz AMPS
48 48 47 64 68 65
48 + 48 + 47 143 64 + 68 + 65 197
= = 47.6 = = 65.7
3 3 3 3
47 − 47.6 −0.6 68 − 65.7 2.3
= = −1.3% = = 3.5%
47.6 47.6 65.7 65.7
47.6 47.6
= = 15.9%
400
∗ 60 300 < 10%
80
OK
≈12 to 20%
OK
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Open stator test – example outcomes
Condition of winding Expect at 12-20% V/Hz
Correct ≈ 100% FLA
Connected WYE, should be DELTA ≈ 30% FLA
Connected DELTA, should be WYE ≈ 300% FLA*
Connected with half the required circuits ≈ 50% FLA
Connected with twice the required circuits ≈ 200% FLA*
Winding turns or pitch slightly off Probably won’t catch it!
Other winding issues Current balance + thermography
* Stop increasing voltage at FLA and evaluate the voltage.
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Open Stator Impedance Testing November 8, 2022
Open stator test – ball test
• Ball bearing will spin
due to the stator’s
rotating magnetic field
• Reversed coils and
stator surface issues will
affect rotation
• Ok but not preferred
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Open stator test – small rotor test
• Small rotor will rotate
smoothly and
consistently if no coils
or groups are reversed
– commercial device like
Spindicators (Laycock)
– small induction rotors
– garage door rollers
• Preferred over spinning
ball bearing
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Open Stator Impedance Testing November 8, 2022
Open stator test + thermography
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Turn-to-turn short
• Locate shorted turns if
they are accessible
• Repair may be possible
• Shorts may be located
during open stator test
or surge test
• Surge test less effective
on complete windings
than individual coils
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Open Stator Impedance Testing November 8, 2022
Poor series connection
• High resistance or poor
connections will cause
elevated heating
• Heating in watts
proportional to I2R
• Defect may not be
significant enough to
find by resistance
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Equalizer error
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Open Stator Impedance Testing November 8, 2022
Misconnected stator winding
• 2000 hp 24 pole
• Electrical noise present
• Diagnostic testing
– Air gap = ok
– Winding resistance = ok
– Surge test = ok
– Open stator test = ok
• Problem found by
adding thermography
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Misconnected stator winding
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Open Stator Impedance Testing November 8, 2022
Misconnected stator winding
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Misconnected stator winding - resolved
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Open Stator Impedance Testing November 8, 2022
Summing it up
• Open stator test is a simple and useful test
– diagnostics of existing windings
– Inspecting new windings before resin treatment
• Including thermography adds value and
improves diagnostic capabilities
– not as expensive as it once was
– opportunities to sell service to customers as well
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How to ask questions
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be called written
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question Ask question verbally
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Open Stator Impedance Testing November 8, 2022
Next webinar
Sensores de Temperatura para
Bobinados y Rodamientos
(Temperature Sensors for Windings and Bearings)
December 14, 2022
7:00 am, 12:00pm and 4:00pm CST
Presented by Carlos Ramirez
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Survey / Recording
Tomorrow, you will be emailed:
• A link to a survey if you would like to provide
feedback.
• A link to a recording of this presentation.
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